Condenser HVAC: Service and Repair
CONDENSER-A/C
REMOVAL
WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH.
CAUTION: Before removing the A/C condenser, note the location of each of the radiator/condenser air seals. These air seals are used to direct air through the A/C condenser and radiator. The air seals must be reinstalled in their proper locations in order for the A/C and engine cooling systems to perform as designed.
1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system.
3. Remove the nuts (4 and 9) that secure the A/C discharge line (3) and the A/C liquid line (10) to the A/C condenser (5).
4. Disconnect the A/C discharge line and the A/C liquid line from the A/C condenser and remove and discard the O-ring seals.
5. Install plugs in, or tape over all of the opened refrigerant line fittings and condenser ports.
6. Remove the grille.
7. Remove the upper radiator crossmember.
8. Remove the bolts that secure the top of the grille opening reinforcement to the body to gain clearance for condenser removal.
9. If equipped with the 2.8L diesel engine, remove the condenser fan assembly from in front of the A/C condenser.
10. If equipped, disconnect the transmission cooler lines from the automatic transmission cooler.
11. If equipped, remove the two bolts (8) that secure the automatic transmission cooler (7) to the radiator and position the transmission cooler aside.
12. Remove the two bolts (6) that secure the upper A/C condenser brackets to the radiator.
13. Carefully lift the A/C condenser straight up to disconnect the lower brackets from the radiator and remove the A/C condenser from the engine compartment.
INSTALLATION
CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system. Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.
NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system.
NOTE:If only the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle. Replacement of the refrigerant line O-ring seals is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals could result in a refrigerant system leak.
NOTE: Be certain that each of the radiator and condenser air seals are installed in their proper locations. These air seals are required for the A/C and engine cooling systems to perform as designed.
1. Carefully position the A/C condenser (5) into the engine compartment and engage the lower condenser brackets to the radiator.
2. Install the two bolts (6) that secure the upper condenser brackets to the radiator. Tighten the bolts to 5 N.m (44 in. lbs.).
3. If equipped, position the automatic transmission cooler (7) to the radiator and install the two retaining bolts (8). Tighten the bolts to 5 N.m (44 in. lbs.).
4. If equipped, connect the transmission cooler lines from the automatic transmission cooler.
5. If equipped with the 2.8L diesel engine, install the condenser fan assembly.
6. Reposition the top of the grille opening reinforcement to the body and install the retaining bolts
7. Install the upper radiator crossmember.
8. Install the grille.
9. Remove the tape or plugs from the refrigerant line fittings and condenser ports.
10. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
11. Connect the A/C liquid line (10) and the A/C discharge line (3) to the A/C condenser and install the retaining nuts (4 and 9). Tighten the nuts to 22.5 N.m (200 in. lbs.).
12. Reconnect the negative battery cable.
13. Evacuate the refrigerant system.
14. If the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
15. Charge the refrigerant system.