Condenser HVAC: Service and Repair

A/C CONDENSER

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. Partially drain the engine cooling system.
4. Remove the cooling recovery container.
5. Disconnect the upper radiator hose from the radiator and position the hose out of the way.
6. Remove the radiator cooling fan and fan shroud.
7. Raise and support the vehicle.
8. Position the lower condenser/radiator air seal out of the way and remove the two bolts that secure the lower condenser mounting bracket to the bottom of the grille panel.
9. Lower the vehicle.

A/C Condenser:

10. If equipped, remove the upper condenser/radiator air seal.
11. Remove the nuts that secure the discharge and liquid lines to the condenser tapping block.
12. Disconnect the discharge and liquid lines from the condenser tapping block and remove and discard the O-ring seals.
13. Install plugs in, or tape over the opened refrigerant line fittings and the condenser ports.
14. Remove the two bolts that secure the upper condenser mounting brackets to the top of the grille panel.
15. Remove the three bolts on each side of the radiator that secure the radiator mounting brackets to the grille panel.
16. Tilt the radiator back towards the engine. Use care to prevent damaging the radiator fins.
17. Carefully remove the A/C condenser from the engine compartment.

INSTALLATION

NOTE: If the A/C condenser is being replaced, add 22 milliliters (0.75 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.

1. Carefully position the A/C condenser into the engine compartment.
2. Install the two bolts that secure the upper condenser mounting brackets to the top of the grille panel. Tighten the bolts to 5 N.m (44 in. lbs.).
3. Align the radiator mounting brackets to the grille panel and install the six bolts that secure the radiator to the grille panel. Tighten the bolts to 8 N.m (72 in. lbs.).
4. Raise and support the vehicle.
5. Position the lower condenser/radiator air seal out of the way and install the two bolts that secure the lower condenser mounting bracket to the bottom of the grille panel. Tighten the bolts to 5 N.m (44 in. lbs.).
6. Lower the vehicle.
7. Remove the tape or plugs from the discharge and liquid line fittings and the condenser ports.
8. Lubricate new rubber O-ring seals with clean refrigerant oil and install them onto the discharge and liquid 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.
9. Install the discharge and liquid lines onto the condenser tapping block.
10. Install the nuts that secures the discharge and liquid lines to the condenser tapping block. Tighten the nuts to 12 N.m (105 in. lbs.).
11. If equipped, install the upper condenser/radiator air seal.
12. Install the radiator cooling fan and fan shroud.
13. Connect the upper radiator hose to the radiator and install the hose clamp.
14. Install the coolant recovery container.
15. Reconnect the battery negative cable.
16. Fill the engine cooling system.
17. Evacuate the refrigerant system.
18. Charge the refrigerant system.