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 and Failure to follow these instructions may result in possible serious or fatal injury.

CAUTION: The A/C receiver/drier must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C receiver drier can cause serious damage to the replacement A/C compressor.

NOTE: Before removing the A/C condenser, note the location of each of the radiator and condenser air seals. These seals are used to direct air through the A/C condenser and the 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. Drain the engine cooling system.
4. Remove the engine cover
5. Remove the air intake hose and air cleaner housing.
6. Remove the coolant recovery container.
7. On 2.8L engine models, disconnect the charge air cooler outlet hose from the Charge Air Cooler (CAC) and position the hose out of the way.
8. Remove the nuts (3 and 5) that secure the A/C discharge line (2) and A/C liquid line (4) to the A/C condenser (1).
9. Disconnect the A/C discharge and liquid line from the A/C condenser and remove and discard the Oring seals and gaskets.
10. Install plugs in, or tape over the opened refrigerant line fittings and condenser ports.







11. Remove the grille (2).
12. When equipped with automatic transmission, remove the bolt (1) and disconnect the transmission cooler lines (3) from the transmission cooler (4).







13. Remove the radiator fan and shroud assembly.
14. On 2.8L engine models, remove the bolts that secure the Charge Air Cooler (CAC) to the front of the radiator.
15. Remove the push-pin retainers that secure the radiator air seals to the radiator support.
16. Remove the radiator (2), A/C condenser (1) and transmission oil cooler (when equipped) as an assembly and place on a workbench.
17. When equipped with automatic transmission, remove the transmission cooler from the front of the A/C condenser.
18. Remove the five bolts (3, 4, 5, 6 and 8) that secure the A/C condenser to the radiator and separate the condenser from the radiator.
19. If required, remove the A/C receiver/drier (7) from the A/C condenser.

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.
- The A/C receiver/drier must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C receiver drier can cause serious damage to the replacement A/C compressor.

NOTE:
- When replacing multiple A/C system components, see the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system.
- If the A/C condenser is being replaced, add 60 milliliters (2 fluid ounces) 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 and gaskets is required anytime a refrigerant line disconnected. Failure to replace the rubber O-ring seals and metal gaskets may result in a refrigerant system leak.
- Be certain that the radiator 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. If required, install the A/C receiver/drier (7) onto the right side of the A/C condenser (1).
2. Position the A/C condenser to the front of the radiator (2) and install the five retaining bolts (3, 4, 5, 6 and 8). Tighten the bolts to 5 N.m (45 in. lbs.).
3. When equipped with automatic transmission, install the transmission cooler onto the front of the A/C condenser.
4. Install the radiator, A/C condenser and transmission oil cooler (when equipped) as an assembly.
5. Position the radiator air seals to the radiator support and install the push-pin retainers.
6. On 2.8L engine models, install the bolts that secure the Charge Air Cooler (CAC) to the front of the radiator.
7. Install the radiator fan and shroud assembly.







8. When equipped with automatic transmission, connect the transmission cooler lines (3) to the transmission cooler (4) using new O-ring seals and install the retaining bolt (1).
9. Install the grille (2).







10. Remove the tape or plugs from the opened refrigerant line fittings and condenser ports.
11. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the refrigerant line fittings. Use only the specified O-ring seals 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.
12. Connect the A/C discharge line (2) and the A/C liquid line (4) to the A/C condenser (1). Install the retaining nuts (3 and 5). Tighten the nuts to 23 N.m (17 ft. lbs.).
13. On 2.8L engine models, connect the air outlet hose to the CAC.
14. Install the coolant recovery container.
15. Install the air cleaner housing and air intake hose.
16. Reconnect the negative battery cable.
17. Refill the engine cooling system.
18. Install the engine cover.
19. Evacuate the refrigerant system.
20. If the A/C condenser is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, see 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.
21. Charge the refrigerant system.
22. If equipped with automatic transmission, check the automatic transmission fluid level and fill as required.