Condenser HVAC: Service and Repair

CONDENSER REPLACEMENT

REMOVAL PROCEDURE
1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.




3. Disconnect the pusher fan electrical connector.
4. Remove the pusher fan harness from the puller fan shroud tabs and push the harness clear of the radiator end tank.




5. Remove the nut that secures the condenser hose to the evaporator hose assembly.

CAUTION: Do not remove hoses or lines before system is fully discharged. System may be under pressure and contact with R134a may cause personal injury.

6. Install the caps on the condenser hose and on the evaporator hose assembly to prevent moisture entry and oil spillage.




7. Raise the vehicle. Refer to Vehicle Lifting.
8. Remove the gasket that separates the radiator from the condenser by pulling down on one end of the gasket and peeling back.




9. Remove the retainer nuts and washers from the pusher fan.




10. Remove the lower fan shroud by pulling the shroud forward and then down.




11. Remove the bolt that secures the condenser hose to the condenser block fitting.




12. Remove the fasteners that secure the hose clamp to the condenser and remove the condenser hose.
13. Install the caps on the condenser hose and on the condenser block fitting to prevent moisture entry and oil spillage.




14. Remove the bolt that secures the discharge line to the condenser block fitting.
15. Install caps on the discharge line and condenser block fitting to prevent moisture entry and oil spillage.




16. Remove the bolt that secures the condenser block fitting to the radiator end tank.




17. Remove the condenser bolts.




18. Slide the condenser down then rotate the bottom forward to remove.




19. Remove the bolts from the receiver dehydrator line fitting.




20. Loosen the bolt from the receiver dehydrator clamp and remove the dehydrator.

INSTALLATION PROCEDURE




1. If replacing the condenser, add PAG oil to the condenser. Refer to Refrigerant System Capacities for system capacity information.
2. Install the receiver dehydrator into the clamp. DO NOT tighten the clamp.
3. Install new O-rings to the receiver dehydrator.

NOTE: Refer to Fastener Notice in Service Precautions.




4. Tighten the receiver dehydrator block bolts

Tighten the bolts to 3 N.m (27 lb in).

5. Tighten the receiver dehydrator clamp bolt.

Tighten the bolt to 5 N.m (44 lb in).




6. Install the condenser to the radiator by sliding the condenser tabs under the radiator brackets.

IMPORTANT: The condenser block must be engaged to the radiator end tank bracket before sliding the condenser upward.




7. Install the bolts that secure the condenser to the radiator.

Tighten the bolts to 5 N.m (44 lb in).




8. Install the condenser block to the radiator end tank bolt.

Tighten the bolt to 5 N.m (44 lb in).




9. Remove the condenser hose to the condenser cap and plug.
10. Install a new seal washer.
11. Remove the condenser block cap and install the discharge line.
12. Install the discharge hose to the condenser block fitting and install the bolt.

Tighten the bolt to 20 N.m (15 lb ft).




13. Install the condenser hose to the condenser block fitting and install the bolt.

Tighten the bolt to 20 N.m (15 lb ft).

14. Install the condenser hose clamps onto the condenser studs and install the bolts.

Tighten the bolts to 5 N.m (44 lb in).




15. Install the gasket that separates the radiator from the condenser.




16. Slide the upper pusher fan shroud under the retaining tabs located at the upper edge of the condenser.
17. Rotate the lower fan shroud onto the lower mounting studs and install the retaining nuts.

Tighten the nuts to 5 N.m (44 lb in).

18. Route the pusher fan electrical harness around the outside of the radiator end tank, below the upper radiator hose.

NOTE: Position pusher fan electrical harness in shroud indentation to prevent harness damage.

19. Lower the vehicle.




20. Remove the evaporator hose assembly and the condenser hose caps.
21. Install new seal washers.
22. Install the evaporator hose assembly to the condenser hose and install the nut.

Tighten the nut to 12 N.m (9 lb ft).

23. Install the condenser hose into the rail clamp.




24. Install the pusher fan harness into the mounting tabs on the puller fan shroud.
25. Connect the pusher fan electrical connector.
26. Connect the negative battery cable.
27. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
28. Using J 39400-A , leak test the fittings of the component.