Condenser HVAC: Service and Repair

Air Conditioning Condenser Replacement

Tools Required

- J 38185 Hose Clamp Pliers
- J 39400-A Halogen Leak Detector

Removal Procedure

1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging Service and Repair.
2. Drain the cooling system. Refer to Cooling System Draining and Filling Service and Repair.
3. Remove the cooling fans with the cooling fan shroud. Refer to Engine Coolant Fan Replacement Service and Repair.






4. Reposition the radiator outlet hose clamp at the water pump housing using the J 38185.
5. Disconnect the radiator outlet hose from the water pump housing.
6. Reposition the radiator outlet hose clamp at the radiator using the J 38185.
7. Disconnect the radiator outlet hose from the radiator.
8. Remove the radiator outlet hose.
9. Disconnect the lower TOC line from the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection .






10. Remove the A/C discharge hose nut from the condenser block.
11. Disconnect the A/C discharge hose from the condenser block.

Important: Cap or tape off the open A/C refrigerant components immediately to prevent system contamination.

12. Cap or tape off the A/C discharge hose.






13. Remove the evaporator inlet tube bolt from the condenser block.
14. Disconnect the evaporator inlet tube from the condenser block.
15. Cap or tape off the evaporator inlet tube.
16. Remove the radiator and condenser assembly.
17. Remove the condenser tube clip bolt.
18. Remove the condenser tube clip.






19. Remove the condenser mounting bolts.
20. Remove the condenser from the radiator.






21. Remove the receiver dehydrator upper bracket bolt.
22. Remove the receiver dehydrator lower mounting bolts.
23. Disconnect the receiver dehydrator from the condenser.
24. Remove and discard the sealing washers.

Installation Procedure

1. If replacing the condenser add the specified amount of PAG oil directly to the condenser. Refer to Refrigerant System Specifications Specifications.
2. Install new sealing washers to the receiver dehydrator. Refer to Air Conditioning System Seal Replacement Service and Repair.






3. Connect the receiver dehydrator to the condenser.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

4. Install the receiver dehydrator lower mounting bolts.

Tighten
Tighten the bolts to 6 Nm (53 lb in).

5. Install the receiver dehydrator upper bracket bolt.

Tighten
Tighten the bolt to 6 Nm (53 lb in).

6. Install the condenser to the radiator.






7. Install the condenser mounting bolts.

Tighten
Tighten the bolts to 6 Nm (53 lb in).

8. Install the condenser tube clip.
9. Install the condenser tube clip bolt.

Tighten
Tighten the bolt to 2.5 Nm (22 lb in).

10. Install the radiator and condenser assembly.
11. Remove cap or tape from the evaporator inlet tube.
12. Install a new sealing washer to the evaporator inlet tube fitting. Refer to Air Conditioning System Seal Replacement Service and Repair.






13. Install the evaporator inlet tube and bolt to the condenser block.

Tighten
Tighten the bolt to 16 Nm (12 lb ft).

14. Remove cap or tape from the A/C discharge hose.
15. Install a new sealing washer to the A/C discharge hose fitting. Refer to Air Conditioning System Seal Replacement Service and Repair.






16. Install the A/C discharge hose and nut to the condenser block.

Tighten
Tighten the nut to 16 Nm (12 lb ft).

17. Connect the lower TOC line to the radiator. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection .






18. Install the radiator outlet hose.
19. Connect the radiator outlet hose to the radiator.
20. Reposition the radiator outlet hose clamp at the radiator to secure the hose using the J 38185.
21. Connect the radiator outlet hose to the water pump housing.
22. Reposition the radiator outlet hose clamp at the water pump housing to secure the hose using the J 38185.
23. Install the cooling fans with the cooling fan shroud. Refer to Engine Coolant Fan Replacement Service and Repair.
24. Fill the cooling system. Refer to Cooling System Draining and Filling Service and Repair.
25. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging Service and Repair.
26. Leak test the fittings of the component using J 39400-A.