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.
2. Drain the cooling system.
3. Remove the cooling fans with the cooling fan shroud.






4. Reposition the hose clamps to release the radiator lower hose using the J 38185.
5. Remove the radiator lower hose.
6. Disconnect the lower TOC line from the radiator.






7. Remove the A/C discharge hose nut from the condenser block.
8. 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.

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






10. Remove the evaporator inlet tube bolt from the condenser block.
11. Disconnect the evaporator inlet tube from the condenser block.
12. Cap or tape off the evaporator inlet tube.
13. Remove the radiator and condenser assembly.
14. Remove the condenser tube clip bolt.
15. Remove the condenser tube clip.






16. Remove the condenser to radiator mounting bolts.
17. Remove the condenser from the radiator.






18. Remove the receiver dehydrator upper bracket bolt.
19. Remove the receiver dehydrator lower mounting bolts.
20. Disconnect the receiver dehydrator from the condenser.
21. Remove and discard the sealing washers.

Installation Procedure

1. If replacing the condenser add the specified amount of PAG oil directly to the condenser.
2. Install the new sealing washers to the receiver dehydrator.






3. Install 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 to radiator 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 fitting.






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.






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.






18. Install the radiator lower hose.
19. Reposition the hose clamps to secure radiator lower hose using the J 38185.
20. Install the cooling fans with the cooling fan shroud.
21. Fill the cooling system.
22. Evacuate and recharge the A/C system.
23. Leak test the fittings using the J 39400-A.