Condenser HVAC: Service and Repair

REMOVAL
The condenser is located between the radiator and the front bumper. The condenser can be serviced without having to drain the cooling system or removal of the radiator.

WARNING:
- AVOID BREATHING A/C REFRIGERANT AND LUBRICANT VAPOR OR MIST EXPOSURE MAY IRRITATE EYES, NOSE AND THROAT. USE ONLY APPROVED SERVICE EQUIPMENT MEETING SAE REQUIREMENTS TO RECOVER R-134a SYSTEM. IF ACCIDENTAL SYSTEM DISCHARGE OCCURS, VENTILATE WORK AREA BEFORE RESUMING SERVICE.
- R-134a SERVICE EQUIPMENT OR VEHICLE A/C SYSTEM SHOULD NOT BE PRESSURE TESTED OR LEAK TESTED WITH COMPRESSED AIR. SOME MIXTURES OF AIR/R-134a HAVE BEEN SHOWN TO BE COMBUSTIBLE AT ELEVATED PRESSURES. THESE MIXTURES ARE POTENTIALLY DANGEROUS AND MAY RESULT IN FIRE OR EXPLOSION CAUSING INJURY OR PROPERTY DAMAGE.

1. Remove refrigerant from the A/C system using a refrigerant recovery machine.
2. Disconnect and cap A/C lines at the condenser.

Fig.2 Radiator Support:

3. Remove upper radiator support bars and cross-member.
4. Remove condenser lines. Use Special Tool kit 7193 for quick disconnect couplers.
5. Remove radiator fan module mounts.

Fig.3 Condenser Mounting:

6. Remove condenser mounting screws.

CAUTION: Avoid bending or breaking condenser inlet tube when lifting condenser from the vehicle.

7. Lift radiator out of lower mounting brackets. Condenser lower mounting bracket is trapped between the radiator lower isolator and plastic radiator tank pin. It is necessary to lift radiator and push down on condenser to free condenser bracket from radiator pins.

Fig.4 Condenser Lines And Mounts:

8. Lift condenser from vehicle.

INSTALLATION
1. Position the condenser in the vehicle.
2. Install the condenser mounting screws.
3. Install the radiator fan module mounts.
4. Connect the refrigerant Tines to the condenser.
5. Install the upper radiator support bars and cross-member.
6. Recharge the A/C system.

NOTE: Check for proper installation of the foam seals around the perimeter of the condenser to ensure airflow through the A/C and cooling systems.