Condenser HVAC: Service and Repair

REMOVAL

WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH.

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 reinstalled in their proper locations in order for the A/C and engine cooling systems to perform as designed.

1. Recover the refrigerant from the refrigerant system.
2. Remove the front fascia.
3. Remove the four radiator sight shield retaining pins and the radiator sight shield.

Radiator Air Seals:

4. Remove the radiator air seal retaining pins and the air seals.
5. Note the hood latch location on the upper radiator crossmember. Mark the location of latch for reinstallation.
6. Remove the two bolts that secure the hood latch to the upper radiator crossmember and position the latch out of the way.
7. Remove the four bolts that secure the transmission fluid oil cooler to the A/C condenser and position the fluid cooler out of the way.

Condenser Lines:

8. Remove the nuts that secure the discharge and liquid lines to the A/C condenser.
9. Disconnect the discharge and liquid lines from the A/C condenser and remove the O-ring seals and gaskets.
10. Install plug in, or tape over the opened refrigerant line fittings and the condenser ports.
11. Remove the two bolts that secure the A/C condenser to the radiator.
12. Lift the A/C condenser and disengage the lower condenser mounting brackets from the radiator.
13. Remove the A/C condenser from the engine compartment.

INSTALLATION

NOTE:
- If the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
- Be certain that each of the radiator and condenser air seals are reinstalled in their proper locations. These air seals are required in order for the A/C and engine cooling systems to perform as designed.

1. Position the A/C condenser into the engine compartment.
2. Engage the lower condenser mounting brackets to the radiator.
3. Install the two bolts that secure the A/C condenser to the radiator. Tighten the bolts to 5 N.m (45 in. lbs.).
4. Remove the tape or plug from the opened refrigerant line fittings the condenser ports.
5. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge and liquid line fittings.
6. Connect the discharge and liquid lines to the A/C condenser.
7. Install the nuts that secure the discharge and liquid lines to the A/C condenser. Tighten the nuts to 23 N.m (17 ft. lbs.).
8. Position the transmission fluid oil cooler onto the A/C condenser and install the four retaining bolts. Tighten the bolts to 5 N.m (45 in. lbs.).
9. Position the hood latch to the front of the upper radiator crossmember.
10. Loosely install the two bolts that secure the hood latch to the upper radiator crossmember. Check and adjust the hood latch position as required. Tighten the bolts to 14 N.m (123 in. lbs.).
11. Install the radiator air seals and the air seal retaining pins.
12. Install the radiator sight shield and the sight shield retaining pins.
13. Install the front fascia.
14. Evacuate the refrigerant system.
15. Charge the refrigerant system.