Condenser HVAC: Service and Repair

Condenser

Removal
1. Disconnect battery ground cable.
2. Drain radiator coolant only.
3. Recover refrigerant from air conditioning system, Service and Repair
4. Release both gas struts, set the engine cover fully forward to the service access position and support with a wooden (or similar) strut.


5. CAUTION: Take care not to damage hood or radiator grille.


Remove twin fan and motor assembly.







6. Disconnect radiator bleed hose.
- Release connection.
7. Remove retaining clip which secures transmission oil cooler upper and lower pipes.







8. Disconnect transmission oil cooler lower pipe from radiator.
1. Release union nut and disconnect pipe.
- Discard O-ring seal.
2. Install suitable blanking plugs.







9. From above the vehicle, disconnect transmission oil cooler upper pipe from radiator.
1. Release union nut and disconnect pipe
- Discard O-ring seal.
2. Install suitable blanking plugs.







10. Disconnect radiator bottom hose.
1. Release hose retaining clip.
2. Disconnect hose.







11. Disconnect radiator top hose.
1. Release hose retaining clip.
2. Disconnect hose.







12. Disconnect connector from pressure switch.







13. Release radiator top retaining panel.
- Remove bolts.







14. Disconnect compressor to condenser discharge line from condenser.
1. Remove bolt.
2. Discard O-ring seal.
3. Install suitable blanking plugs.







15. Disconnect condenser to receiver/drier line from receiver/drier.
1. Remove bolt.
2. Discard O-ring seal.
3. Install suitable blanking plugs.







16. Remove radiator retaining panel.
1. Remove panel.
2. Remove mounting bushes.







17. Disconnect hood switch harness connector.







18. Remove radiator/condenser assembly.
- Clean coolant spillage from radiator lower carrier panel.







19. Separate condenser from radiator.
1. Remove bolts.
2. Remove condenser.







20. If necessary, remove condenser to receiver/drier line from condenser.
- Remove bolt.
- Detach hose from clip.
- Discard O-ring seal.
- Install suitable blanking plugs.

Installation







1. If necessary, renew radiator top and bottom foam sealing strips.







2. If previously removed, install condenser to receiver/drier line at condenser.
- Remove blanking plugs.
- Install new O-ring seal and lubricate with clean compressor oil.
- Install bolt (8 - 10 Nm).
- Locate hose to clip.







3. Install condenser to radiator.
- Install bolts (8 - 10 Nm).







4. Install radiator/condenser assembly.







5. Connect condenser to receiver/drier line at receiver/drier.
- Remove blanking plugs.
- Install new O-ring seal and lubricate with clean A/C compressor oil.
- Connect hose.
- Install bolt (8 - 10 Nm).







6. Connect compressor to condenser discharge line at condenser.
- Remove blanking plugs.
- Install new O-ring seal and lubricate with clean A/C compressor oil.
- Connect hose.
- Install bolt (8 - 10 Nm).







7. Connect transmission oil cooler upper pipe.
- Remove blanking plugs.
- Install new O-ring seal and lubricate with clean automatic transmission fluid.
- Connect union nut to radiator and tighten.







8. Connect transmission oil cooler lower pipe.
- Remove blanking plugs.
- Install new O-ring seal and lubricate with clean automatic transmission fluid.







9. Connect radiator bleed hose to radiator.







10. Connect radiator top hose to radiator.
1. Connect top hose.
2. Reposition and tighten hose clip.







11. Install radiator retaining panel.
- Install bolts and sequentially tighten from center outwards.







12. Connect radiator bottom hose to radiator.
1. Connect bottom hose.
2. Reposition and tighten hose cup.
13. Install twin fan and motor assembly.






14. Connect pressure switch.
15. Remove the temporary wooden support strut and reconnect gas struts to the hood.
16. Check transmission fluid level and top up as required; refer to TRANSMISSION SYSTEMS both N/A and SC.
17. Refill the cooling system.
18. Recharge air conditioning system, Service and Repair
19. Reconnect battery ground cable.