Condenser HVAC: Service and Repair

Condenser

Service Repair No - 82.15.07

Remove
1. Disconnect battery earth lead.
2. Recover refrigerant from A/C system.
3. Td4 models: Remove intercooler.
4. Remove bumper valance.







5. KV6 models: Remove 2 bolts securing PAS fluid cooler to armature.







6. Up to 04MY: Remove 4 nuts and 4 bolts securing armature to body, remove armature.
7. 04MY on: Remove 4 bolts securing armature to crash cans and remove armature.
8. If fitted, remove 4 scrivets securing LH and RH air deflectors, remove both deflectors.







9. Remove 2 bolts securing condenser to radiator.







10. Remove 2 bolts securing receiver drier mounting brackets to radiator.







11. Remove 2 bolts securing A/C pipes to condenser and release pipes from condenser.

CAUTION: Before disconnecting or removing components, ensure the immediate area around joint faces and connections are clean. Plug open connections to prevent contamination.

12. Remove and discard 'O' rings from A/C pipes.







13. Remove condenser.
14. Remove 8 screws, securing 4 mounting brackets to condenser and move aside.
15. Remove and discard receiver drier, plug connections.

Refit
1. Fit condenser mounting brackets, fully tighten LH screws. Leave RH screws loose until receiver drier is fitted.

CAUTION: Ensure that bolts of the correct length are used on refit.

2. Lubricate new 'O' rings with clean refrigerant oil, fit one seal to each condenser pipe.
3. Position A/C pipes to condenser, fit bolts and tighten to 8 Nm (6 lbf.ft).
4. Fit bolts securing condenser to radiator and tighten to 8 Nm (6 lbf.ft).
5. Fit receiver drier assembly to condenser.
6. Fit air deflectors and secure with scrivets.
7. Up to 04MY: Position armature, fit and tighten 4 nuts and bolts securing armature to body to 25 Nm (18 lbf.ft).
8. 04MY on: Position armature, fit bolts securing armature to crash cans and tighten to 25 Nm (18 lbf.ft).
9. KV6 models: Align PAS fluid cooler and tighten bolts to 8 Nm (6 lbf.ft).
10. Fit bumper valance.
11. Td4 models: Fit intercooler.
12. Recharge A/C system.
13. Connect battery earth lead.