Condenser HVAC: Service and Repair
CONDENSER REMOVAL1. Recover refrigerant using an approved refrigerant recoverv system.
2. On DOHC (LLO) engines, remove air cleaner housing and air induction hose at intake manifold.
3. On SOHC (LKO) engines, remove air induction ducts.
4. Remove compteasor discharge hose from condenser inlet.
CAUTION: MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED. TO HELP AVOID PERSONAL INJURY WHEN A VEHICLE IS ON A HOIST, PROVIDE ADDITIONAL SUPPORT FOR THE VEHICLE ON THE OPPOSITE END FROM WHICH COMPONENTS ARE BEING REMOVED.
5. Raise vehicle.
6. Remove lower splash shield.
7. Remove receiver-dehydrator hose from condenser outlet.
8. Remove condenser bracket-to-radiator bolts
9. Facing the vehicle, pull the condenser back slightly to release it from the mounting pads. Carefully slide condenser straight down.
10. Rotate left end of condenser down so inlet pipe is straight up.
11. Rotate bottom of condenser rearward to unhook inlet pipe from the lower radiator mount. Remove condenser from vehicle.
IMPORTANT: Make sure to use the proper condenser for engine application.
^ DOHC (LKO) Engine: Serpentine condenser
^ SOHC (LLO) Engine: Tabe and fin cundenser
^ 1993 DOHC (LKO) engine uses a new "Header Type" condenser. This is a lightweight aluminum high efficiency design. All 1991 through 1993 Saturn models will be serviced with this type of condenser.
INSTALLATION
1. Install condenser by holding it at a right angle to the radiator with the inlet pointing upward. Hook the inlet over the lower radiator mount and carefully rotate to a position parallel with the radiator.
2. Carefully slide condenser up snd install on mounting pads.
3. Install condenser bracket-to-radiator bolts.
4. Lubricate and install new O-ring on receiver-dehydrator hose.
5. Install receiver-dehydrator hose to condenser outlet.
IMPORTANT: Make sure receiver-dehydrator hose is parallel with the condenser after tightening the fitting. This will provide hose clearance to the body and frame, avoiding potential damage to the hose.
6. Install lower splash shield.
7. Lower vehicle.
8. Lubricate and install new 0-ring on compressor discharge hose.
9. Install compressor discharge hose to condenser inlet.
10. Tighten fitting.
IMPORTANT: Make sure discharge hose pipe is horizontal after tightening the fitting. This will prevent the discharge hose from contacting the suction hose and transaxie oil cooler lines, avoiding potential damage to the hoses.
11. On DOHC (LLO) engines, install air cleaner housing and air induction hose.
12. On SOHC (LKO) engines, install air induction ducts.
13. Evacuate, charge, and leak test A/C system.