Condenser HVAC: Service and Repair

WARNING: Follow safety instructions for working on air-conditioning system, Service Precautions

NOTE:
- Read instructions on fast and slow leaks first in General repair Instruction. Service and Repair
- When replacing condenser, always replace 0-rings and snap-on connections.





1. Disconnect battery negative cable.
2. Drain system of refrigerant. Service and Repair
3. Disconnect air Intake hose (P3)
- Remove hose connector to fan cover.
4. Remove control unit box air intake hoses (P4).
- Remove diagnostic unit from control unit box.
- Disconnect control unit box air intake hoses.
- Remove inlet hose connector to fan cover (2 clips).
5. Remove fan cover (P5).
- Disconnect relays from relay casing.
- Disconnect fan cover (4 screws), fold cover back towards engine.
- Remove relay shelf and spacers





6. Remove cover plate (3 x Torx T25 screws)(P6).
7. Remove air controls (2 x Torx T30)(P7).
8. Remove condenser (P8).
- Disconnect pipes from condenser.
- Disconnect high-pressure sensor connector.
- Remove high-pressure sensor.
- Disconnect condenser (4 screws), upper screws first.
- The lower left-hand screw also holds two brackets remove these as well.
- Lift condenser out.
- Switch high-pressure sensor and rubber gasket to new condenser. Torque setting 10 Nm (7 ft.lb.).

Installation:
9. Install Condenser.(P9)
- Pipe connections to condenser. Pipe connection torque settings: to condenser 20 Nm (15 ft.lb.), from condenser 20 Nm.

Note:
- The bracket for the pressure hose to compressor is located between the condenser and cooler. Ensure pressure hose is clear of fan cover underside.
- Use new O-rings lubricated with compressor oil.

10. Fill system with refrigerant and test for leaks. Service and Repair
11.Install;
- Air guide.
- Cover plate.
- Fan cover.
- Relays in relay shelf.
- Control unit box fresh air hoses and vent.
- Control unit box diagnostic unit.
- Air intake hose and vent.
- Battery negative cable.