Condenser HVAC: Service and Repair

Air Conditioning Condenser Replacement

Special Tools

J 39400-A Halogen Leak Detector

Removal Procedure

1. Remove the charged air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement (Charge Air Cooler Outlet Pipe Replacement)
2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).




4. Remove the compressor hose from the condenser.




5. Remove the condenser tube from the condenser.




6. Remove the condenser bolts.




7. Slide the condenser down to disengage the upper mounting tabs from the radiator.




8. Remove the right and left radiator side baffles.

Installation Procedure

1. If replacing the condenser add the specified amount of polyalkylene glycol (PAG) oil directly to the condenser. Refer to Refrigerant System Capacities (Capacity Specifications).




2. Install the right and left radiator side baffles.




3. Slide the condenser up to engage the upper mounting tabs into the radiator.

Caution: Refer to Fastener Caution (Fastener Caution).




4. Install the condenser bolts.

Tighten the bolts to 10 Nm (88 lb in).




5. Install the compressor hose and new seal washer to the condenser. Refer to Sealing Washer Replacement (Service and Repair).

Tighten the bolt to 20 Nm (15 lb ft).




6. Install the condenser tube and new seal washer to the condenser. Refer to Sealing Washer Replacement (Service and Repair).

Tighten the bolt to 20 Nm (15 lb ft).

7. Lower the vehicle.
8. Install the charged air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement (Charge Air Cooler Outlet Pipe Replacement)
9. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging (Refrigerant Recovery and Recharging).
10. Leak test the fittings using the J 39400-A .