A/C Condenser Housing

REMOVAL

WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH.

1. Disconnect and isolate the negative battery cable.
2. Remove the air filter from the rear A/C evaporator housing.
3. Recover the refrigerant from the rear refrigerant system.
4. Remove the cover from the rear A/C condenser housing.

Rear A/C Condenser Housing:

5. Disconnect the rear A/C wire harness from the rear blower motor suppression filter and the rear A/C high pressure switch.
6. Remove the retaining straps that secure the rear A/C wire harness to the rear liquid line and position the wire harness out of the way.
7. Remove the screw and bracket that secures the rear discharge line to the right side of the rear condenser housing.
8. Disconnect the rear discharge line from the rear A/C condenser and remove and discard the O-ring seal.
9. Disconnect the rear liquid line from the rear refrigerant reservoir outlet and remove and discard the O-ring seal.
10. Install plugs into, or tape over the rear refrigerant line fittings and condenser and reservoir ports.
11. Remove the eight nuts and washers that secure the rear A/C condenser housing to the roof panel.
12. Carefully separate the body sealer between the rear A/C condenser housing and the roof panel and with help from an assistant, remove the condenser housing.
13. Remove any shims and trim the body sealer on top of the roof panel down to a thickness of 2 mm (0.078 in.).

INSTALLATION

NOTE: Be certain to add refrigerant oil if the rear A/C condenser is being replaced. The refrigerant oil must be drained from the old condenser and measured to determine the amount of refrigerant oil to add to the new condenser. Use only refrigerant oil of the type recommended for the rear A/C compressor in the vehicle.

1. If the rear A/C condenser is being replaced, install the correct amount and type of refrigerant oil into the new rear A/C condenser. Drain the old condenser and measure the refrigerant oil. Fill the new condenser with the same amount of new refrigerant oil that was drained out of the old condenser.
2. Install new body sealant and any removed shims onto the top of the roof panel.
3. With help from an assistant, position the rear A/C condenser housing onto the top of the roof panel.
4. Install the eight nuts and washers that secure the rear A/C condenser housing to the roof panel. Tighten the nuts to 25 N.m (18 ft. lbs.).
5. Remove the tape or plugs from the rear liquid line fitting and rear refrigerant reservoir port.
6. Lubricate a new O-ring seal with clean refrigerant oil and install it onto the rear liquid line fitting. Use only the specified O-ring seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the rear A/C compressor in the vehicle.
7. Connect the rear liquid line to the rear refrigerant reservoir outlet. Tighten the liquid line nut to 35 N.m (26 ft. lbs.).
8. Remove the tape or plugs from the rear discharge line fitting and rear condenser port.
9. Lubricate a new O-ring seal with clean refrigerant oil and install it onto the rear discharge line fitting. Use only the specified O-ring seal as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the rear A/C compressor in the vehicle.
10. Connect the rear discharge line to the rear A/C condenser. Tighten the discharge line nut to 35 N.m (26 ft. lbs.).
11. Install the bracket and screw that secures the rear discharge line to the right side of the rear condenser housing. Tighten the screw securely.
12. Connect the rear A/C wire harness to the rear blower motor suppression filter and to the rear A/C high pressure switch.
13. Install new retaining straps to secure the rear A/C wire harness to the rear liquid line.
14. Install a new rear receiver/drier.
15. Reconnect the negative battery cable.
16. Evacuate the rear refrigerant system.
17. Charge the rear refrigerant system.
18. Install the rear air filter.
19. Install the cover onto the rear A/C condenser housing.