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Air Conditioning Condenser Replacement

Removal Procedure

    Warning: Refer to Battery Disconnect Warning in the Preface section.


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  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  2. Discharge and recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  3. Remove the bonnet primary catch bracket. Refer to Bonnet Primary Catch Bracket Replacement Radiator Replacement.
  4. Remove the liquid line bolt from the condenser.
  5. Remove the liquid line from the condenser.
  6. Remove the compressor hose bolt from the condenser.
  7. Remove the compressor hose from the condenser.

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  9. Remove the upper condenser mount bolts.
  10. If equipped with diesel, remove the right headlamp assembly. Refer to Headlamp Replacement : Long Body → Short Body
  11. If equipped with diesel, remove right side radiator baffle.
  12. If equipped with diesel, remove lower condenser mounting bolts.
  13. Tilt the condenser away from the radiator mount support.
  14. Lift the condenser up and out of the engine compartment.
  15. Cap all the open fittings to prevent contamination.

Installation Procedure


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  1. Ensure that the condenser rubber mounts are in place.
  2. Install the condenser into the vehicle. The lower mount shock protectors must fit into the holes provided.
  3. Position the condenser into the radiator support mount holes.
  4. If equipped with diesel, install lower condenser mounting bolts.
  5. If equipped with diesel, install right side radiator baffle.
  6. If equipped with diesel, install the right headlamp assembly. Refer to Headlamp Replacement : Long Body → Short Body
  7. Caution: Refer to Fastener Caution in the Preface section.

  8. Install the upper condenser mount bolts and tighten to 4 N·m (35 lb in).
  9. Install a new seal washer onto the compressor hose at the condenser.
  10. Install the compressor hose to the condenser.
  11. Install the compressor hose bolt to the condenser and tighten the bolt to 16 N·m (12 lb in).

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  13. Install a new seal washer onto the liquid line at the condenser.
  14. Install the liquid line to the condenser.
  15. Install the liquid line bolt to the condenser and tighten to 16 N·m (12 lb ft).
  16. Install the bonnet primary catch bracket. Refer to Bonnet Primary Catch Bracket Replacement Radiator Replacement.
  17. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
  18. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  19. Operate the HVAC control to verify the correct function of the heating and cooling systems.
   


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