Air Conditioning Condenser Replacement Heavy Duty Cooling

Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the power steering cooler mounting bolts. Refer to Power Steering Fluid Cooler Replacement .
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
4. Remove the front air deflector retainers.
5. Remove the front air deflector.
6. Remove the lower air baffle push pin retainers.



7. Remove the condenser upper bracket bolts.



8. Remove the condenser lower mounting bolts.



9. Remove the discharge line bolt.
10. Disconnect the discharge line from the condenser.
11. Remove and discard the O-ring.



12. Remove the condenser tube bolt.
13. Disconnect the condenser tube from the condenser.
14. Remove and discard the O-ring.




Important: Reposition the power steering cooler aside to aid in removing the condenser.

15. Reposition the power steering cooler.
16. Remove the condenser.

1. If replacing the condenser, add the specified amount of PAG oil directly to the condenser. Refer to Refrigerant System Capacities .
2. Install the condenser.
3. Reposition the power steering cooler into position.
4. Install a new O-ring to the condenser tube. Refer to O-Ring Replacement .
5. Connect the condenser tube to the condenser.

Notice: Refer to Fastener Notice in the Preface section.




6. Install the condenser tube bolt.

Tighten
Tighten the bolt to 9 N·m (80 lb in).

7. Install a new O-ring to the discharge line. Refer to O-Ring Replacement .
8. Connect the discharge line to the condenser.



9. Install the discharge line bolt.

Tighten
Tighten the bolt to 9 N·m (80 lb in).




10. Install the condenser lower mounting bolts.

Tighten
Tighten the bolts to 5.4 N·m (48 lb in).




11. Remove the condenser upper bracket bolts.

Tighten
Tighten the bolts to 5.4 N·m (48 lb in).

12. Install the lower air baffle push pin retainers.
13. Install the front air deflector.
14. Install the front air deflector retainers.
15. Lower the vehicle.
16. Install the power steering cooler mounting bolts. Refer to Power Steering Fluid Cooler Replacement .



17. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
18. Leak test the fittings of the component using the J 39400-A .

Air Conditioning Condenser Replacement Standard Cooling

Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
3. Remove the front air deflector retainers.
4. Remove the front air deflector.
5. Remove the lower air baffle push pin retainers.



6. Remove the condenser upper bracket bolts.



7. Remove the condenser lower mounting bolts.



8. Remove the discharge line bolt.
9. Disconnect the discharge line from the condenser.
10. Remove and discard the O-ring.



11. Remove the condenser tube bolt.
12. Disconnect the condenser tube from the condenser.
13. Remove and discard the O-ring.



14. Remove the power steering cooler line to condenser retaining bolts.
15. Remove the condenser.

1. If replacing the condenser, add the specified amount of PAG oil directly to the condenser. Refer to Refrigerant System Capacities .
2. Install the condenser.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the power steering cooler line to condenser retaining bolts.

Tighten
Tighten the bolt to 9 N·m (80 lb in).

4. Install a new O-ring to the condenser tube. Refer to O-Ring Replacement .
5. Connect the condenser tube to the condenser.



6. Install the condenser tube bolt.

Tighten
Tighten the bolt to 9 N·m (80 lb in).

7. Install a new O-ring to the discharge line. Refer to O-Ring Replacement .
8. Connect the discharge line to the condenser.



9. Install the discharge line bolt.

Tighten
Tighten the bolt to 9 N·m (80 lb in).




10. Install the condenser lower mounting bolts.

Tighten
Tighten the bolts to 5.4 N·m (48 lb in).




11. Remove the condenser upper bracket bolts.

Tighten
Tighten the bolts to 5.4 N·m (48 lb in).

12. Install the lower air baffle push pin retainers.
13. Install the front air deflector.
14. Install the front air deflector retainers.
15. Lower the vehicle.
16. Install the power steering cooler mounting bolts. Refer to Power Steering Fluid Cooler Replacement .



17. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
18. Leak test the fittings of the component using the J 39400-A .

Air Conditioning Condenser Replacement LC3

Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
3. Remove the front air deflector retainers.
4. Remove the front air deflector.
5. Remove the lower air baffle push pin retainers.
6. Remove the charge air cooler radiator. Refer to Charge Air Cooler Radiator Replacement.



7. Remove the condenser upper bracket bolts.



8. Remove the condenser lower mounting bolts.



9. Remove the discharge line bolt.
10. Disconnect the discharge line from the condenser.
11. Remove and discard the O-ring.



12. Remove the condenser tube bolt.
13. Disconnect the condenser tube from the condenser.
14. Remove and discard the O-ring.



15. Remove the power steering cooler line to condenser retaining bolts.
16. Remove the condenser.

1. If replacing the condenser, add the specified amount of PAG oil directly to the condenser. Refer to Refrigerant System Capacities .
2. Install the condenser.

Notice: Refer to Fastener Notice in the Preface section.

3. Install the power steering cooler line to condenser retaining bolts.

Tighten
Tighten the bolt to 9 N·m (80 lb in).

4. Install a new O-ring to the condenser tube. Refer to O-Ring Replacement .
5. Connect the condenser tube to the condenser.



6. Install the condenser tube bolt.

Tighten
Tighten the bolt to 9 N·m (80 lb in).

7. Install a new O-ring to the discharge line. Refer to O-Ring Replacement .
8. Connect the discharge line to the condenser.



9. Install the discharge line bolt.

Tighten
Tighten the bolt to 9 N·m (80 lb in).




10. Install the condenser lower mounting bolts.

Tighten
Tighten the bolts to 5.4 N·m (48 lb in).




11. Instal the condenser upper bracket bolts.

Tighten
Tighten the bolts to 5.4 N·m (48 lb in).

12. Install the charge air cooler radiator. Refer to Charge Air Cooler Radiator Replacement.
13. Install the lower air baffle push pin retainers.
14. Install the front air deflector.
15. Install the front air deflector retainers.
16. Lower the vehicle.
17. Install the power steering cooler mounting bolts. Refer to Power Steering Fluid Cooler Replacement.



18. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
19. Leak test the fittings of the component using the J 39400-A .