REMOVAL & INSTALLATION

Except Montero

CAUTION
The compressed refrigerant used in the air conditioning system expands into the atmosphere at a temperature of 2°F (-16.5°C) or lower. This will freeze any surface, including your eyes, that it contacts. In addition, the refrigerant decomposes into a poisonous gas in the presence of a flame. Do not open or disconnect any part of the air conditioning system until you have read the safety warnings in Section 1.

1. Have the air conditioning system discharged by a trained and certified mechanic using a recovery/recycling machine.
2. Disconnect the negative battery cable.

   Fig. 1: Condenser assembly and related components

3. Remove the grille and, if needed for access to the condenser mounting bolts, the front bumper. Remove anything else that is restricting access to the condenser mounting bolts.
4. Remove the condenser refrigerant lines and plug them.

   NOTE: On the some models the receiver/drier assembly need to be removed first to allow easier access to the condenser.

5. Remove the condenser retaining bolts. Remove the condenser from the vehicle.

   To install:

6. Install the condenser in the vehicle and evenly tighten all the mounting bolts equally.

   NOTE: Always use new O-rings in all refrigerant lines.

7. Reconnect all the refrigerant lines.
8. Install all the equipment which was removed to gain access to the condenser mounting bolts.
9. Connect the negative battery cable.
10. Have the system evacuated and recharged as soon as possible.

Montero — 2.6L and 3.0L (12 Valve) Engines

SINGLE AIR CONDITIONER

1. Have the air conditioning system discharged by a trained and certified mechanic using a recovery/recycling machine.
2. Remove the grille. Use care not to damage the plastic.
3. Carefully, and with the use of two wrenches, disconnect the lines in front of and running to the condenser. On the V6 there are three line junctions on the right side of the condenser and and four junctions on the left side. On the 4-cylinder engine, disconnect the lines at the condenser ports and disconnect the receiver/dryer.
4. Remove the receiver/dryer mounting bolts(s) and remove the receiver/drier.
5. Unplug the electric condenser fan, remove the mounting bolts for the fan and remove the fan.
6. Remove the condenser mounting bolt on the side opposite the receiver/dryer and carefully lift the condenser out of the vehicle.

   Fig. 2: Montero single air conditioner system line routing and torque specifications — 2.6L and 3.0L (12 valve) engines

   To install:

7. Install the unit and tighten the right retaining bolt.
8. Install the fan assembly and tighten the retaining bolts. Connect the fan wiring harness.
9. Install the receiver/dryer and its mounting bolt(s); at least one of these bolts serves as the other condenser mounting bolt.
10. Connect each line and hose by hand, making certain the O-rings are intact and not damaged during installation. Tighten each fitting by hand first, then using two wrenches, tighten them to 18 ft. lbs. (24 Nm). Do not overtighten these fittings.
11. Evacuate and recharge the system; check carefully for leaks.
12. Reinstall the grille.

DUAL AIR CONDITIONERS

1. Have the air conditioner system discharged by a trained and qualified mechanic using a recovery/recycling machine.
2. Remove the grille. Use care not to damage the plastic.
3. Carefully, and with the use of two wrenches, disconnect the lines in front of and running to the condenser. The presence of the second condenser adds two more lines to the maze; disconnect the lines at the joints closest to each condenser. Disconnect both ends of any line in the way; do not bend or force the lines out of the way.
4. Remove the receiver/dryer mounting bolts(s) and remove the receiver/drier.
5. Unplug the large electric condenser fan, remove the mounting bolts for the fan and remove the fan.
6. Remove the condenser mounting bolt on the side opposite the receiver/dryer and carefully lift the main condenser out of the vehicle.
7. Unplug the connector for the smaller auxiliary fan. Unbolt the sub-condenser from its brackets and remove it.
8. Remove the fan assembly from the sub-condenser.

   Fig. 3: Montero dual air conditioner system line routing and torque specifications — 2.6L and 3.0L (12 valve) engines

   To install:

9. Attach the small fan to the condenser before placing the unit in the vehicle. Install the bracket bolts.
10. Install the main condenser and tighten the right retaining bolt.
11. Install the large fan assembly and tighten the retaining bolts. Connect the fan wiring harness.
12. Install the receiver/dryer and its mounting bolt(s); at least one of these bolts serves as the other condenser mounting bolt.
13. Connect each line and hose by hand, making certain the O-rings are intact and not damaged during installation. Tighten each fitting by hand first, then using two wrenches, tighten them to 18 ft. lbs. (24 Nm). Do not overtighten these fittings.
14. Have the air conditioner system evacuated and recharged by a trained and qualified mechanic.
15. Reinstall the grille.

Montero — 3.0L (24 Valve) and 3.5L Engines

1. Have the air conditioning system discharged by a trained and certified mechanic using a recovery/recycling machine.
2. Disconnect the negative battery cable from the battery.
3. Remove the radiator grille from the front of the vehicle.
4. Remove the hood latch stay and bracket assembly.
5. Remove the transmission cooler mounting bolts.
6. Remove the engine oil cooler mounting bolts and bracket.
7. Remove the condenser mounting bolts.
8. Disconnect the high pressure pipe A from the condenser and the receiver. Remove and replace the O-rings in these fittings with new upon reinstallation.
9. Remove the receiver bracket and receiver.
10. Remove the condenser electric fan assembly from the front of the condenser.
11. Disconnect the upper high pressure hose from the condenser. This hose junction will also need a new O-ring upon reassembly.
12. Extract the condenser out of the engine compartment. After the condenser has been removed from the vehicle, the three side seals can be removed from it.

    Fig. 4: Condenser and condenser fan motor assembly — 3.0L (24 valve) and 3.5L engines

    To Install:

13. Before installation, check the condenser fan for crushing and other damage. Check the condenser's high pressure hose and pipe installation parts for damage or deformation. Check the condenser fan shroud for damage. Clean any dirt or debris from the condenser vanes.
14. Affix the side seals to the condenser, position the condenser back into its place, and reattach the upper high pressure hose to the condenser. Reinstall any brackets for this hose.
15. Install the fan assembly back to the front of the condenser. Reattach the receiver assembly to the condenser.
16. Install the lower high pressure hose, then secure the condenser in place, using the condenser mounting bolts.
17. Remount the transmission cooler and the engine oil cooler into their respective places.
18. Remount the hood latch and assembly bracket.
19. Install the radiator grille back in place. Reconnect the negative battery cable.
20. Have the air conditioning system evacuated and recharged as soon as possible.