CONDENSER-A/C
DESCRIPTION
NOTE: A/C condenser with automatic transmission cooler shown. A/C Condenser without cooler similar.
The A/C condenser (1) is located in the front of the engine compartment behind the grille. The A/C condenser is a heat exchanger that allows the high-pressure refrigerant gas being discharged by the A/C compressor to give up its heat to the air passing over the condenser fins, which causes the refrigerant to cool and change to a liquid state.
The A/C condenser is equipped with tapping blocks for the A/C discharge line and the A/C liquid line (2) and an integral automatic transmission cooler (3), when equipped with an automatic transaxle.
OPERATION
When air passes through the fins of the A/C condenser, the high-pressure refrigerant gas within the A/C condenser gives up its heat. The refrigerant then condenses as it leaves the A/C condenser and becomes a high-pressure liquid. The volume of air flowing over the condenser fins is critical to the proper cooling performance of the A/C system. Therefore, it is important that there are no objects placed in front of the radiator grille openings at the front of the vehicle or foreign material on the condenser fins that might obstruct proper air flow. Also, any factory-installed air seals or shrouds must be properly reinstalled following radiator or A/C condenser service.
NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak.
The A/C condenser has no serviceable parts except for the O-ring seals and gaskets. The O-ring seals used on the connections are made from a special type of rubber not affected by R-134a refrigerant. The O-ring seals and gaskets must be replaced whenever a refrigerant line is removed from the A/C condenser.
The A/C condenser cannot be repaired and must be replaced if found to be leaking or damaged.
REMOVAL
WARNING: Refer to the applicable warnings and cautions for this system before performing the following operation (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - WARNING) and (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - CAUTION). Failure to follow the warnings and cautions could result in possible personal injury or death.
CAUTION: Before removing the A/C condenser, note the location of each of the radiator/condenser air seals. These air seals are used to direct air through the A/C condenser and radiator. The air seals must be reinstalled in their proper locations in order for the A/C and engine cooling systems to perform as designed.
1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM RECOVERY).
3. If equipped with the 2.2L diesel engine, remove the front fascia (refer to 13 - FRAME & BUMPERS/BUMPERS/FRONT FASCIA - REMOVAL).
NOTE: It is not necessary to remove the hood latch from the upper radiator support on gasoline engine equipped models for A/C condenser service.
4. If equipped with a gasoline engine, remove the upper radiator support and position it out of the way (refer to 23 - BODY/EXTERIOR/SUPPORT-UPPER RADIATOR - REMOVAL).
5. On gasoline engine equipped models, carefully push the radiator (1) slightly rearward to gain access to the A/C condenser (2).
6. Remove the nut (3) that secures the A/C discharge line (4) to the right side of the A/C condenser and remove and discard the O-ring seal and gasket.
7. Install plugs in, or tape over the opened discharge line fitting and the condenser inlet port.
NOTE: Illustration shown with front fascia removed for clarity.
8. Raise and support the vehicle.
NOTE: On gasoline engine equipped models, reach up through the opening in the bottom of the front fascia located in the right front corner of the vehicle to gain access to the A/C liquid line.
9. Remove the nut (1) that secures the A/C liquid line (2) to the right side of the A/C condenser (3).
10. Disconnect the A/C liquid line from the A/C condenser and remove and discard the O-ring seal and gasket.
11. Install plugs in, or tape over the opened liquid line fitting and the condenser outlet port.
NOTE: Illustration shown with front fascia and diesel engine charge air cooler (CAC) (when equipped) removed for clarity.
12. Remove the two bolts (3) that secure the lower condenser brackets to the radiator (5).
13. Lower the vehicle.
14. If equipped, disconnect the automatic transmission cooler lines (2) from the left side of the A/C condenser (1) (refer to 7 - COOLING/TRANSMISSION - STANDARD PROCEDURE - TRANSMISSION COOLER LINE QUICK CONNECT FITTING).
15. If equipped with the 2.2L diesel engine, remove the charge air cooler (CAC) (refer to 7 - COOLING/ENGINE/CHARGE AIR COOLER - REMOVAL).
16. Carefully lift the A/C condenser straight up and disengage the two upper condenser brackets (4) from the radiator and remove the condenser from the engine compartment.
INSTALLATION
CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL). Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.
NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL).
NOTE: If only the A/C condenser is being replaced, add 20 milliliters (0.7 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
NOTE: Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak.
NOTE: Illustration shown with front fascia and diesel engine charge air cooler (CAC) (when equipped) removed for clarity.
1. Carefully lower the A/C condenser (1) straight down in front of the radiator (5) and engage the upper condenser brackets (4) to the radiator.
2. If equipped with the 2.2L diesel engine, install the charge air cooler (CAC) (refer to 7 - COOLING/ENGINE/CHARGE AIR COOLER - INSTALLATION).
3. If equipped, connect the automatic transmission cooler lines (2) to the left side of the A/C condenser (refer to 7 - COOLING/TRANSMISSION - STANDARD PROCEDURE - TRANSMISSION COOLER LINE QUICK CONNECT FITTING).
4. Raise and support the vehicle.
5. Install the two bolts (3) that secure the lower condenser brackets to the radiator. Tighten the bolts to 4.5 N·m (40 in. lbs.).
NOTE: Illustration shown with front fascia removed for clarity.
NOTE: On gasoline engine equipped models, reach up through the opening in the bottom of the front fascia located in the right front corner of the vehicle to gain access to the A/C liquid line.
6. Remove the tape or plug from the liquid line fitting and the condenser outlet port.
7. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
8. Connect the A/C liquid line (2) to the A/C condenser (3) and install the retaining nut (1). Tighten the nut to 5 N·m (44 in. lbs.).
9. Lower the vehicle.
10. Remove the tape or plug from the discharge line fitting and the condenser inlet port.
11. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. Use only the specified O-ring as it is made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
12. On gasoline engine equipped models, carefully push the radiator (1) slightly rearward to gain access to the A/C condenser (2).
13. Connect the A/C discharge line (4) to the A/C condenser and install the retaining nut (3). Tighten the nut to 5 N·m (44 in. lbs.).
14. If equipped with a gasoline engine, reposition and install the upper radiator support (refer to 23 - BODY/EXTERIOR/SUPPORT-UPPER RADIATOR - INSTALLATION).
15. If equipped with the 2.2L diesel engine, install the front fascia (refer to 13 - FRAME & BUMPERS/BUMPERS/FRONT FASCIA - INSTALLATION).
16. Reconnect the negative battery cable.
CAUTION: Do NOT run the engine with a vacuum pump in operation or with a vacuum present within the A/C system. Failure to follow this caution will result in serious A/C compressor damage.
17. Evacuate the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM EVACUATE)
18. If the A/C condenser is being replaced, add 20 milliliters (0.7 fluid ounce) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING/REFRIGERANT OIL - STANDARD PROCEDURE - REFRIGERANT OIL LEVEL). Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
19. Charge the A/C system (refer to 24 - HEATING & AIR CONDITIONING/PLUMBING - STANDARD PROCEDURE - REFRIGERANT SYSTEM CHARGE).