Condenser HVAC: Service and Repair

Cooler Condenser Assy Part 1:

Cooler Condenser Assy Part 2:

COOLER CONDENSER ASSY

OVERHAUL

HINT:
- Installation is in the reverse order of removal.

1. DISCONNECT NEGATIVE TERMINAL CABLE FROM BATTERY
2. EVACUATE REFRIGERANT HFC-134A (R134A)
3. REMOVE AIR CLEANER INLET NO.1
4. REMOVE AIR CLEANER ASSY




5. DISCONNECT DISCHARGE HOSE SUB-ASSY NO.1
a. Remove the bolt and disconnect the discharge hose sub-assy No.1 from the condenser assy.
b. Remove the O-ring from the discharge hose sub-assy No.1.

NOTE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.




6. DISCONNECT LIQUID TUBE SUB-ASSY A
a. Remove the bolt and disconnect the liquid tube sub-assy A from the cooler condenser assy.
b. Remove the O-ring from the liquid tube sub-assy A.

NOTE: Seal the opening of the disconnected parts using vinyl tape to prevent moisture and foreign matter from entering.

7. REMOVE HIGH PITCHED HORN ASSY
8. REMOVE LOW PITCHED HORN ASSY




9. REMOVE SMOG VENTILATION SENSOR
a. Disconnect the connector.
b. Remove the bolt and smog ventilation sensor.




10. REMOVE HOOD LOCK ASSY
a. Remove the 2 bolts, nut and hood lock assy.

11. REMOVE RADIATOR SUPPORT SUB-ASSY UPPER




a. Remove the 2 nuts and 2 radiator brackets.




b. Remove the 4 bolts and 2 condenser brackets.




c. Remove the 3 wire harness clamps.

NOTE: Do not damage the claw of clamp.




d. Remove the 4 bolts and radiator support sub-assy upper.




12. REMOVE COOLER CONDENSER ASSY
a. Push down the 2 condenser brackets.
b. Push the radiator toward the engine.
c. Push the condenser toward the radiator and then pull it upward as shown in the illustration.

13. REMOVE DRYER




a. Using a hexagon wrench 10 mm (0.39 in.), remove the cap from the modulator.
b. Remove the filter from the modulator.




c. Using pliers, remove the dryer.

14. INSTALL DRYER




a. Insert a new dryer into the modulator.

NOTE:
- Do not remove the dryer from its plastic bag until it is ready to be inserted into the modulator.
- Install the dryer with the 2 layered parts facing upward.




b. Insert the filter into the modulator.

NOTE: Install the filter with its protrusion facing downward.




c. Install the cap to the modulator.
1. Apply compressor oil to the O-rings and thread of the cap.
Compressor oil: ND-OIL 8 or equivalent
2. Using a hexagon wrench 10 mm (0.39 in.), install the caps.

Torque: 12.3 Nm (125 kgf.cm, 9 ft.lbf)




15. INSTALL LIQUID TUBE SUB-ASSY A
a. Remove the attached vinyl tape from the tube and connecting part of the cooler condenser assy.
b. Sufficiently apply compressor oil to a new O-ring and pipe joint.
Compressor oil: ND-OIL 8 or equivalent
c. Install the O-ring to the liquid tube sub-assy A.
d. Connect the liquid tube sub-assy A to the cooler condenser assy with the bolt.

Torque: 5.4 Nm (55 kgf.cm, 48 in.lbf)




16. INSTALL DISCHARGE HOSE SUB-ASSY NO.1
a. Remove the attached vinyl tape from the tube and connecting part of the cooler condenser assy.
b. Sufficiently apply compressor oil to a new O-ring and hose joint.
Compressor oil: ND-OIL 8 or equivalent
c. Install the O-ring to the discharge hose sub-assy No.1.
d. Connect the discharge hose sub-assy No.1 to the cooler condenser assy with the bolt.

Torque: 5.4 Nm (55 kgf.cm, 48 in.lbf)

17. CONNECT NEGATIVE TERMINAL CABLE TO BATTERY
18. CHARGE REFRIGERANT
19. WARM UP ENGINE
20. INSPECT FOR REFRIGERANT LEAKAGE