For 1990-2009 cars

## Air Conditioning Condenser Replacement 2.5L

### Removal Procedure

1. Remove the front grille. Refer to Grille Replacement in Exterior Trim.

Important: When installing a new condenser, add 20-30 ml (0.7-1.0 fl oz) of refrigerant oil to the refrigeration system.

2. Discharge and recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
3. Disconnect the condenser fan electrical connector (2).
4. Disconnect the refrigerant pressure sensor electrical connector (1).
5. Remove the 4 nuts (3) from the condenser fan and position the condenser fan aside.

Important: Cap the refrigerant openings in order to prevent moisture and dirt from entering the system.

6. Remove the 1 bolt and the condenser inlet tube (1) from the condenser.
7. Remove the condenser outlet tube (6).
8. Remove the upper 2 brackets from the condenser.
9. Remove the lower 2 bolts from the condenser.
10. Remove the upper radiator mounting bolts.
11. Tilt the top of the radiator towards the engine and slide the condenser out between the radiator and the front upper panel.
12. Tilt the top of the radiator towards the engine and slide the condenser fan out between the radiator and the front upper panel .

### Installation Procedure

1. Tilt the top of the radiator towards the engine and install the condenser fan between the radiator and the front upper panel.
2. Tilt the top of the radiator towards the engine and install the condenser between the radiator and the front upper panel.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the upper radiator mounting bolts.

Tighten
Tighten the radiator mounting bolts to 20 N·m (15 lb ft).

4. Secure the condenser with the lower 2 bolts and the upper 2 brackets.

Tighten
Tighten the condenser mounting bolts to 20 N·m (15 lb ft).

5. Install new O-rings lubricated with mineral base 525 viscosity refrigerant oil to the condenser fittings.
6. Connect the condenser outlet tube (6).

Tighten
Tighten the condenser outlet tube fitting to 35 N·m (26 lb ft).

7. Install the condenser inlet tube (1). Secure with the bolt.

Tighten
Tighten the bolt to 25 N·m (19 lb ft).

8. Install the condenser fan to the condenser. Secure with the 4 nuts (3).
9. Connect the condenser fan electrical connector (2).
10. Connect the refrigerant pressure sensor electrical connector (1).
11. Evacuate and recharge the air conditioning system. Refer to Refrigerant Recovery and Recharging .
12. Operate the A/C system and test for refrigerant leaks. Refer to Leak Testing .
13. Install the front grille. Refer to Grille Replacement in Exterior Trim.

## Air Conditioning Condenser Replacement 1.6L and 2.0L

### Removal Procedure

Important: When installing a new condenser, add 20- 30 ml (0.7-1.0 fl oz) of refrigerant oil to the refrigeration system.

1. Discharge and recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the front grille. Refer to Grille Replacement in Exterior Trim.
3. Remove the front bumper fascia. Refer to Front Bumper Fascia Replacement in Bumpers.
4. Remove the 2 bolts and the bumper fascia brace.

Important: Cap the refrigerant openings in order to prevent moisture and dirt from entering the system.

5. Remove the 1 bolt and the condenser inlet tube (1) from the condenser.
6. Remove the condenser outlet tube (6).
7. Disconnect the condenser fan electrical connector (2).
8. Disconnect the refrigerant pressure sensor electrical connector (1).
9. Remove the 4 condenser mounting bolts and lower the condenser with the fan out of the vehicle.
10. Remove the 4 nuts (3) and the condenser fan from the condenser.

### Installation Procedure

1. Install the condenser fan to the condenser. Secure with the 4 nuts (3).

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the condenser with the fan to the vehicle and secure with the 4 mounting bolts.

Tighten
Tighten the condenser mounting bolts to 20 N·m (15 lb ft).

3. Install new O-rings lubricated with mineral base 525 viscosity refrigerant oil to the condenser fittings.
4. Connect the condenser outlet tube (6).

Tighten
Tighten the condenser outlet tube fitting to 35 N·m (26 lb ft).

5. Install the condenser inlet tube (1). Secure with the bolt.

Tighten
Tighten the bolt to 25 N·m (19 lb ft).

6. Connect the condenser fan electrical connector (2).
7. Connect the refrigerant pressure sensor electrical connector (1).
8. Install the bumper fascia brace. Secure with the 2 bolts.
9. Install the front bumper fascia. Refer to Front Bumper Fascia Replacement in Bumpers.
10. Install the front grille. Refer to Grille Replacement in Exterior Trim.
11. Evacuate and recharge the air conditioning system. Refer to Refrigerant Recovery and Recharging .
12. Operate the A/C system and test for refrigerant leaks. Refer to Leak Testing .