For 1990-2009 cars

### Tools Required

J 39400 Halogen Leak Detector

### Removal Procedure

1. Remove the air filter assembly. Refer to Air Cleaner Assembly Replacement for 3.6L engine, or Air Cleaner Assembly Replacement for 6.0L engine.
2. Remove the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement

Caution: Refer to Safety Glasses Caution in the Preface section.

3. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .

Important: Remove the upper radiator support brackets by raising the securing lock upwards 10mm and slide the bracket out of the radiator slide pin.

4. Remove the upper radiator support brackets (1).

Caution: Refer to Vehicle Lifting Caution in the Preface section.

5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
6. Remove the air deflector front. Refer to Front Air Deflector Replacement.
7. Place a large suitable container under the condenser.
8. Disconnect the power steering cooler hoses (1).

Important: Plug or cap the power steering cooler hose (1) ends to prevent leaks and/or contamination.

9. Plug or cap the power steering cooler hose (1) ends.
10. Remove the liquid pipe to the condenser port retaining nut (1).
11. Lower the vehicle.
12. Disconnect the liquid pipe (1) from the condenser port (3).

Important: The sealing washer (2) is a single use item and must be discarded after use.

13. Remove the sealing washer (2). Refer to Sealing Washer Replacement.

Discard the sealing washer

Important: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

14. Cap or plug the liquid pipe (1) and the condenser port (3).
15. Lower the vehicle.

Important: Gently push the radiator and condenser towards the engine to allow removal of the discharge pipe to condenser retaining nut (1).

16. Remove the discharge pipe to condenser retaining nut (1).
17. Disconnect the discharge pipe (1) from condenser (3) and position aside.
18. Remove the sealing washer (2). Refer to Sealing Washer Replacement.

Discard the sealing washer.

Important: Cover any opening of the A/C system with a suitable cap or tape immediately, to prevent absorption of moisture from the atmosphere.

19. Cap or plug the discharge pipe (1) and the condenser (3).

Important: Gently push the radiator and condenser towards the engine to allow removal of the condenser to radiator retaining bolts (1).

20. Remove the condenser to radiator retaining bolts (1).

Important: Remove the condenser (1) by lifting it up between the radiator and radiator support.

21. Remove the condenser (1) from the engine compartment.

### Installation Procedure

Important: Install the condenser (1) by lowering down between the radiator and radiator support.

1. Install the condenser (1) to the engine compartment.

Notice: Refer to Fastener Notice in the Preface section.

Important: Gently push the radiator and condenser towards the engine to allow installation of the condenser to radiator retaining bolts (1).

2. Install the condenser to radiator retaining bolts (1).

Tighten
Tighten the bolts to 11 N·m (97 lb in).

3. Remove the plugs or caps from the discharge pipe (1) and the condenser (3).

Important: DO NOT coat the NEW sealing washer (2) with oil, they must be fitted dry. The use of mineral oil will render the sealing washer (2) useless, as the sealing washer (2) WILL swell causing refrigerant to leak out.

4. Install a NEW sealing washer (2). Refer to Sealing Washer Replacement.
5. Install the discharge pipe (1) to condenser (3).

Notice: Refer to Fastener Notice in the Preface section.

Important: Gently push the radiator and condenser towards the engine to allow installation of the discharge pipe to condenser retaining nut (1).

6. Install the discharge pipe to condenser retaining nut (1).

Tighten
Tighten the nut to 22 N·m( 16 lb ft).

7. Raise the vehicle.
8. Remove the plugs or caps from the suction pipe liquid pipe (1) and the condenser port (3).

Important: DO NOT coat the NEW sealing washer (3) with oil, they must be fitted dry. The use of mineral oil will render the sealing washer (3) useless, as the sealing washer (3) WILL swell causing refrigerant to leak out.

9. Install a NEW sealing washer (3). Refer to Sealing Washer Replacement.
10. Connect the liquid pipe (1) to the condenser port (3).
11. Install the liquid pipe to condenser port retaining nut (1).

Tighten
Tighten the nut to 22 N·m(16 lb ft).

12. Remove the plug or cap at the power steering cooler hose (1) ends.
13. Connect the power steering cooler hoses (1).
14. Install the air deflector front. Refer to Front Air Deflector Replacement.
15. Lower the vehicle.
16. Install radiator upper retaining brackets (1).
17. Fill the power steering fluid reservoir as necessary. Refer to Checking and Adding Power Steering Fluid.
18. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
19. Install the air filter assembly. Refer to Air Cleaner Assembly Replacement for 3.6L engine, or Air Cleaner Assembly Replacement for 6.0L engine.
20. Leak test the fittings of the component using J 39400 .
21. Install the radiator air baffle and deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement.