For 1990-2009 cars

### Removal Procedure

1. Disconnect the negative battery cable.

Important: Verifying the purity of the refrigerant with a purity identifier before recovery is recommended.

2. Recover refrigerant using an approved refrigerant recovery system. Measure the amount of oil removed during recovery and record the amount.
3. Disconnect the pusher fan electrical connector.
4. Remove the pusher fan harness from the puller fan shroud tabs and push the harness clear of the radiator end tank.

Caution: Refer to HVAC Compressor Lines/Hoses Caution in the Preface section.

5. Remove the liquid line to suction/liquid line assembly nut.
6. Install caps on the liquid line and the suction/liquid line assembly to prevent moisture entry and oil spillage.

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

7. Raise the vehicle.
8. Remove the radiator to condenser gasket by pulling down on one end and peeling back.
9. Remove the pusher fan retainer nuts and washers.
10. Pull the lower fan shroud forward and then down to remove it.
11. Remove the liquid line-to-condenser block bolt.
12. Remove the liquid line clamp to condenser fasteners and remove the liquid line.
13. Install caps on the liquid line and condenser block to prevent moisture entry and oil spillage.
14. Remove the discharge line-to-condenser block bolt.
15. Install caps on the discharge line and condenser block to prevent moisture entry and oil spillage.
16. Remove the condenser block to radiator end tank bolt.
17. Remove the condenser bolts.
18. Slide the condenser down then rotate the bottom forward to remove.
19. Remove the receiver/dehydrator line fitting bolts.
20. Loosen the receiver/dehydrator clamp bolt and remove receiver/dehydrator.

### Installation Procedure

1. Add any compressor oil that was removed during discharge to the receiver/dehydrator bottle.
2. Add the appropriate amount of compressor oil to the system for the parts replaced. Refer to Oil Distribution procedure in this service manual.
3. Install the receiver/dehydrator bottle into the clamp but do not tighten.

Notice: Refer to Refrigerant Oil Notice in the Preface section.

Important: Always install new O-rings.

4. Lubricate the O-rings and install the line block fittings to the receiver/dehydrator bottle bolt.

Tighten
Tighten the receiver/dehydrator block bolts to 3 N·m (27 lb in).

5. Tighten the receiver/dehydrator clamp bolt.

Tighten
Tighten the receiver/dehydrator clamp bolt to 5 N·m (44 lb in).

Important: The condenser block must be engaged to the radiator end tank bracket before sliding the condenser upward.

6. Install the condenser to radiator by sliding condenser tabs under radiator brackets.
7. Install the condenser-to-radiator bolts.

Tighten
Tighten the condenser-to-radiator bolts to 5 N·m (44 lb in).

8. Install the condenser block-to-radiator end tank bolt.

Tighten
Tighten the condenser block-to-radiator end tank bolt to 5 N·m (44 lb in).

Important:

• | Do not lubricate the seal washers.

• | Always install new seal washers to prevent refrigerant leaks.

9. Remove the discharge line cap and install a new seal washer.
10. Remove the condenser block cap and install the discharge line.
11. Hand start the discharge line to condenser block bolt.

Tighten
Tighten the discharge line-to-condenser block bolt to 20 N·m (15 lb ft).

Important:

• | Do not lubricate the seal washers.

• | Always install new seal washers to prevent refrigerant leaks.

12. Remove the liquid line to condenser cap and plug and install a new seal washer.
13. Install the liquid line to condenser block and hand start bolt.

Tighten
Tighten the liquid line-to-condenser block bolt to 20 N·m (15 lb ft).

14. Install the liquid line clamps onto the condenser studs and install the fasteners.

Tighten
Tighten the suction/liquid line assembly clamps to 5 N·m (44 lb in).

15. Install the radiator-to-condenser gasket.
16. Slide the upper pusher fan shroud under the retaining tabs located at the upper edge of the condenser.
17. Rotate the lower fan shroud onto the lower mounting studs and install the retaining nuts.

Tighten
Tighten the lower fan shroud retaining nuts to 5 N·m (44 lb in).

Notice: Position pusher fan electrical harness in shroud indentation to prevent harness damage.

18. Route the pusher fan electrical harness around the outside of the radiator end tank, below the upper radiator hose.
19. Lower the vehicle.
20. Remove the liquid/suction line assembly and the liquid line caps and install a new seal washer.
21. Remove the liquid/suction line assembly and the liquid line caps and install a new seal washer.

Tighten
Tighten the suction liquid line-to-liquid line to 12 N·m (9 lb ft).

22. Install the liquid line into the rail clamp.
23. Install the pusher fan harness into the mounting tabs on the puller fan shroud.
24. Connect the pusher fan electrical connector.
25. Connect the negative battery cable.

Tighten
Tighten the battery terminal bolts to 17 N·m (13 lb ft).

26. Evacuate, charge, and leak check the A/C system.