Chrysler Front Wheel Drive Cars 4-CYL 1981-1995 Repair Information

A/C Condenser

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REMOVAL & INSTALLATION




CAUTION
The air conditioning system is filled with refrigerant under high pressure. The refrigerant must be discharged by a qualified professional mechanic before you can safely work on any of the components.

Except Premier

See Figure 1

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Fig. Fig. 1: Condenser refrigerant lines and mounting assembly-except Premier


CAUTION
The refrigeration system must be completely discharged before proceeding with this operation. Have the system discharged by a qualified professional mechanic using an approved recovery/recycling machine.

The A/C condenser is mounted to the radiator with bolts (upper) and mounting pads (lower).

  1. Have the A/C system discharged by a qualified professional mechanic.
  2.  
  3. Remove the refrigerant line mounting nut and separate the refrigerant lines from the condenser.
  4.  
  5. Cover the open ends of the A/C lines and condenser to minimize system contamination.
  6.  
  7. Remove the coolant overflow bottle, electric cooling fans and radiator assembly.
  8.  

On some models, complete removal of the radiator or coolant drainage is not necessary. The radiator may be moved slightly rearward to remove the condenser.

  1. Remove the 2 bolts securing the condenser assembly to the radiator.
  2.  
  3. Slip the condenser from the lower radiator mounting brackets.
  4.  
  5. Remove the condenser from the vehicle.
  6.  

To install:
  1. Replace all O-rings and gaskets with new ones and coat the sealing surfaces with the approved refrigerant oil. Add 1 fl. oz. (30 ml) of refrigerant oil to the condenser if it is a new condenser.
  2.  

It is important to have the correct amount of oil in the A/C system to ensure proper lubrication. Too little oil will result in damage to the compressor, while too much oil will reduce the cooling capacity of the system and consequently result in higher discharge air temperatures.

  1. Position the condenser into its mounting position.
  2.  
  3. Press the condenser into the lower radiator mounting brackets.
  4.  
  5. Install and tighten the 2 bolts to secure the condenser assembly to the radiator.
  6.  
  7. Install the radiator assembly (if removed), the cooling fans, and the coolant overflow bottle.
  8.  
  9. Install the A/C lines to the condenser and tighten the refrigerant line mounting nut to 17 ft. lbs. (23 Nm).
  10.  
  11. Have the A/C system evacuated and recharged by a qualified professional mechanic, utilizing the proper equipment.
  12.  

Premier

See Figures 2, 3, 4, 5, 6 and 7

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Fig. Fig. 2: Remove the bolts and nuts to remove the radiator crossmember



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Fig. Fig. 3: Remove the crossmember brace by removing the attaching bolts



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Fig. Fig. 4: Remove the passenger-side condenser lower mounting bolt



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Fig. Fig. 5: Remove the driver-side condenser lower mounting bolt also



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Fig. Fig. 6: Unplug the electrical wiring harness connectors leading to the cooling fans



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Fig. Fig. 7: Separate the condenser from the radiator


CAUTION
The refrigeration system must be completely discharged before proceeding with this operation. Have the system discharged by a qualified professional mechanic using an approved recovery/recycling machine.

  1. Have the A/C system discharged by a qualified professional mechanic using an approved a recovery/recycling machine.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Attach one end of a 24 in. (61cm) long, 1 / 4 in. (6mm) inside diameter hose to the radiator drain. Place the other end into a clean container.
  6.  

When servicing the cooling system, care must be taken to ensure that coolant does not contact the accessory drive belt or pulleys. Cover the belt and pulleys with shop towels prior to servicing the cooling system.

  1. Remove the cap from the coolant expansion bottle (overflow container).
  2.  
  3. Open the radiator drain and allow the radiator to drain.
  4.  
  5. Disconnect the upper and lower radiator hoses.
  6.  
  7. Remove the front radiator grille retaining screws and remove the grille from the vehicle.
  8.  
  9. Remove the upper radiator crossmember attaching bolts.
  10.  
  11. Loosen the retaining nuts and remove the crossmember.
  12.  
  13. Remove the crossmember brace.
  14.  
  15. Remove the two lower condenser-to-radiator frame attaching bolts.
  16.  
  17. Unplug the coolant temperature switch connector and fan power connector.
  18.  
  19. Using the appropriate Spring Lock Coupling Tool (from the A/C Tool Kit 6125) or the equivalent, detach the refrigerant lines at the condenser hose connections. Refer to the procedures for refrigerant lines in this section.
  20.  
  21. Remove the fan/radiator/condenser assembly from the vehicle.
  22.  
  23. Remove the retaining screws and separate the condenser from the fan/radiator.
  24.  
  25. Remove the side seals.
  26.  

To install:

WARNING
Failure to maintain the correct oil level in the system will cause compressor failure. Too much oil in the system will decrease system efficiency and possibly cause system noise.

  1. Add 1 fl. oz. (30 ml) of clean refrigerant oil to the condenser or the accumulator/drier if the condenser is replaced with a new one.
  2.  
  3. Attach the condenser to the fan/radiator assembly with the retaining screws.
  4.  
  5. Install new side seals to the new condenser.
  6.  
  7. Install the fan/radiator/condenser assembly using the 2 lower bolts.
  8.  
  9. Connect the coolant temperature switch and fan power wire.
  10.  
  11. Install the crossmember brace with its bolts. Tighten the bolts until snug.
  12.  
  13. Connect the upper and lower radiator hoses to the radiator.
  14.  
  15. Install the crossmember with the bolts and nuts. Tighten until snug.
  16.  
  17. Install the radiator grille onto the front of the vehicle and secure in place with the retaining screws.
  18.  
  19. Close the radiator drain and fill the radiator. Refer to Routine Maintenance for the correct procedure for filling the cooling system.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Have the A/C system evacuated and recharged by a qualified professional mechanic, utilizing the proper equipment.
  24.  

 
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