Contents: Dismantling ⇩ Installation ⇩
Dismantling
1. Disconnect the negative battery terminal.
2. Drain the air conditioning system and collect the refrigerant.
AIR CONDITIONING SYSTEM, AIR CONDITIONER DRAINING, REFRIGERANT RECOVERY AND CHARGING, Air conditioner draining - refrigerant recovery and refilling.
3. Models with Td4 engine: Remove the intercooler.
DIESEL ENGINE FUEL SUPPLY SYSTEM, REPAIR WORK, Air-to-air intermediate cooling radiator.
4. Remove the bumper.
EXTERIOR PARTS, REPAIR WORK, Front bumper assembly - for cars up to model year 2004.

5. Models with KV6 engine: Remove the 2 bolts securing the power steering fluid cooler to the radiator frame.

6. For vehicles up to model year 2004: Remove the 4 nuts and 4 bolts securing the radiator frame to the body and remove the frame.
7. For 2004 model year vehicles: Remove the 4 bolts securing the radiator frame to the guards and remove the frame.
8. Unscrew the 4 screws securing the left and right deflectors and remove both deflectors, if installed.

9. Unscrew the 2 bolts securing the condenser to the radiator.

10. Unscrew the 2 bolts securing the support brackets of the receiver moisture separator to the radiator.

11. Unscrew the 2 bolts securing the air conditioner pipes to the condenser. Disconnect the pipes from the condenser.
CAUTION: Before disconnecting or removing system components, make sure that the adjacent surfaces of the joints are free of dirt. Install plugs in the openings of the fittings and pipes to prevent dirt from entering the system.
12. Remove and discard the sealing rings from the air conditioner pipes.

13. Remove the capacitor.
14. Remove the 8 screws that secure the 4 support brackets to the condenser and set them aside.
15. Remove and discard the receiver moisture separator and plug the openings.
Installation
1. Install the condenser support brackets. Fully tighten the left bracket mounting screws. Do not fully tighten the right bracket mounting screws until the condenser is installed on the vehicle.
CAUTION: Make sure to use bolts of the correct length.
2. Lubricate new sealing rings with clean special oil and install them one by one into each of the air conditioner pipes.
3. Connect the air conditioner pipes to the condenser, tighten the mounting bolts and tighten them to a torque of 8 Nm.
4. Tighten the condenser mounting bolts to the radiator to a torque of 8 Nm.
5. Install the receiver moisture separator assembly onto the condenser.
AIR CONDITIONING SYSTEM, Air conditioning compressor drive belt - for models with Td4 engine, Receiver moisture separator.
6. Install the deflectors and secure them with screws.
7. For vehicles up to model year 2004: Reinstall the radiator frame. Tighten and secure the 4 nuts and bolts that secure the frame to the body. Tightening torque: 25 Nm.
8. For 2004 model year vehicles: Reinstall the radiator cage. Install the cage mounting bolts to the guards and tighten them to 25 Nm.
9. Models with KV6 engine: Install the power steering fluid cooler and tighten its mounting bolts to 8 Nm.
10. Install the bumper.
EXTERIOR PARTS, REPAIR WORK, Front bumper assembly - for cars up to model year 2004.
11. Models with Td4 engine: Install an intercooler.
DIESEL ENGINE FUEL SUPPLY SYSTEM, REPAIR WORK, Air-to-air intermediate cooling radiator.
12. Fill the air conditioning system.
AIR CONDITIONING SYSTEM, AIR CONDITIONER DRAINING, REFRIGERANT RECOVERY AND CHARGING, Air conditioner draining - refrigerant recovery and refilling.
13. Connect the negative battery terminal.
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