Dismantling
1. Disconnect "negative" battery terminal.
2. Empty the air conditioning system and collect the refrigerant.
AIR CONDITIONING SYSTEM, AIR CONDITIONER DRAINAGE, REFRIGERANT RECOVERY AND CHARGING, Air Conditioner Emptying - Refrigerant Recovery and Charging.
3. Models with Td4 engine: Remove the intercooler.
DIESEL ENGINE FUEL SUPPLY, REPAIR WORK, Intercooler air.
4. Remove the bumper.
EXTERIOR PARTS, REPAIR WORKS, Front bumper assembly - for vehicles up to 2004 model year.
5. Models with KV6 engine: Remove the 2 bolts securing the power steering fluid cooler to the radiator frame.
6. For vehicles prior to model year 2004: Remove the 4 nuts and 4 bolts securing the radiator frame to the body and remove the frame.
7. For cars of the 2004 model year: Turn away 4 bolts of fastening of a radiator frame to protective elements and remove a frame.
8. Turn away 4 self-tapping screws of fastening of the left and right deflectors and remove both deflectors if they are installed.
9. Turn away 2 bolts of fastening of the condenser to a radiator.
10. Turn away 2 bolts of fastening of basic arms of a dehumidifier of a receiver to a radiator.
11. Turn away 2 bolts of fastening of pipelines of the conditioner to the condenser. Disconnect the lines from the condenser.
CAUTION: Before disconnecting or removing system components, make sure that the surfaces adjacent to the connection points are free of dirt. Install plugs in fittings and piping to keep dirt out of the system.
12. Remove and discard O-rings from A/C lines.
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 receiver water separator and plug holes.
Installation
1. Install the condenser support brackets. Fully tighten the left bracket screws. Do not fully tighten the screws securing the right brackets before installing the condenser on the vehicle.
CAUTION: Be sure to use the correct length bolts.
2. Lubricate the new O-rings with clean special oil and install one in each of the A/C lines.
3. Connect the pipelines of the air conditioner to the condenser, wrap the mounting bolts and tighten them with a torque of 8 Nm.
4. Wrap bolts of fastening of the condenser to a radiator and tighten them with the moment of 8 Nm.
5. Install the receiver dry trap assembly to the condenser.
AIR CONDITIONING SYSTEM, A/C compressor drive belt - for models with Td4 engine, Receiver water separator.
6. Install the deflectors and secure them with self-tapping screws.
7. For vehicles prior to model year 2004: Reinstall the radiator frame. Install and tighten 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 frame. Screw in the bolts securing the frame to the protective elements and tighten them with a torque of 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 WORKS, Front bumper assembly - for vehicles up to 2004 model year.
11. Models with Td4 engine: Install the intercooler.
DIESEL ENGINE FUEL SUPPLY, REPAIR WORK, Intercooler air.
12. Refill the A/C system.
AIR CONDITIONING SYSTEM, AIR CONDITIONER DRAINAGE, REFRIGERANT RECOVERY AND CHARGING, Air Conditioner Emptying - Refrigerant Recovery and Charging.
13. Attach "negative" battery terminal.
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