Rev: 30/05-2005 by Wod DENMARK

© Wod DENMARK 01/03-1999

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Restoration, Replacement of AirCondioningCondenser P38A

This page is about restauration, and I renounce any claims according to use the tips on this Site. It is on one's own responsibility to follow the restauration-step.
Personal and environmental security:
Aiconditioning contains freon. Be sure, that there is no freon in the system when You start.
If there still is freon in the system, go to a special garage, and let them emty the system.
Overview:
Material: New airconditioningcondeser and new Dryer (Dryfilter)
Unmount the frontgrille
Unmount the top cover schield over the condeser
Unmount the front bumper
Unmount the tubes to the airconditioningcondeser (here the freon will come if any left)
Unmount the dryer (dryfilter)
Unmount the airconditioningcondeser
Check the O-rings (best to replace)
Mount he new dryer (dryfilter)
Mount the new Airconditioningcondeser
Connect the tubes
Mount the front bumper
Mount the top cover schield over the airconditioningcondeser
Mount the front grille
Replacement of Air Conditioning Condenser Step 1:
Rise the vehicle top top level with the air suspension
Open the bonnet
Disconect the battery
Replacement of Air Conditioning Condenser Step 2:
Loosen the 2 front screws in the front grille
Replacement of Air Conditioning Condenser Step 3:
The right screw in the front grille
Replacement of Air Conditioning Condenser Step 4:
The left screw in the front grille
Replacement of Air Conditioning Condenser Step 5:
Loosen the four top screws and remove the front grille
Replacement of Air Conditioning Condenser Step 6:
Losen the 2 right bolts in the top cover schield over the airconditioningcondenser.
Replacement of Air Conditioning Condenser Step 7:
osen the 2 left bolts in the top cover schield over the airconditioningcondenser.
Replacement of Air Conditioning Condenser Step 8:
turn around the top cover schield. There is two strips holder a wire beneath.
Replacement of Air Conditioning Condenser Step 9:
Cut the to strip holding the wire in place and remove the top cover schield.
Replacement of Air Conditioning Condenser Step 10:
There is two bolts beneath the front bumper.
Replacement of Air Conditioning Condenser Step 11:
They look like this, but can be losened with an eleven  millimeter wrench without problem.
Replacement of Air Conditioning Condenser Step 12:
Loosen the bolt in the left side and the bolt in the right side
Replacement of Air Conditioning Condenser Step 13:
In each corner of the bumper in front of the wheelarch, there is a clips, which locking the bumper.
It is here, that it gives more workspace, it the vehicle is in raised position.
This is the right side.
Start in the right side the clips.
You have to take the clips of the hook.
Replacement of Air Conditioning Condenser Step 14:
Then You schuold be able to pull the right side of the bumper foreward, BUT we could not, and had to remove this bolt, and remove the angel-iron.
Replacement of Air Conditioning Condenser Step 15:
It is the same procedure in the left side, but here You can not see the clips from down under.
Replacement of Air Conditioning Condenser Step 16:
Take the clips of the hook in the left side.
Replacement of Air Conditioning Condenser Step 17:
We could not slide the bumper foreward here as well, and needed to take this bolt off and remove the angel-iron.
Replacement of Air Conditioning Condenser Step 18:
You need a helper to remove the bumper, pull it forewards, gently, because there is wires conected with the fog lamps.
Disconnect the foglamps in both sides, and remove the bumper.
Replacement of Air Conditioning Condenser Step 19:
Now the bumper is off and You can see the angel-iron where the clip was hooked, and the bolt was removed.
Replacement of Air Conditioning Condenser Step 20:
Remove the two wires to fan from the clips
Replacement of Air Conditioning Condenser Step 21:
Disconnect the two wire plugs to the fan
Replacement of Air Conditioning Condenser Step 22:
The ventilatorfan is mounted with four bolts.
Remove the upper left bolt
Replacement of Air Conditioning Condenser Step 23:
Remove the upper right bolt
Replacement of Air Conditioning Condenser Step 24:
Remove the lower left bolt (shown her) and the lower right bolt.
And remove the ventilator fan
Replacement of Air Conditioning Condenser Step 25:
Before You continue, be sure, that there is no freon in the system, otherwise it comes out in this step.
Disconnect the upper tube at the lower right side of the airconditioningcondenser.
Be careful not to loose the green O-ring.
Replacement of Air Conditioning Condenser Step 26:
Just another picture of above.
Then disconnect the lower tube, which is conected to the Dryer (Dry-filter)
Replacement of Air Conditioning Condenser Step 27:
The airconditioningcondenser has 4 bolts.
Remove the lower left bolt (shown here) and the lower right bolt.
Replacement of Air Conditioning Condenser Step 28:
Remove the upper right bolt
Replacement of Air Conditioning Condenser Step 29:
Remove the upper left bolt
Replacement of Air Conditioning Condenser Step 30:
And remove the airconditioning condenser
Replacement of Air Conditioning Condenser Step 31:
The two O-rings from the tubes
Inspect the before reuse. if any doubt, relace them.
Replacement of Air Conditioning Condenser Step 32:
Disconect the right wire plug from the Dryer (Dry-filter)
Replacement of Air Conditioning Condenser Step 33:
Disconect the leftt wire plug from the Dryer (Dry-filter)
Replacement of Air Conditioning Condenser Step 34:
Disconnect the upper tube from the Dryer (Dry-filter)
Replacement of Air Conditioning Condenser Step 35:
just another picture of above
Replacement of Air Conditioning Condenser Step 36:
Remove the two bolts, which is holding the Dryer (Dry-folter) in place
 
Replacement of Air Conditioning Condenser Step 37:
Just another picture of above
When both bolts is removed, remove the Dryer (dry-filter)
Replacement of Air Conditioning Condenser Step 38:
Place th old Dryer in a vice, and remove the last tube
Replacement of Air Conditioning Condenser Step 39:
Just another picture of above
Replacement of Air Conditioning Condenser Step 40:
Take off the connectors with a wrench.
Replacement of Air Conditioning Condenser Step 41:
Clean the connector before monting it on the new Dryer
Replacement of Air Conditioning Condenser Step 42:
Mount the connector
Replacement of Air Conditioning Condenser Step 43:
Mount the tube again. Make sure it is clean, and that the O-ring is OK. use some coppergrease on the rews, before mounting the nut.
Replacement of Air Conditioning Condenser Step 44:
here a close up og the rews, O-ring, tube and nut.
Replacement of Air Conditioning Condenser Step 45:
Mount the new dryer with the two mounting bolts.
Replacement of Air Conditioning Condenser Step 46:
and tighten the two bolts
Replacement of Air Conditioning Condenser Step 47:
Just another picture of above
Replacement of Air Conditioning Condenser Step 48:
When the Dryer is mounted, connect the upper tube
Replacement of Air Conditioning Condenser Step 49:
and tighten the nut with a wrench
Replacement of Air Conditioning Condenser Step 50:
Spray som WD40 in the connectors
Replacement of Air Conditioning Condenser Step 51:
Mount the left connector to the Dryer
Replacement of Air Conditioning Condenser Step 52:
Mount the right  connector to the Dryer
Replacement of Air Conditioning Condenser Step 53:
spray thin waxoil (tectrol or tectyl) on edges and plate-connection in the chassis before mounting the rest.
Replacement of Air Conditioning Condenser Step 54:
put the new airconditioningcondenser in place.
There is a hole in each side a third from the bottom, which has to fit over a tap.
Replacement of Air Conditioning Condenser Step 55:
Mount the upper right bolt
and the upper left bolt
Replacement of Air Conditioning Condenser Step 56:
make sure, that the two taps is in each hole.
Replacement of Air Conditioning Condenser Step 57:
tigthen the two upper bolts
Replacement of Air Conditioning Condenser Step 58:
mount the lower left and the lower right bolt
Replacement of Air Conditioning Condenser Step 59:
the left lower bolt
Replacement of Air Conditioning Condenser Step 60:
Tighten the bolts.
Replacement of Air Conditioning Condenser Step 61:
Mount the O-ring on the tube from the Dryer.
Replacement of Air Conditioning Condenser Step 62:
Close up of O-ring on tube from Dryer
Replacement of Air Conditioning Condenser Step 63:
Mount the tube in the lower hole in the Airconditioningcondenser
Replacement of Air Conditioning Condenser Step 64:
Close up of above.
Tighten the tube with the nut
Replacement of Air Conditioning Condenser Step 65:
The other tube has to go in the upper hole
Replacement of Air Conditioning Condenser Step 66:
Close up of the tube with O-ring to the upper hole in the airconditioningcondenser
Replacement of Air Conditioning Condenser Step 67:
Tighten the upper tube with the nut
Replacement of Air Conditioning Condenser Step 68:
close up of above
Replacement of Air Conditioning Condenser Step 69:
Put coppergrease on the bolts to the ventilatorfan.
Replacement of Air Conditioning Condenser Step 70:
Clean the electric fan and put it back in place
Replacement of Air Conditioning Condenser Step 71:
Mount the upper right bolt (seen here) and the upper left bolt
Replacement of Air Conditioning Condenser Step 72:
Mount the lower right bolt
Replacement of Air Conditioning Condenser Step 73:
Close up of lower right bolt on  ventilatorfan
Replacement of Air Conditioning Condenser Step 74:
Mount the lower left bolt
Replacement of Air Conditioning Condenser Step 75:
tighten the 4 bolts on the fan
Replacement of Air Conditioning Condenser Step 76:
Mount the two wire connectors  to the electric ventilator fan
Replacement of Air Conditioning Condenser Step 77:
Mount the two wires in the clips
Replacement of Air Conditioning Condenser Step 78:
Mount the right and left angel iron to the front bumper mounting. Do not tighten the bolts yet
Replacement of Air Conditioning Condenser Step 79:
here is seen the profile in the fron bumper, which has to slide over the angel-iron.
 
Replacement of Air Conditioning Condenser Step 80:
You need a helper to mount the bumper, push it back in place, gently, and connect the wire-plugs to the fog lamps.
And push the bumper completely back in place.
Replacement of Air Conditioning Condenser Step 81:
Mount the two mounting bolts (right and left side) in the front bumper
Replacement of Air Conditioning Condenser Step 82:
tighten the angel iron in the right side
Replacement of Air Conditioning Condenser Step 83:
In each corner of the bumper in front of the wheelarch, there is a clips, which locking the bumper.
This is the right side.
Start in the right side where You can see the clips.
You have to put the clips back on the hook.
Replacement of Air Conditioning Condenser Step 84:
tighten the angel iron in the left side
Replacement of Air Conditioning Condenser Step 85:
put back the clips on the hook in the left side of the vehicle

Now the front bumper is copletely in place
Replacement of Air Conditioning Condenser Step 86:
get ready to mount the top cover schield over the airconditioningcondenser.
Place i upwards down and mount the wire with two new strips.
Replacement of Air Conditioning Condenser Step 87:
Turn around the top cover schield
Replacement of Air Conditioning Condenser Step 88:
and mount the two left bolts
Replacement of Air Conditioning Condenser Step 89:
just another picture of above
Replacement of Air Conditioning Condenser Step 90:
and mount the two right bolts
Replacement of Air Conditioning Condenser Step 91:
Mount the front grille again
First the 4 screws on the top
Replacement of Air Conditioning Condenser Step 92:
 and then the lower right screw 8seen here) and the lower right screw
Replacement of Air Conditioning Condenser Step 93
Close up of lower right screw
 
Replacement of Air Conditioning Condenser Step 94:
Close up of lower left screw
Replacement of Air Conditioning Condenser Step 95:
Finished result.

And now You hav to go to a specialist garage and get the airconditioning system refilled.

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