Okay guys, update on this fix. I changed the condenser yesterday in a few hours and got it pressured up with N2, leak checked and then vacuum down to remove any air. We then blead it back up slowly with N2 to a neutral pressure, removed the plug on the integrated receiver dryer and added the new dryer media bag, re-corked that and checked once more for any leaks before the final pump down of the system. All went well, we then started refilling the system with refrigerant R134A and ran the system to see how it did. it was 40 deg outside so I wasn't expecting too much of a difference from the cold air streaming from the vents, but on "Max Cold" I was getting 24 deg!!! Wow. Anyway wanted to let you guys know that the swap wasn't that bad. I got all my parts from Advance Auto just because I didn't feel like paying double or triple for the OEM stuff this time even though most times I do, just to stay OEM. Total cost, with the kit to recharge the refrigerant, was ~$300.00. I leveraged a good friend who is an A/C technician and his equipment to pump down and to monitor the system via his gauge set. He also had plenty of N2 for the purge and pressure check. A Hundo to him and I'm done for about $400. This was going to be $1200 at the dealer.
As far as what happened to my old condenser - I've been trying to determine the demise of the old unit... see pics. I think this is not the original and the PO had it replaced at some point. I think the folks replacing it pushed up on the bottom and it was probably hung up on something like a top bracket or something else and the easy to bend condenser was bent up. Then they (not wanting to buy another one) pressure tested it and it held. So they simply put all back together and the PO was none the wiser. BUT, it was weakened by this bending and so it failed on me a few weeks back.
Tips for the removal and replacement. As mentioned above, you can hang up on stuff doing this. I removed the front grill (easy), detached the trans cooler, but left hoses connected (be careful and bring it forward and down to rest there). Then unbolted the top and middle brackets on both sides of the condenser. Then I detached the top inlet and the bottom outlet tubes to the condenser. I removed the entire little "J" pipe up top. Plugged the tubes on the vehicle with ear plugs (worked perfect). Now you have to finagle a little to get the bottom mount brackets off, after removing the bolts that attached the bracket to the car. If you come from the bottom and lift on the condenser and go as far left as you can the right bolt can be gotten to. Likewise if you lift and go as far right as you can the left bolt can be gotten to.
Now drop it down and out. Reinstallation is the same in reverse. You have to get these two bottom bolts on those condenser brackets first moving the bracket around until you get the bolt lined up and then the whole condenser up and over to reveal the bolt head. When those brakes are attached to the condenser you can then start with the mid mounts, then get all brackets loosely attached to the vehicle, then once all are lined up, start the tightening. I got some compressor oil out off the old condenser's lower port (just tilt it) for the new o-rings (they need to be wetted with this oil). Re install the "J" pipe and connect the lower outlet tube. Good to go. Get it leak checked, vacuumed down, and refilled.
Hope this helps someone, cheers! Clay
