I'm preparing to replace my condenser and reading in the service manual that I'm supposed to take out the radiator. What?? Why? Is this really the case? Seems like a huge pain in the butt, needing to drain and refill coolant just to replace an A/C component.

In this condenser replacement walkthrough on a P38A, nothing is mentioned about removing the radiator. http://www.wods.dk/rangerover/rs/Air...r/r-aircon.htm I thought P38A's were very similar to the Disco II?

Anyone replaced their condenser before and can tell me how hard/long it takes, and what to watch out for? And if I really need to remove the radiator?

 

I can't imagine any other way to get it out. Get the Rave manual and make sure and follow the order of how to remove and install the radiator. That will save you time.

 

You'll have to loosen all the radiator fasteners so it can move, but I don't see why you'd have to completely remove it. Should be able to lift it up and back especially if you remove the fan blade/fan clutch.

 

I replaced mine on a D1 and removing the fan and shroud you will have enough room to push it back and remove the condenser. Just keep in mind if you open the system or have had no Freon in the system for some time it would be a good idea to replace the dryer and add a little oil to the system to replace what is in the old condenser.

 

I've done it a number of times on trucks that I've been dismantling. It can be done but, as Best4x4 said, you have to remove the fan clutch assembly and force the radiator and coolers are far back as you can.

 

Thanks for the tips guys! Makes me a little more confident. Going to tackle this next week and keep you posted.

 

All done!

For future adventurers, ignore the service manual. It's lying to you, very terribly. You do NOT need to remove the horn covers, the freaking radiator, or drain your coolant (they're so mean to suggest that), or any of that. It's surprisingly simple, just takes a little time and trial-and-error.

Remove the viscous fan and the fan shroud.
Remove the front grille (three screws on top, then it just lifts out, on 03-04 models).
Remove the two crossbars behind the front grille to get them out of your way, something like a 13mm, can't remember for sure.
Remove the condenser fan (8mm), and all screws attached to the condenser (8mm's and 10mm's), and you'll need an 8mm spanner to get to one of the condenser fan screws on the upper right.
Disconnect all multiplugs having anything to do with the condenser.
Have a new receiver/drier on hand (like $15 at AutoZone) to replace the old one with, as you must do this with a new condenser. Also have PAG 46 refrigerant oil ready, I forgot to get some and when I got to inserting the new condenser, AutoZone was closed and I couldn't get any, so had to postpone work until the next day. So you'll need to add some PAG 46 oil into the new condenser. Just watch a YouTube video on the rules of thumb for replacing a condenser and all other associated things to bear in mind (i.e. plug all holes with paper to prevent air, pull a vacuum with a loaned tool, have loaned manifold gauges on hand, so on).
Once all things are disconnected from the condenser, two little rivets at the bottom should pop out of their holes if you pull up and the condenser should wiggle free. I just turned it and played with it until it slid out on the engine-side, in front of the radiator and oil cooler. It will fit if you just turn it the right way.

Something like that. Just recent-memory tips for future fellows.

 

Anyway. It's all done and the A/C is running great. But I have a problem.

I had tried to add a can of refrigerant with the yellow hose in the center of the manifold gauges, and I connected it to my refrigerant can with an adapter fitting, punctured the can, then unscrewed the pin back off a little to open it up. Opened up the low pressure side on the gauges, and of course on the car. But even though the compressor is engaged, it's not drawing refrigerant into the system. Why?

I added about two cans of refrigerant using an A/C Pro trigger nozzle and gauge that I had lying around, and the A/C's now running well, but I need to add a bit more and my third and final can of refrigerant is stuck on the manifold gauges, because I already punctured it, so I can't remove it without all the refrigerant spewing out, right? Any suggestions?

 

I'll answer my own question.

Even though the refrigerant can is punctured with a T-fitting adapter, you can still disconnect the yellow hose that comes out the side, leading to the manifold gauges, as long as you have screwed the T thing back into the can and tightened it to seal it back off. Then you just leave the T-fitting on the can until your next use, and your yellow hose is now disconnected and free.

As for getting the refrigerant to suck into my system when the compressor was engaged, I just fiddled with it. Disconnected my yellow hoses, reconnected, opened the refrigerant can, bled the air out of the yellow hose, opened the low pressure side port, and all these things made it work. Maybe I had strange manifold gauges, I'm not sure, but messing with it enough eventually worked.

My low pressure side is at 55psi, high pressure around 300, and vent temps are 46 with ambient temp 90!