Instruction Sheet

IS-14904

CONDENSER PIVOT REINFORCEMENT PLATE
MATERIAL
.LWLQFOXGHVWKHIROORZLQJSDUWV
Part No.

Description

Qty

5HLQIRUFHPHQW3ODWH

1\ORQ%XVKLQJ

5LYHWV[´

&DEOHWLH

,6

,QVWUXFWLRQ6KHHW

5HFRPPHQGHGHTXLSPHQW
Material

Description

Note

'ULOOELWVHW ƒWLS

´ WR ´ 6KHHW PHWDO FRPSDWL
EOHZLWKƒWLSV

4)UHY!

,6
3DJH

'ULOOELWVWRSSHUV

WRPDWFKWKHGULOOELWVXVHG

´VKHHWPHWDOKROHVDZ

:LWK FHQWHULQJ WLS DV VKRUW DV
SRVVLEOH RUDGMXVWDEOH

(OHFWULF'ULOO

´VKDQNUHFRPPHQGHG

$QJOH*ULQGHU DVUHTXLUHG

(OHFWULFRU3QHXPDWLF

8VHZLWKPHWDOFXWWLQJGLVN

6RFNHWZUHQFKVHW

PP DQG PP VRFNHWV UH
TXLUHG

3RSULYHWJXQ

0DQXDORUSQHXPDWLF

&XWWLQJSOLHU

2UVXLWDEOHHTXLYDOHQWWRRO

4)!

,6
3DJH

PPFDUELGHJULQGLQJWRRO

2U6$(´HTXLYDOHQWWRRO

&HQWHUSXQFK

$XWRPDWLF

/LIWWDEOH

:KHHOHG

NOTE
Material can be obtained through regular channels.

PROCEDURE

DANGER

3DUN YHKLFOH VDIHO\ DSSO\ SDUNLQJ EUDNH VWRS HQJLQH DQG VHW EDWWHU\ PDVWHU VZLWFK HV WR WKH 2))
SRVLWLRQSULRUWRZRUNLQJRQWKHYHKLFOH

PART 1: CONDENSER PREPARATION
2SHQWKHFRQGHQVHUGRRUE\SXOOLQJWKHODWFKORFDWHGLQWKHIXHOILOOHUFRPSDUWPHQW )LJ

Fig.1

Fig.2

4)!

,6
3DJH

'LVFRQQHFWWKHGRRUOLPLWHUVWUDSDWWKHGRRUHQGWRDOORZFRPSOHWHRSHQLQJRIWKHGRRU )LJ

Fig.3

Fig.4

3XOOWKHFRQGHQVHUODWFKDQGWLOWWKHFRPSUHVVRUGHJRXWE\SXOOLQJRQWKHVWUDSORFDWHGRQWKHVLGH
RIWKHFRQGHQVHU )LJ

CAUTION

2QO\WKHVWUDSVKRXOGEHXVHGWRSXOOWKHFRQGHQVHUIDQDVVHPEO\RSHQ'DPDJHWRFRQGHQVHUFRXOG
UHVXOWLISXOOLQJE\RWKHUPHDQV

Fig.5

Fig.6

3XWDK\GUDXOLFOLIWWDEOHXQGHUWKHFRQGHQVHUWRVXSSRUWLW/LIWVOLJKWO\MXVWHQRXJKWRUHPRYHZHLJKW
RQWKHORZHUVXSSRUWSLYRW )LJ

Fig.7

Fig.8

4)!

,6
3DJH

&XWWKHFDEOHWLHRQWKHWRSSLYRWEUDFNHWDQGWKHDGMDFHQWZLULQJKDUQHVV )LJ
5HPRYH WKH EUDFNHW IURP WKH YHKLFOH E\ XQVFUHZLQJ WKH WZR 0 KH[ EROWV PP RU ´ KHDG
VHFXULQJLWWRWKHIUDPH )LJ

Fig.9

Fig.10

:LWK WKH OLIW WDEOH UDLVH WKH FRQGHQVHU DERXW DQ LQFK WR GLVHQJDJH DQG FOHDU WKH ORZHU SLYRW SLQ
)LJ

Fig.11

Fig.12

3XOODZD\WKHFRQGHQVHUIURPWKHYHKLFOHWRDOORZVXIILFLHQWFOHDUDQFHRQWKHFRQGHQVHUWRSWRLQVWDOO
WKHUHLQIRUFLQJSODWHVXSSOLHGLQWKHNLW )LJ

Fig.13

4)!

IS-14904
Page 6 / 10

PART 2: UPPER PIVOT PIN INSPECTION AND REMOVAL
9. Inspect the upper pivot pin breakage to determine subsequent actions to be performed before
installation of the reinforcing plate. Three breakage type are usually observed:
- Pin welds broke and pin went out of the condenser leaving a blind hole at the top (Fig.14).
The hole will need to be progressively enlarged to allow the plate installation. Up to 1/2”, uses sharp
sheet metal bits (with a 135° tip angle) mounted on an electric drill and mount drill stops at the tip of
the drills so they will not penetrate more than 1/4” in the condenser core (Fig.15). Enlarge the 1/2”
hole to about 1 inch with a carbide bit (the bottom of the reinforcing plate pin (Fig.22) must fit in the
hole).

Fig.14

Fig.15

CAUTION
Do not drill pass 1/4” below the pin body or serious damage could occur to the condenser core tubes
- Pin is sheared and the remaining part of the pin sits flush with the condenser top (Fig.16).
The pin body will need to be center drilled and the hole enlarged to 1 inch following the steps below.

Fig.16

IS-14904
Page 7 / 10

- Use a center punch to precisely locate the center of the pin (Fig.17).
- Drill the center of the pin with a small 1/8” drill equipped with a drill stop to avoid drilling more
than 1/8” deep in the condenser and hitting the core tubes (Fig.18).
- Cut a 1 inch hole with a hole saw using the 1/8” hole as a guide (Fig.19).

NOTE
Bottom of the reinforcement plate pin must fit the hole, enlarge the 1 inch hole with a carbide bit as
necessary (see Fig.22)

Fig.17

Fig.18

Fig.19

CAUTION
Do not drill pass 1/4” below the pin body or serious damage could occur to the condenser core tubes

- Pin weld broke but pin is still present and move/spin freely in the condenser top hole. With an
angle grinder and a suitable cutting disk, the pin body will need to be cut flush to the condenser body and
then pushed down while enlarging the hole to 1 inch with a hole saw (Fig.20 & 21).

Fig.20

Fig.21

IS-14904
Page 8 / 10

DANGER
Always wear eye protection when using an angle grinder or rotary cutting tools

NOTE
Bottom of the reinforcement plate pin must fit the hole, enlarge the 1 inch hole with a carbide bit as
necessary (see Fig.22)

PART 3: REINFORCING PLATE INSTALLATION
10. With the hole enlarged to one inch, position the reinforcing plate at the condenser top. The bottom
part of the plate pin must be inserted in the one inch hole and the edges of the plate must fit flush with
the condenser body as shown below (Fig.22 & 23).

Fig.22

Fig.23

11. With the plate correctly positioned on the condenser top, mark the center of each four (4) rivet holes
in the plate (Fig.24).
12. Using a 3/16” drill bit and appropriate drill stop, drill four (4) holes at the top of the condenser being
careful not to go past the specified 1/4” depth (Fig.25).

Fig.24

Fig.25

IS-14904
Page 9 / 10

13. Rivet the plate in place using four blind 3/16” rivets and an appropriate rivet gun (Fig.26 & 27).

Fig.26

Fig.27

PART 4: CONDENSER REINSTALLATION
14. Carefully slide back and lower the condenser into position (Fig.28) ensuring that the lower pivot pin is
positively engaged (Keep the lift table under the condenser to support it).

Fig.28

15. On the upper pivot bracket, slightly loosen the pivot pin retainer nut so the retainer can freely slide
back and forth in the bracket as shown in the illustrations below (Fig.29, 30 & 31).

Fig.29

Fig.30

Fig.31

IS-14904
Page 10 / 10

16. Install a new #507260 retainer nylon bushing in the assembly and hand tight the upper bracket in
place (Fig 32 & 33).

Fig.32

Fig.33

NOTE
On some vehicles, due to the slight difference in upper pin height after the reinforcing plate installation,
it may be necessary to slightly enlarge the upper bracket mounting holes with a 9mm carbide bit as
shown in the picture below

17. With the upper bracket loosely fixed, remove the lift table and push back the condenser into the
vehicle.
18. Tighten the two two (2) M8 hex bolts to 25 lb-ft.
19. Slightly tighten the retainer bolt and push/pull the condenser in and out a few times to ensure that it is
moving freely and that the pin retainer ins in its optimal position.
20. Tighten the retainer nut.
21. Reinstall the two wiring harness to the upper bracket using the supplied cable tie.
22. Reinstall the door limiter strap.

PARTS / WASTE DISPOSAL
Discard waste according to applicable environmental regulations (Municipal/State[Prov.]/ Federal)