AC Condenser

This procedure covers the removal and replacement of the AC condenser on a 2023 Chevrolet Bolt EUV, including refrigerant recovery, condenser removal, and system recharge.

Warnings

Tools required

Parts

• AC Condenser × 1 — Use OEM specification
• AC line O-ring kit × 1 — GM AC O-ring kit for R-1234yf systems
• PAG oil (compatible with R-1234yf) × 1 — Use OEM specification
• R-1234yf refrigerant × 1 — As required by system capacity
• Front bumper cover clips (if damaged) × 1 — GM trim clips

Preparation

1. Disable the high-voltage system following manufacturer lockout/tagout procedure and verify with multimeter that system is de-energized
2. Disconnect the 12V battery negative terminal and wait 2 minutes
3. Raise vehicle on lift or jack stands to access underside components
4. Remove front undertray/splash shield to access lower condenser area
5. Document pre-service refrigerant charge amount if system is functional

Procedure

1. 1

   Recover AC refrigerant
   Connect R-1234yf recovery machine to service ports following machine manufacturer instructions. Recover all refrigerant from the system and record the amount recovered. Verify system pressure is at 0 PSI before proceeding with line disconnection.
2. 2

   Remove front bumper cover
   Remove fasteners securing front bumper cover. Disconnect any electrical connectors for parking sensors or lighting. Carefully remove bumper cover and set aside in safe location to prevent damage. This provides access to condenser mounting points.
3. 3

   Remove upper grille and supports
   Remove upper grille assembly by releasing clips and removing retaining screws. Remove upper radiator support panel or air deflector as needed to access top condenser mounting bolts. Take care not to damage plastic clips during removal.
4. 4

   Disconnect AC lines from condenser
   Locate AC line connections at condenser inlet and outlet. Use appropriate AC line disconnect tool to release fittings. Cap all open AC line ends immediately with plastic caps to prevent contamination and moisture entry. Inspect O-rings and discard - new ones will be installed during reassembly.
   ⚠Ensure system is fully recovered before disconnecting lines. Residual pressure can cause injury and refrigerant release.
5. 5

   Disconnect condenser fan electrical connector
   If equipped with dedicated condenser fan, disconnect electrical connector. Press release tab and pull connector straight off. Secure wiring harness away from work area.
6. 6

   Remove condenser mounting bolts
   Remove upper condenser mounting bolts from the radiator support. Support condenser weight while removing bolts. There are typically 2-4 mounting points securing condenser to radiator core support or dedicated brackets.
   Torque spec

   Condenser Mounting Bolts12 Nm (9 lb-ft)
7. 7

   Remove condenser assembly
   Carefully tilt and maneuver condenser assembly out from between radiator and front bumper area. Take care not to damage radiator cooling fins. Remove condenser from vehicle and inspect mounting brackets - transfer to new condenser if reusable.
   ⚠Condenser fins are delicate. Avoid contact with radiator and other components during removal to prevent damage.
8. 8

   Prepare new condenser
   Remove shipping caps from new condenser ports. Verify condenser comes pre-charged with correct amount of PAG oil for R-1234yf system (typically 1-2 oz). If not pre-charged, add manufacturer-specified amount of compatible PAG oil through inlet port. Install new O-rings on AC line fittings, lubricating lightly with refrigerant oil.
9. 9

   Install new condenser
   Carefully position new condenser into mounting location between radiator and front support. Align mounting holes with brackets. Install condenser mounting bolts and tighten to specification starting from top center and working outward.
   Torque spec

   Condenser Mounting Bolts12 Nm (9 lb-ft)
10. 10

    Reconnect AC lines
    Remove caps from AC lines and condenser ports. Inspect new O-rings are properly seated. Apply small amount of PAG oil to O-rings. Connect AC lines to condenser inlet and outlet ports, ensuring proper alignment. Thread fittings by hand first, then tighten to specification using line wrench or flare nut wrench.
    ⚠Do not over-tighten AC fittings as this can damage O-rings and cause leaks. Use torque wrench for accurate torque application.
    Torque spec

    AC Line Fittings20 Nm (15 lb-ft)
11. 11

    Reconnect electrical connections
    Reconnect condenser fan electrical connector if applicable. Ensure positive connection and verify connector locks in place. Route wiring to avoid pinch points and moving components.
12. 12

    Reinstall grille and supports
    Reinstall upper radiator support panel or air deflector. Install upper grille assembly ensuring all clips are properly seated. Install any retaining screws to specification.
13. 13

    Reinstall front bumper cover
    Reconnect any electrical connectors for parking sensors or lighting. Position front bumper cover and align with mounting points. Install all fasteners and verify proper fitment with consistent gaps.
14. 14

    Evacuate and recharge AC system
    Connect AC service machine to system service ports. Evacuate system to deep vacuum (minimum 29 inches Hg) for at least 30 minutes. Monitor vacuum gauge - system should hold vacuum without rising, indicating no leaks. Once vacuum test passes, recharge system with manufacturer-specified amount of R-1234yf refrigerant according to service machine instructions.
    ⚠If system will not hold vacuum, there is a leak. Do not proceed with recharge until leak is located and repaired.

Reassembly

1. Reinstall front undertray/splash shield and tighten all fasteners
2. Reconnect 12V battery negative terminal
3. Re-enable high-voltage system following manufacturer procedures
4. Lower vehicle to ground

Verification

• Start vehicle and turn AC to maximum cold with fan on high
• Verify condenser fan operates when AC is activated
• Check for cold air from vents within 2-3 minutes of operation
• Inspect all AC line connections for signs of refrigerant leakage (oil residue)
• Verify no unusual noises from AC compressor or condenser fan
• Use electronic leak detector around all fittings to verify no refrigerant leaks
• Monitor AC performance during test drive - should reach and maintain cold temperature
• Verify proper bumper cover fitment and alignment

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