AC Condenser

Replace the AC condenser on a 2008 Dodge Viper, including refrigerant recovery, front fascia and radiator support removal, and system recharge.

Warnings

Tools required

Parts

• AC condenser × 1 — Mopar 68003996AA or equivalent
• AC line O-ring kit × 1 — Use OEM specification
• Radiator support fastener clips × 1 — Replace any broken clips

Fluids

• R-134a refrigerant

Preparation

1. Ensure engine is completely cool before beginning work
2. Park vehicle on level ground and engage parking brake
3. Disconnect negative battery cable and secure away from terminal
4. Place fender covers to protect painted surfaces during front-end disassembly

Procedure

1. 1

   Recover AC refrigerant
   Connect AC recovery machine to the service ports on the AC lines. Follow machine instructions to completely recover all refrigerant from the system. Record the amount recovered for recharge reference. Allow system to equalize to atmospheric pressure before proceeding with line disconnection.
2. 2

   Remove front fascia and lower air dam
   Remove the front fascia by locating and removing the mounting fasteners along the top edge, wheel well openings, and underside. Refer to the 2008 Viper body service manual for the exact count and type of fasteners securing the front fascia assembly. Carefully pull the fascia forward to disengage any remaining clips and remove from vehicle. Note the routing of any fog light wiring if equipped.
3. 3

   Disconnect AC lines from condenser
   Locate the AC line connections at the condenser inlet and outlet (typically on the passenger side of the condenser). Clean the connection areas thoroughly to prevent contamination. Using the appropriate AC line disconnect tool, separate both the high-pressure and low-pressure lines from the condenser. Immediately cap all open fittings with plugs or tape to prevent moisture and debris entry. Remove and discard the old O-rings from the line fittings.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
4. 4

   Remove grille and radiator support components
   Remove the upper grille assembly and any remaining components obscuring access to the condenser mounting area. Locate and remove fasteners securing the upper radiator support crossmember or condenser mounting brackets. The Gen IV Viper condenser mounts to the front radiator support structure with the fasteners/brackets specified in the service manual (verify exact mounting count and type before removal).
   Torque spec

   Condenser Mounting Bolts12 Nm (9 lb-ft)
5. 5

   Create clearance for condenser removal
   With the front fascia removed, assess the clearance between the condenser and radiator. You may need to slightly tilt or angle the condenser during removal to clear the radiator fins. Do not force contact between components. If necessary, remove additional lower splash shields or support brackets to create adequate working room.
6. 6

   Remove condenser mounting bolts and extract condenser
   Remove the condenser mounting bolts/fasteners from the brackets as identified during disassembly. Support the condenser weight as you remove the final bolts. Carefully lift the condenser upward and forward, angling as necessary to clear the radiator core. Tilt the condenser to drain any residual oil into a clean container and measure the amount for replacement reference.
   Torque spec

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

   Prepare new condenser
   Inspect the new condenser for shipping plugs and remove them. Add the correct PAG oil type and quantity specified for the 2008 Viper AC system to the new condenser (match the amount drained from the old condenser and confirm against the service manual). Verify that mounting brackets and rubber isolators transfer correctly from the old condenser or are included with the new unit.
8. 8

   Install new condenser
   Carefully lower the new condenser into position between the radiator and front support structure, angling as needed to avoid contact with the radiator. Align the mounting bracket holes with the support structure. Install the condenser mounting bolts/fasteners and tighten to the service-manual specification in a cross pattern to ensure even seating.
   Torque spec

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

   Connect AC lines with new O-rings
   Install new O-rings onto the AC line fittings, lubricating lightly with refrigerant oil. Remove the protective caps from the condenser ports. Connect the high-pressure and low-pressure lines to the corresponding condenser ports, ensuring proper alignment. Tighten the line fittings to specification using a torque wrench.
   Torque spec

   AC Line Fittings20 Nm (15 lb-ft)
10. 10

    Reinstall radiator support and grille components
    Reinstall the upper radiator support crossmember or brackets removed during disassembly. Replace any clips or fasteners that were damaged during removal. Reinstall the grille assembly and secure with original fasteners.
11. 11

    Reinstall front fascia
    Position the front fascia onto the vehicle, reconnecting any fog light wiring if equipped. Align the fascia mounting points and engage any locating clips. Install all fascia mounting fasteners along the top edge, wheel wells, and underside, working from the center outward to ensure proper alignment.
12. 12

    Evacuate and recharge AC system
    Reconnect the battery negative cable. Connect the AC service machine and perform a vacuum test by pulling the system down to 29+ inches of vacuum for at least 30 minutes to verify there are no leaks and to remove all moisture. If vacuum holds, recharge the system with the factory-specified amount of R-134a as listed in the 2008 Viper service manual or underhood AC label (verify exact capacity before charging). Add UV dye if desired for future leak detection.

Reassembly

1. Verify all AC line connections are tight and properly torqued
2. Confirm all front fascia fasteners are secure and panel gaps are correct
3. Check that no tools or hardware were left in the engine bay

Verification

• Start the engine and turn AC to maximum cold with blower on high
• Allow system to run for 5-10 minutes and verify cold air output from vents
• Check compressor clutch engages properly and cycles normally
• Inspect all AC line connections for signs of refrigerant leakage (oil residue or frost)
• Use electronic leak detector or UV light to verify no leaks at condenser connections
• Verify system pressures are within specification (typically 30-35 PSI low side, 200-250 PSI high side at idle with ambient temp 70-80°F)
• Verify front fascia is properly aligned with consistent panel gaps

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