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Air Conditioning Receiver Drier Replacement (03-01-008)

Publication date: 2003-08-01
Reference number: 03-01-008

AIR CONDITIONING RECEIVER DRIER REPLACEMENT

AIR CONDITIONING RECEIVER DRIER REPLACEMENT

SERVICE CAMPAIGN BULLETIN

Reference Number(s): 03-01-008, Date of Issue:  August 2003
HYUNDAI: 2003-2004 XG350; 2003 Sonata
GROUP: Campaign

DESCRIPTION

Some 2003 Sonata and 2003-2004 XG350 air conditioner receiver drier desiccant bags may become detached. If the desiccant bag becomes detached, the performance of the air conditioning system will decrease. A new receiver drier is available and should only be installed as outlined in this Service Bulletin.

VEHICLES AFFECTED

2003 Sonata's produced beginning November 13, 2002 through April 17, 2003

2003-2004 XG's produced beginning November 14, 2002 through April 17, 2003

INSPECTION PROCEDURE

  1. Verify that the vehicle qualifies for this campaign.
  2. Verify the production date.
  3. Open the hood and inspect the receiver drier for either of the following conditions:
    1. An "X" marked on top of the receiver drier (campaign has already been performed). See Fig 1 .
      Fig 1: Campaign Completion Mark
      G00229123
    2. A different style receiver drier with a detachable outlet pipe (identified by the large mounting nut, and the pressure switch on the right side). See Fig 2 .
      Fig 2: Alternate Style Receiver Drier
      G00229124
    NOTE: Vehicles with the "X" or the alternate style receiver drier do not require this campaign replacement procedure.

PARTS LIST

Fig 3: Receiver Drier Parts
G00229125
PARTS LIST

Part Name Part Number Comments
(1) Receiver Drier with integral outlet pipe 97801-38003-C Refer To Figure 3
(2) O-Ring (8mm dia) Outlet Pipe 97801-38003-C Refer To Figure 3
(3) O-Ring (9.25mm dia) Triple Pressure Switch 97801-38003-C Refer To Figure 3
(4) O-Ring (12mm dia) Inlet Pipe 97801-38003-C Refer To Figure 3

REPLACEMENT PROCEDURE

  1. Recover the refrigerant with a Charging and Recovery Station such as the SPX-Robinair "Cooltech 700" Model 34700-2K (or equivalent). Refer to your machine's operation manual for the proper operating procedure. See Fig 4 .
    NOTE: While the refrigerant is being recovered, perform steps 2 - 7.
    Fig 4: Charging and Recovery Station
    G00229126
  2. Disconnect the condenser fan motor connector (Fig 5 ) and place the connector in a highly visible area.
    Fig 5: Condenser Fan Motor Connector
    G00229127
  3. Remove the two condenser fan shroud mounting bolts, and the 2 radiator mounting bracket bolts (one radiator bolt is not shown in Fig 6 ). Remove the brackets, but do not remove the radiator.
    Fig 6: Mounting Bolts
    G00229128
  4. Remove the fan and shroud by slightly moving the top of the fan away from the radiator, then pull up.
    NOTE: Use caution not to damage the radiator fins while removing the fan.
  5. Create a condenser fin protector by cutting a piece of cardboard to the dimensions shown in Fig 7 .
    Fig 7: Condenser Fin Protector
    G00229129
  6. Protect the paint on the bumper in front of the receiver drier assembly with shop towels Fig 8 (or equivalent). Also slide the cardboard protector behind the receiver drier to prevent damage to the condenser fins.
    Fig 8: Shop Towels on Bumper
    G00229130
  7. After recovering the refrigerant, operate the station in "VACUUM" mode for 5 minutes to completely remove the air conditioning refrigerant. Document the amount of refrigerant recovered on the repair order.
  8. Disconnect the air conditioning charging/recovery station. This will provide working space to remove the receiver drier.
  9. Remove the receiver drier outlet pipe/hose mounting nut located near the high pressure port shown in Fig 9 .
    Fig 9: Receiver Drier Outlet Pipe/Hose Mounting Nut
    G00229131
  10. Remove the receiver drier inlet pipe mounting capscrew (Fig 10 ) from the bottom of the receiver drier.
    Fig 10: Inlet Pipe Mounting Capscrew
    G00229132
    NOTE: The inlet pipe is dowelled for proper location. The receiver drier must be lifted to clear the dowel pin before it can be removed (later in the procedure).
  11. Disconnect the receiver drier pressure switch connector (Fig 11 ) and remove the switch.
    Fig 11: Receiver Drier Pressure Switch Connector
    G00229133
    NOTE: Save the switch for reinstallation in step 18.
  12. Remove the 2 receiver drier mounting capscrews in Fig 16 from the engine side of the condenser and remove the receiver drier from the vehicle.
    NOTE: The inlet pipe is dowelled for proper location. The receiver drier must be lifted to clear the dowel pin before it can be removed.
    NOTE: Be careful not to spill PAG oil on the paint of the vehicle.
  13. Install the 12 mm diameter o-ring (P/N 97690-34350) shown in Fig 12 onto the receiver drier inlet pipe. Lubricate the o-ring with PAG oil (use Hyundai PAG Oil- ISO 46 P/N 00232-18001; or equivalent).
    Fig 12: O-Ring
    G00229135
  14. Remove the sealing tape from the bottom side of the receiver drier as shown in Fig 13 . Leave the cap plugs on the pressure switch port and outlet pipe.
    Fig 13: Removing the Sealing Tape
    G00229136
  15. With the cardboard protector in place, install the new receiver drier by guiding the outlet pipe around the condenser and radiator assembly. Ensure that the outlet tube (Fig 14 ) is properly positioned in the slot of the mounting block.
    Fig 14: Outlet Tube
    G00229137
    NOTE: The new receiver drier is prefilled with PAG oil. It is not necessary to add additional oil.
  16. Guide the receiver drier over the inlet pipe as shown in Fig 15 . Ensure the dowel pin on the receiver drier properly engages the inlet pipe. Install the mounting capscrew and torque to 4-7 lb-ft.
    Fig 15: Inlet Pipe
    G00229138
  17. Install the 2 receiver drier mounting capscrews (Fig 16 ) at the front of the condenser and torque to 3-4 lb-ft.
    Fig 16: Receiver Drying Mount Screws
    G00229139
  18. Perform the following with the triple pressure switch that was removed in step 11:
    1. Remove and discard the old o-ring.
    2. Install the new 9.25 mm diameter o-ring onto the pressure switch and lubricate the o-ring with PAG oil (use Hyundai PAG Oil P/N 00232-18001 ISO 46; or equivalent).
    3. Install the pressure switch onto the new receiver drier as shown in Fig 17 . Torque the switch to 9-11 lb-ft.
    Fig 17: Installing Triple Pressure Switch
    G00229140
  19. Lubricate the 8 mm diameter o-ring (P/N 97690-34310) on the outlet tube with PAG oil as shown in Fig 18 .
    Fig 18: Lubricate with PAG Oil
    G00229141
  20. Tighten and torque the outlet pipe (Fig 19 ) near the high side port to 4-7 lb-ft.
    Fig 19: Tighten and Torque Outlet Pipe
    G00229142
  21. Reconnect the recovery/charging station and evacuate the system for 5 minutes. Confirm that the system holds a vacuum.
  22. Charge the air conditioning system with 1.5 +/- 0.05 lb (680 +/- 25 g) R-134a.
  23. Mark the new receiver drier with an "X" to identify that the campaign has been completed. See Fig 20 .
    Fig 20: Mark New Receiver Drier
    G00229143
  24. Install the 2 radiator mounting bracket bolts and torque to 14-18 lb-ft
  25. Install the condenser fan, ensuring the lower mounting tabs are properly inserted into the lower mounting points. Install and torque the mounting bolts to 6-7 lb-ft.
  26. Connect the condenser fan motor electrical connector.
  27. Start the engine and switch the air conditioning system "ON" to verify system performance.

CAMPAIGN CLAIM INFORMATION

NOTE: Submit claims using the campaign claim screen.
CAMPAIGN CLAIM INFORMATION

OP-Code Operation OP-Time
30B026R2 Receiver Drier Replacement 0.7 M/H
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