93/94 ZEXEL A/C Condenser Repair Tutorial
Posted: Fri Jul 14, 2006 9:25 pm
I don't know if this is useful, but it may be so I thought I'd detail my effort for the potential benefit of others. =)
I replaced my condenser because my oil and refrigerant had leaked out of my condenser where now only oily-dirt-clogs remained.
I'll only guarantee this works on a 1993 ZEXEL A/C system and the instructions below are aimed at the wagon (though the same _should_ be true for the sedans as well).
Background information-
The condenser you need is determined by the manufacturer of the system, which is listed on the compressor. My 1993 legacy Mfd in 8/92 came with a ZEXEL (apparently sometimes listed as DKS or DKKC) compressor and its design is _entirely different_ from the "CalSonic" design. Neither RockAuto (nor anywhere else as far as I can tell) sells a drop-in replacemnt (other than the 'spensive factory replacement) but there is an excellent alternative that RockAuto has.
If you have the ZEXEL (DKKC) system, look up the A/C Condenser for a 1991 Subaru Legacy and get the WAGON or SEDAN unit according to your car. The condenser block and fins, refrigerant tube mounting connections (locations and orientations), and the pegs on the bottom are identical and an exact fit BUT the 2 mounting bolt holes are each 1/2" or so too close to the centerline of the car. This is due to the "facelift" of front end on the the 93-94 Subaru Legacies which are otherwise mostly identical to 91-92. Other than those two bolt holes, the condensers are identical.
NORMAL REMOVAL PROCEDURE (in super-detail. This WHOLE removal, modification, and reinstallation takes about 1.5 hours if you go slow)
* I assume the system is discharged. If your condenser needs to be replaced, then it probably is MOSTLY discharged. If you're not sure and don't know how you might go about discharging it safely go read online some more or take it to a licenensed refrigerant shop. *
- Remove the Grille
- Remove the 2 bolts that hold the radiator in place.
- * Lean the Radiator back and brace it in this position *
- Remove the 2 10mm mounting bolts to the condenser unit (10mm socket)
- remove the top right 12mm refrigerant tube bolt (12mm socket)
- uncouple the refrigerant tube at the union near the ABS unit (2 adjustable wrenches or metric wrenches)
- carefully pull the old condenser out
MODIFICATION STEP
- Put the new unit in place so it seats proerly
- Use a hammer and punch punch or sharp metal rod to make a mark on the condenser mounting brackets where the centers of the new bolt holes should go. Don't puncture the condenser tubes goofball.
- remove the new condenser
- Drill and tap to M6x1.00 (the size just about every metric bolt on foreign cars that are 10mm socket sizes are; no, really.) When drilling, use a piece of sheet metal or something to protect the condenser fins and refrigerant tubes.
BACK TO NORMAL PROCEDURE AGAIN
- Move the left hand side refrigerant tube from the old condenser to the new one (12mm socket)
- Put condenser in and attach the top right refrigerant line
- Replace the 2 10mm mounting bolts
- Reattach the top left refrigerant union (by ABS module, nearish passenger side headlamp)
- Replace appropriate amount and type of compressor oil (mebbe an ounce or 2?)
- Refill with the appropriate refrigerant
PS, it's also by the book to replace the Receiver-dryer when you open the system. RockAuto sells them for $8 or so, so grab one. Adds only about 15 minutes. My A/C is back to its r134a retrofitted coolness. =)
I replaced my condenser because my oil and refrigerant had leaked out of my condenser where now only oily-dirt-clogs remained.
I'll only guarantee this works on a 1993 ZEXEL A/C system and the instructions below are aimed at the wagon (though the same _should_ be true for the sedans as well).
Background information-
The condenser you need is determined by the manufacturer of the system, which is listed on the compressor. My 1993 legacy Mfd in 8/92 came with a ZEXEL (apparently sometimes listed as DKS or DKKC) compressor and its design is _entirely different_ from the "CalSonic" design. Neither RockAuto (nor anywhere else as far as I can tell) sells a drop-in replacemnt (other than the 'spensive factory replacement) but there is an excellent alternative that RockAuto has.
If you have the ZEXEL (DKKC) system, look up the A/C Condenser for a 1991 Subaru Legacy and get the WAGON or SEDAN unit according to your car. The condenser block and fins, refrigerant tube mounting connections (locations and orientations), and the pegs on the bottom are identical and an exact fit BUT the 2 mounting bolt holes are each 1/2" or so too close to the centerline of the car. This is due to the "facelift" of front end on the the 93-94 Subaru Legacies which are otherwise mostly identical to 91-92. Other than those two bolt holes, the condensers are identical.
NORMAL REMOVAL PROCEDURE (in super-detail. This WHOLE removal, modification, and reinstallation takes about 1.5 hours if you go slow)
* I assume the system is discharged. If your condenser needs to be replaced, then it probably is MOSTLY discharged. If you're not sure and don't know how you might go about discharging it safely go read online some more or take it to a licenensed refrigerant shop. *
- Remove the Grille
- Remove the 2 bolts that hold the radiator in place.
- * Lean the Radiator back and brace it in this position *
- Remove the 2 10mm mounting bolts to the condenser unit (10mm socket)
- remove the top right 12mm refrigerant tube bolt (12mm socket)
- uncouple the refrigerant tube at the union near the ABS unit (2 adjustable wrenches or metric wrenches)
- carefully pull the old condenser out
MODIFICATION STEP
- Put the new unit in place so it seats proerly
- Use a hammer and punch punch or sharp metal rod to make a mark on the condenser mounting brackets where the centers of the new bolt holes should go. Don't puncture the condenser tubes goofball.
- remove the new condenser
- Drill and tap to M6x1.00 (the size just about every metric bolt on foreign cars that are 10mm socket sizes are; no, really.) When drilling, use a piece of sheet metal or something to protect the condenser fins and refrigerant tubes.
BACK TO NORMAL PROCEDURE AGAIN
- Move the left hand side refrigerant tube from the old condenser to the new one (12mm socket)
- Put condenser in and attach the top right refrigerant line
- Replace the 2 10mm mounting bolts
- Reattach the top left refrigerant union (by ABS module, nearish passenger side headlamp)
- Replace appropriate amount and type of compressor oil (mebbe an ounce or 2?)
- Refill with the appropriate refrigerant
PS, it's also by the book to replace the Receiver-dryer when you open the system. RockAuto sells them for $8 or so, so grab one. Adds only about 15 minutes. My A/C is back to its r134a retrofitted coolness. =)