GM Service Manual Online
For 1990-2009 cars only

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure

    Important: The desiccant is inside the condenser and is not serviced separately. The condenser must be replaced if new desiccant is required.

  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. Remove the left headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement .
  3. Remove the right headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement .
  4. Loop a rope around each of the 2 upper tabs of the radiator and tie the rope around the upper tie bar.

  5. Object Number: 1201917  Size: SH
  6. Remove both upper radiator support bracket bolts.
  7. Remove both upper radiator support brackets.

  8. Object Number: 1202411  Size: SH

    Object Number: 1203537  Size: SH
  9. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .
  10. Remove the lower radiator air deflector retainers.
  11. Remove the lower radiator air deflector.

  12. Object Number: 1203530  Size: SH
  13. Remove the right front fender liner. Refer to Front Fender Liner Replacement .
  14. Remove the right radiator air deflector retainers.
  15. Remove the right radiator air deflector.

  16. Object Number: 1203535  Size: SH
  17. Remove the left radiator air deflector retainers.
  18. Remove the left radiator air deflector.

  19. Object Number: 1201921  Size: SH
  20. Remove the liquid line and compressor hose bolt from condenser.
  21. Remove the compressor hose from the condenser.
  22. Remove the liquid line from the condenser.
  23. Remove both lower radiator mounting bracket bolts.
  24. Remove both lower radiator mounting brackets.

  25. Object Number: 1203468  Size: SH

    Object Number: 1203511  Size: SH
  26. Remove and discard the condenser mounting bolts.
  27. Remove and discard the condenser mounting nuts.

  28. Object Number: 1201922  Size: SH
  29. Push upward on the radiator and downward on the condenser to unsnap the condenser mounting tabs from the radiator clip.
  30. Remove the condenser.
  31. Remove the upper seal.
  32. Important: Cap all A/C components immediately to prevent system contamination.

  33. Remove and discard the sealing washers.

Installation Procedure

  1. Uncap A/C components.
  2. Install new sealing washers. Refer to Sealing Washer Replacement .
  3. Install the upper seal.
  4. If replacing the condenser, add the specific amount of PAG® oil directly to the condenser. Refer to Refrigerant System Capacities .

  5. Object Number: 1336545  Size: SH
  6. Install the radiator air side seals onto the condenser mounting tabs on the radiator.

  7. Object Number: 1201922  Size: SH
  8. Insert condenser mounting tabs into the radiator clips.
  9. Notice: The bolt retaining the condenser to the radiator end tank is a special length and should be the ONLY bolt used upon reinstallation. The use of a longer bolt will damage the radiator end tank.

    Important: Replace the condenser mounting bolts and nuts.

  10. Install the condenser mounting nuts.
  11. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1203511  Size: SH
  12. Install the condenser mounting bolts.
  13. Tighten
    Tighten the mounting bolts to 6 N·m (53 lb in).


    Object Number: 1336474  Size: SH
  14. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.

  15. Object Number: 1337348  Size: SH
  16. The radiator air side seals must be in the proper position for proper airflow.
  17. Install both lower radiator mounting brackets.

  18. Object Number: 1203468  Size: SH
  19. Install both lower radiator mounting brackets bolts.
  20. Tighten
    Tighten the bolts to 60 N·m (44 lb ft).

  21. Install the liquid line to the condenser.
  22. Install the compressor hose to the condenser.

  23. Object Number: 1201921  Size: SH
  24. Install the liquid line and compressor hose bolt to the condenser.
  25. Tighten
    Tighten the bolt to 20 N·m (15 lb ft).


    Object Number: 1203535  Size: SH

    Important: Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur.

  26. Install the left radiator air deflector.
  27. Install the left radiator air deflector retainers.

  28. Object Number: 1203530  Size: SH
  29. Install the right radiator air deflector.
  30. Install the right radiator air deflector retainers.
  31. Install the right front fender liner. Refer to Front Fender Liner Replacement .

  32. Object Number: 1203537  Size: SH
  33. Install the lower radiator air deflector.
  34. Install the lower radiator air deflector retainers.
  35. Lower the vehicle.
  36. Remove the rope attached to the radiator and upper tie bar.

  37. Object Number: 1202411  Size: SH
  38. Install both upper radiator support brackets.
  39. Important: Do not allow the upper bracket to twist when tightening the radiator mounting bolts or vibration may result.


    Object Number: 1212430  Size: SH
  40. Install both upper radiator support bracket bolts.
  41. Tighten
    Tighten the bolt to 10 N·m (89 lb in).

  42. Install the right headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement .
  43. Install the left headlamp. Refer to Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement .
  44. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
  45. Leak test the fittings using the J 39400-A .