GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 1998 🢒 Cavalier 🢒 HVAC 🢒 HVAC Systems - Manual 🢒 Air Conditioning Condenser Replacement

Removal Procedure

    Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

  1. Disconnect the negative battery cable.
  2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  3. Remove the upper closeout panel.
  4. Remove the hood latch from the mounting plate.
  5. Remove the following headlight assemblies:
    6. • The right side
    • The left side
  6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  7. Disconnect the forward supplemental inflatable restraint (SIR) sensor harness.
  8. Lower the vehicle.
  9. Remove the right radiator mount.
  10. Remove the following components:
    11. • The hood latch support bracket
    • The forward sensor with the harness

    Object Number: 302603 Size: SH
  11. Remove the following components from the condenser (1):
    12. • The compressor hose
    • The evaporator line
  12. Discard the O-rings.

    13. Important: Use a back-up wrench in order to prevent twisting of the block fitting.

  13. Remove the condenser (1).

Installation Procedure

    Object Number: 302603 Size: SH
  1. Install the condenser (1) to the vehicle.

    2. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

    Important: Use a back-up wrench in order to prevent twisting of the block fitting.

  2. Install the following components to the condenser (1):
    3. • The compressor hose
    • The evaporator line

    Tighten
    Tighten the nuts to 16 N·m (12 lb ft).

  3. Install the following components:
    4. • The hood latch support bracket
    • The forward sensor with the harness
  4. Install the right radiator mount.
  5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  6. Connect the forward SIR harness.
  7. Lower the vehicle.
  8. Install the following headlamp assemblies:
    9. • The right side
    • The left side
  9. Install the hood latch assembly. Adjust the hood latch assembly.
  10. Install the upper closeout panel.
  11. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  12. Connect the negative battery cable.

    13. Tighten
    Tighten the bolt to 16 N·m (12 lb ft).