GM Service Manual Online
For 1990-2009 cars only

Tools Required

    • J 38185 Hose Clamp Pliers
    • J 39400-A Halogen Leak Detector

Removal Procedure

  1. Remove the battery. Refer to Battery Replacement in Engine Electrical.
  2. Remove the battery tray.
  3. Recover the A/C system. Refer to Refrigerant Recovery and Recharging in Heating, Ventilation and Air Conditioning.

  4. Object Number: 1310291  Size: SH
  5. Drain the cooling system. Refer to Cooling System Draining and Filling .
  6. Use the J 38185 in order to reposition the radiator inlet hose clamp (1).
  7. Remove the radiator inlet hose (2) from the radiator.
  8. Use the J 38185 in order to reposition the surge tank outlet/radiator outlet hose clamp (4) from the surge tank.
  9. Remove the surge tank outlet/radiator outlet hose (6) from the surge tank.
  10. Use the J 38185 in order to reposition the surge tank outlet/radiator outlet hose clamp (7) from the radiator.
  11. Remove the surge tank outlet/radiator outlet hose (6) from the radiator.

  12. Object Number: 161040  Size: SH
  13. Remove the upper transaxle cooler line.

  14. Object Number: 588312  Size: SH
  15. Remove the refrigerant pressure sensor electrical connector.

  16. Object Number: 588318  Size: SH
  17. Remove the condenser inlet fitting from the discharge hose.
  18. Important: Cap or tape off the open A/C hose to prevent system contamination.

  19. Remove and discard the sealing washer.

  20. Object Number: 1366085  Size: SH
  21. Disconnect the cooling fan electrical connector.
  22. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  23. Remove the lower closeout panel.

  24. Object Number: 161040  Size: SH
  25. Remove the lower transaxle cooler line fitting.

  26. Object Number: 590055  Size: SH
  27. Remove the bolt from the evaporator hose to the condenser.
  28. Remove the evaporator hose from the condenser.
  29. Remove and discard the seal washer.

  30. Object Number: 486715  Size: SH
  31. Remove the lower radiator support mounting panel.

  32. Object Number: 181871  Size: SH
  33. Remove the radiator, fan, and condenser as an assembly from the vehicle.

  34. Object Number: 1364791  Size: SH
  35. Remove the fan shroud from the radiator.
  36. Remove the condenser from the radiator.

Installation Procedure


    Object Number: 1364791  Size: SH
  1. Install the fan shroud to the radiator.
  2. Install the condenser to the radiator.
  3. 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.

  4. Install the condenser to radiator bolts.
  5. Tighten
    Tighten the bolts to 5 N·m (44 lb in).


    Object Number: 181871  Size: SH
  6. Install the radiator, fan, and condenser as an assembly to the vehicle.

  7. Object Number: 486715  Size: SH
  8. Install the lower radiator support mounting panel.
  9. Tighten
    Tighten the bolts to 10 N·m (89 lb in).


    Object Number: 590055  Size: SH
  10. Remove the cap or tape from the evaporator hose.
  11. Install a new seal washer on the condenser end of the evaporator hose assembly. Refer to Sealing Washer Replacement in Heating, Ventilation and Air Conditioning.
  12. Install the evaporator hose to the condenser outlet.
  13. Install the condenser outlet to the evaporator line bolt.
  14. Tighten
    Tighten the bolt to 25 N·m (18 lb ft).


    Object Number: 161040  Size: SH
  15. Install the lower transaxle cooler line fitting.
  16. Tighten
    Tighten the fitting to 30 N·m (22 lb ft).


    Object Number: 1366085  Size: SH
  17. Install the cooling fan electrical connectors.
  18. Install the lower closeout panel.
  19. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

  20. Object Number: 1310291  Size: SH
  21. Install the surge tank outlet/radiator outlet hose (6) to the radiator.
  22. Use the J 38185 in order to reposition the surge tank outlet/radiator outlet hose clamp (7) to the radiator.
  23. Install the surge tank outlet/radiator outlet hose (6) to the surge tank.
  24. Use the J 38185 in order to reposition the surge tank outlet/radiator outlet hose clamp (4) to the surge tank.
  25. Install the radiator inlet hose (2) to the radiator.
  26. Use the J 38185 in order to reposition the radiator inlet hose clamp (1) to the radiator.

  27. Object Number: 588318  Size: SH
  28. Remove the cap or tape from the discharge hose.
  29. Install a new sealing washer to the discharge hose. Refer to Sealing Washer Replacement in Heating, Ventilation and Air Conditioning.
  30. Install the condenser inlet fitting to the discharge hose.
  31. Tighten
    Tighten the fitting to 25 N·m (18 lb ft).


    Object Number: 588312  Size: SH
  32. Install the refrigerant pressure sensor electrical connector.

  33. Object Number: 161040  Size: SH
  34. Install the upper transaxle oil cooler line fitting.
  35. Tighten
    Tighten the fitting to 30 N·m (22 lb ft).

  36. Refill the cooling system. Refer to Cooling System Draining and Filling .
  37. Recharge the A/C system. Refer Refrigerant Recovery and Recharging to in Heating, Ventilation and Air Conditioning.
  38. Leak test the fittings of the reinstalled components using the J 39400-A .
  39. Install the battery. Refer to Battery Replacement in Engine Electrical.