Air Conditioning Condenser Replacement. Pontiac Sun Runner - 4WD (Canada) 1998

For 1990-2009 cars

### Removal Procedure

Important: When installing a new condenser, add 20-30 mL (0.7-1.0 fl oz) of refrigerant oil to the refrigeration system.

1. Discharge and recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the front grille. Refer to Grille Replacement in Exterior Trim.
3. Disconnect the 2 horn electrical connectors.
4. Remove the following in order to remove the front end upper panel (5) from the radiator core support. Position the upper panel aside.

• | The 6 upper bolts

• | The 4 lower bolts

• | The 2 upper screws from the center brace

5. Remove the condenser inlet pipe from the condenser.
6. Remove the condenser outlet pipe from the condenser.
7. Disconnect the condenser fan electrical connector.
8. Remove the condenser mounting bolts (2).
9. Remove the condenser (3) and fan (1) from the vehicle.
10. Remove 4 bolts and the condenser fan from the condenser, if necessary.
11. Cap the refrigerant openings in order to prevent moisture and dirt from entering the system.

### Installation Procedure

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.

1. Install the condenser fan (1) to the condenser (3), if necessary. Secure with 4 bolts.

Tighten
Tighten the condenser fan mounting bolts to 15 N·m (11 lb ft).

2. Install the condenser and fan to the vehicle and secure with the mounting bolts (2).

Tighten
Tighten the condenser mounting bolts to 20 N·m (15 lb ft).

3. Coat new O-rings with 525 viscosity mineral oil.
4. Install the O-rings to the condenser pipe fittings.
5. Install the condenser inlet pipe to the condenser and secure with 1 bolt.
6. Install the condenser outlet pipe to the condenser and secure with 1 bolt.

Tighten

• | Tighten the condenser inlet pipe bolt to 25 N·m (18 lb ft).

• | Tighten the condenser outlet pipe bolt to 35 N·m (26 lb ft).

7. Connect the condenser fan electrical connector.
8. Install the front end upper panel (5) to the radiator core support. Secure the installation with the 6 upper bolts, the 4 lower bolts and the 2 upper screws for the center brace.

Tighten
Tighten the front end upper panel bolts to 20 N·m (15 lb ft).

9. Connect the 2 horn electrical connectors.
10. Install the front grille. Refer to Grille Replacement in Exterior Trim.
11. Evacuate and recharge the air conditioning system. Refer to Refrigerant Recovery and Recharging .
12. Operate the A/C system and test for refrigerant leaks. Refer to Leak Testing .