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Installation Procedure

WARNING: This page is about a different car, the 2003 Pontiac Aztek and 2003 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the condenser to the radiator.
    NOTE: Refer to FASTENER NOTICE in Cautions and Notices.
  2. Install the mounting bolts that secure the condenser to the radiator.

    Tighten 

    Tighten the bolts to 6 N.m (53 lb. in).

  3. Install the condenser tube clip bolt.

    Tighten 

    Tighten the bolt to 2.5 N.m (22 lb. in).

  4. Install the radiator and condenser assembly.
  5. Remove the cap or the tape from the evaporator inlet tube.
  6. Install a new seal washer to the evaporator inlet tube. Refer to SEALING WASHER REPLACEMENT .
    Fig 1: Installing Condenser To Radiator
    G01500997Courtesy of GENERAL MOTORS CORP.
  7. Install the evaporator inlet tube and the bolt to the condenser block.

    Tighten 

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

    Fig 2: Installing Evaporator Inlet Tube And Bolt
    G01500998Courtesy of GENERAL MOTORS CORP.
  8. Remove the cap or the tape from the A/C discharge hose.
  9. Install a new sealing washer to the A/C discharge hose. Refer to SEALING WASHER REPLACEMENT .
  10. Install the A/C discharge hose and the nut to the condenser block.

    Tighten 

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

  11. Raise the vehicle.
  12. Connect the lower TOC line to the radiator. Refer to TRANSMISSION OIL COOLER LINE QUICK CONNECT FITTING in Automatic Transaxle - 4T65-E.
    Fig 3: Installing Sealing Washer
    G01500999Courtesy of GENERAL MOTORS CORP.
  13. Install the radiator outlet hose.
  14. Connect the radiator outlet hose to the radiator.
  15. Reposition the hose clamp at the radiator to secure the hose using the J 38185. 
  16. Lower the vehicle.
  17. Connect the radiator outlet hose to the water pump housing.
  18. Reposition the hose clamp at the water pump housing to secure the hose using the J 38185. 
  19. Install the cooling fans with the cooling fan shroud. Refer to COOLING FAN REPLACEMENT - ELECTRIC  .
  20. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM  .
  21. Evacuate and recharge the A/C system. Refer to REFRIGERANT RECOVERY AND RECHARGING in Heating, Ventilation and Air Conditioning.
  22. Leak test the fittings of the component using the J 39400-A. 
  23. Inspect the transmission fluid level. Refer to TRANSMISSION FLUID CHECKING PROCEDURE in Automatic Transaxle - 4T65-E.
Fig 4: Installing Radiator Outlet Hose
G01501000Courtesy of GENERAL MOTORS CORP.
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