GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2003 🢒 L300/LW300 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Air Conditioning Condenser Replacement

Removal Procedure
  1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .

    3. Object Number: 894560 Size: SH
  3. Disconnect the pusher fan electrical connector.
  4. Remove the pusher fan harness from the puller fan shroud tabs and push the harness clear of the radiator end tank.

    5. Object Number: 892706 Size: SH

    Caution: Do not remove hoses or lines before system is fully discharged. System may be under pressure and contact with R134a may cause personal injury.

  5. Remove the nut that secures the condenser hose to the evaporator hose assembly.
  6. Install the caps on the condenser hose and on the evaporator hose assembly to prevent moisture entry and oil spillage.

    7. Object Number: 894311 Size: SH
  7. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  8. Remove the gasket that separates the radiator from the condenser by pulling down on one end of the gasket and peeling back.

    9. Object Number: 894558 Size: SH
  9. Remove the retainer nuts and washers from the pusher fan.

    10. Object Number: 894308 Size: SH
  10. Remove the lower fan shroud by pulling the shroud forward and then down.

    11. Object Number: 892737 Size: SH
  11. Remove the bolt that secures the condenser hose to the condenser block fitting.

    12. Object Number: 893625 Size: SH
  12. Remove the fasteners that secure the hose clamp to the condenser and remove the condenser hose.
  13. Install the caps on the condenser hose and on the condenser block fitting to prevent moisture entry and oil spillage.

    14. Object Number: 894011 Size: SH
  14. Remove the bolt that secures the discharge line to the condenser block fitting.
  15. Install caps on the discharge line and condenser block fitting to prevent moisture entry and oil spillage.

    16. Object Number: 894382 Size: SH
  16. Remove the bolt that secures the condenser block fitting to the radiator end tank.

    17. Object Number: 894018 Size: SH
  17. Remove the condenser bolts.

    18. Object Number: 894019 Size: SH
  18. Slide the condenser down then rotate the bottom forward to remove.

    19. Object Number: 894026 Size: SH
  19. Remove the bolts from the receiver dehydrator line fitting.

    20. Object Number: 894022 Size: SH
  20. Loosen the bolt from the receiver dehydrator clamp and remove the dehydrator.

Installation Procedure

    Object Number: 894022 Size: SH
  1. If replacing the condenser, add PAG oil to the condenser. Refer to Refrigerant System Capacities for system capacity information.
  2. Install the receiver dehydrator into the clamp. Do NOT tighten the clamp.
  3. Install new O-rings to the receiver dehydrator. Refer to O-Ring Replacement .

    4. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 894026 Size: SH
  4. Tighten the receiver dehydrator block bolts

    5. Tighten
    Tighten the bolts to 3 N·m (27 lb in).

  5. Tighten the receiver dehydrator clamp bolt.

    6. Tighten
    Tighten the bolt to 5 N·m (44 lb in).


    Object Number: 894020 Size: SH

    Important: The condenser block must be engaged to the radiator end tank bracket before sliding the condenser upward.

  6. Install the condenser to the radiator by sliding the condenser tabs under the radiator brackets.

    7. Object Number: 894018 Size: SH
  7. Install the bolts that secure the condenser to the radiator.

    8. Tighten
    Tighten the bolts to 5 N·m (44 lb in).


    Object Number: 894382 Size: SH
  8. Install the condenser block to the radiator end tank bolt.

    9. Tighten
    Tighten the bolt to 5 N·m (44 lb in).


    Object Number: 894011 Size: SH
  9. Remove the condenser hose to the condenser cap and plug.
  10. Install a new seal washer. Refer to Sealing Washer Replacement .
  11. Remove the condenser block cap and install the discharge line.
  12. Install the discharge hose to the condenser block fitting and install the bolt.

    13. Tighten
    Tighten the bolt to 20 N·m (15 lb ft).


    Object Number: 892737 Size: SH
  13. Install the condenser hose to the condenser block fitting and install the bolt.

    14. Tighten
    Tighten the bolt to 20 N·m (15 lb ft).

  14. Install the condenser hose clamps onto the condenser studs and install the bolts.

    15. Tighten
    Tighten the bolts to 5 N·m (44 lb in).


    Object Number: 894311 Size: SH
  15. Install the gasket that separates the radiator from the condenser.

    16. Object Number: 894555 Size: SH
  16. Slide the upper pusher fan shroud under the retaining tabs located at the upper edge of the condenser.
  17. Rotate the lower fan shroud onto the lower mounting studs and install the retaining nuts.

    18. Tighten
    Tighten the nuts to 5 N·m (44 lb in).

    Notice: Position pusher fan electrical harness in shroud indentation to prevent harness damage.

  18. Route the pusher fan electrical harness around the outside of the radiator end tank, below the upper radiator hose.
  19. Lower the vehicle.

    20. Object Number: 892706 Size: SH
  20. Remove the evaporator hose assembly and the condenser hose caps.
  21. Install new seal washers. Refer to Sealing Washer Replacement .
  22. Install the evaporator hose assembly to the condenser hose and install the nut.

    23. Tighten
    Tighten the nut to 12 N·m (9 lb ft).

  23. Install the condenser hose into the rail clamp.

    24. Object Number: 894560 Size: SH
  24. Install the pusher fan harness into the mounting tabs on the puller fan shroud.
  25. Connect the pusher fan electrical connector.
  26. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
  27. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  28. Using J 39400-A , leak test the fittings of the component.