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JamesH
JamesH, Auto Service Tech
Category: Pontiac
Satisfied Customers: 663
Experience:  Auto Service Tech 3 Years Hands On Experience
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how to replace condenser on 2001 pontiac aztek need detailed

Resolved Question:

how to replace condenser on 2001 pontiac aztek need detailed step by step directions
Submitted: 5 years ago.
Category: Pontiac
Expert:  JamesH replied 5 years ago.
Here are the instructions as you have requested them. If you have any problems let me know.. Thanks!

REMOVAL PROCEDURE


  1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging.
  2. Remove the LH and RH diagonal braces.
  3. Remove the air cleaner assembly. IMPORTANT: Cap or tape the open A/C lines immediately, to prevent system contamination.
  4. Remove the evaporator inlet tube to condenser fitting bolt.
  5. Disconnect the evaporator inlet tube from the condenser.
  6. Remove the discharge hose to condenser fitting nut.
  7. Disconnect the discharge hose from the condenser.
  8. Remove the radiator.
  9. Remove the condenser pipe to radiator mounting bolt.
  10. Remove the condenser to radiator mounting bolts.
  11. Remove the condenser from the radiator.


  1. Remove the receiver dehydrator upper bracket bolts.
  2. Remove the receiver dehydrator to condenser mounting bolts.
  3. Disconnect the receiver dehydrator from the condenser.
  4. Discard the sealing washers.

INSTALLATION PROCEDURE


  1. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C line and fittings on the condenser. IMPORTANT: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new seal washers to enter the refrigerant system.
  2. Lightly coat the new sealing washers with mineral base 525 viscosity refrigerant oil.


  1. Install the sealing washers to the receiver dehydrator.
  2. Connect the receiver dehydrator to the condenser. NOTE: Refer to Fastener Notice in Service Precautions.
  3. Install the receiver dehydrator to condenser mounting bolts. Tighten Tighten the bolts to 6 N.m (53 lb in ).
  4. Install the receiver dehydrator upper bracket bolts. Tighten Tighten the bolts to 6 N.m (53 lb in ).
  5. Install the condenser to the radiator.


  1. Install the condenser to radiator mounting bolts. Tighten Tighten the bolts to 6 N.m (53 lb in ).
  2. Install the condenser pipe to radiator mounting bolt. Tighten Tighten the bolt to 2.5 N.m (22 lb in ).
  3. Install the radiator.
  4. Install the sealing washer to the evaporator inlet fitting.
  5. Connect the evaporator inlet tube to the condenser.
  6. Install the evaporator inlet tube fitting bolt. Tighten Tighten the bolt to 16 N.m (12 lb ft ).
  7. Install the sealing washer to the discharge hose fitting.
  8. Connect the discharge hose to the condenser.
  9. Install the discharge hose fitting nut. Tighten Tighten the nut to 16 N.m (12 lb ft ).
  10. Install the air cleaner assembly.
  11. Install the LH and RH diagonal braces.
  12. Evacuate and recharge the A/C system.
  13. Leak test the fittings of the component using J 39400-A.

 

 

Customer: replied 5 years ago.
Jim, This is excellent info for removing the condenser once I'm there, but I also need the info and procedures to get to that point, specifically how to remove the radiator, blower motors etc to GET TO THE condenser....would you pls be able to provide that info....
Expert:  JamesH replied 5 years ago.
You have to remove the radiator, air cleaner radiator fans and also the battery. I have included the steps to removal and installation of these items. Thanks


  1. Remove and reposition the underhood electrical center in order to provide access for removal of the battery.
  2. Remove the front end sheet metal diagonal brace.
  3. Remove the battery ground (negative) cable from the battery.
  4. Remove the battery positive cable from the battery.
  5. Remove the battery hold down retainer. IMPORTANT: Do not tip the battery more than 40 degrees during removal.
  6. Remove the battery.
  7. Remove the battery insulator from the battery.

INSTALLATION PROCEDURE


  1. Install the battery insulator to the battery. IMPORTANT: Do not tip the battery more than 40 degrees during installation.


  1. Install the battery. Make sure the battery is positioned under the battery tray retainer edge.
  2. Install the battery hold down retainer.
  3. Install the battery positive cable to the battery.
  4. Install the battery ground (negative) cable to the battery.
  5. Install the front end sheet metal diagonal brace.

 

 






  1. Turn the ignition off.
  2. Remove the cooling fans with the cooling fan shroud.
  3. Remove the cooling fan.
  4. Remove the cooling fan motor electrical connector.
  5. Remove the cooling fan motor screws.
  6. Remove the cooling fan motor.


AIR CLEANER ASSEMBLY REPLACEMENT

REMOVAL PROCEDURE


  1. Disconnect the negative battery cable.
  2. Remove the coolant reservoir.
  3. Remove the cruise control module.
  4. Remove the left front sheet metal diagonal brace.
  5. Remove the air cleaner housing and element.
  6. Unsnap the latch on the upper cover and remove the cover.
  7. Carefully remove the Powertrain Control Module (PCM) leaving the 2 harnesses connected and set aside.


  1. Remove the 2 bolts (2) from the air cleaner assembly and remove the housing.

INSTALLATION PROCEDURE


  1. Position the air cleaner housing on the stud (3).
NOTE: Refer to Fastener Notice in Service Precautions.
  1. Install the 2 bolts (1) through the housing Tighten Tighten the air cleaner housing bolts to 10 N.m (89 lb in ).


  1. Carefully install the PCM into the housing.
  2. Install the air cleaner housing and element (3).
  3. Install the upper cover and snap the cover into place.
  4. Install the left front sheet metal diagonal brace.
  5. Install the coolant reservoir.
  6. Install the cruise control module.
  7. Connect the negative battery cable.



 




Radiator Replacement

Removal Procedure



  1. Remove air cleaner and duct assembly.
  2. Drain the coolant.
  3. Recover the refrigerant.
  4. Loosen the engine mount strut-to-engine mount strut bracket bolts.
  5. Remove the engine mount strut bracket brace bolts from the upper radiator support and reposition the struts and brackets rearward.
  6. Remove the battery.
  7. Remove the cooling fans with the cooling fan shroud.
  8. Remove the radiator lower hose from the radiator.
  9. Disconnect the transaxle oil cooler lines from the radiator.
  10. Remove A/C discharge hose from condenser block.
  11. Remove condenser to evaporator inlet tube from condenser block.
  12. Remove radiator/condenser assembly.
  13. Remove condenser tube bracket bolt.
  14. Remove condenser to radiator mounting bolts.
  15. Remove the condenser from the radiator.

Installation Procedure



  1. Install the condenser to the radiator. Notice: Refer to Fastener Notice in Service Precautions.
  2. Install condenser to radiator mounting bolts.
    • Tighten the bolts to 6 Nm (53 inch lbs.) .
  1. Install condenser tube bracket bolt
    • Tighten bolt to 2.5 Nm (22 inch lbs.) .
  1. Install radiator/condenser assembly.
  2. Install condenser to evaporator inlet tube and bolt to condenser block.
    • Tighten bolt to 16 Nm (12 ft. lbs.) .
  1. Install A/C discharge hose and nut to condenser block.
    • Tighten bolt to 16 Nm (12 ft. lbs.).
  1. Connect the transaxle oil cooler lines to the radiator.
  2. Install the radiator lower hose to the radiator.
  3. Install the cooling fans with the cooling fan shroud.
  4. Reposition and install the engine mount strut bracket brace bolts to the upper radiator support.
    • Tighten bolts to 28 Nm (21 ft. lbs.) .
  1. Install battery. Notice: When adding coolant, it is important that you use GM Goodwrench DEX-COOL or HAVOLINE DEX-C00L coolant. If Coolant other than DEX-COOL or HAVOLINE DEX-COOL is added to the system the engine coolant will require change sooner; at 50,000 km (30,000 mi) or 24 months.
  2. Fill the cooling system
  3. Recharge A/C system.
  4. Install the air cleaner and duct assembly.

 

JamesH, Auto Service Tech
Category: Pontiac
Satisfied Customers: 663
Experience: Auto Service Tech 3 Years Hands On Experience
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