Mechanics

DO I NEED TO REMOVE MY RADIATOR IN ORDER TO REPLACE MY A/C CONDENSER....?

2006 Chevrolet Malibu • 8,000 miles

My a/c condenser was damaged amd all the oil and refrigerant has leaked out.I was wondering the steps to remove the condenser? Can I leave the rad in the car and still remove my condenser? I just don't want to remove the rad if it's possible to replace the a/c condenser with it there. Thanks. Dave.
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Davimms
September 23, 2011.



The radiator may not have to be removed, but I recommend that you do it anyway. When installing a condenser, the more room you have will prevent damaging the condenser during installation. The steel transmission cooler lines that run through a separate core in your radiator will inhibit much movement of the radiator. It's best to remove it - give yourself a little room to work. The couple of extra steps are well worth the trouble.


Dan_K
Sep 23, 2011.
Thank you. Would you have the steps to remove the rad and condenser from my 2006 Malibu. It's a 3.5 liter V6. Thanks again.


Tiny
Davimms
Sep 23, 2011.
CONDENSER REPLACEMENT

Tools Required J 39400-A Halogen Leak Detector

Removal Procedure

1. Recover the refrigerant.

2. Remove the left headlamp.

3. Remove the right headlamp.

4. Loop a rope around each of the 2 upper tabs of the radiator and tie the rope around the upper tie bar.

5. Remove both upper radiator support bracket bolts.

6. Remove both upper radiator support brackets.

7. Raise the vehicle. Refer to Lifting and Jacking the Vehicle.

8. Remove the lower radiator air deflector retainers.

9. Remove the lower radiator air deflector.

10. Remove the right front fender liner.

11. Remove the right radiator air deflector retainers.

12. Remove the right radiator air deflector.

13. Remove the left radiator air deflector retainers.

14. Remove the left radiator air deflector.

15. Remove the liquid line and compressor hose bolt from condenser.

16. Remove the compressor hose from the condenser.

17. Remove the liquid line from the condenser.

18. Remove both lower radiator mounting bracket bolts.

19. Remove both lower radiator mounting brackets.

20. Remove and discard the condenser mounting bolts.

21. Remove and discard the condenser mounting nuts.

22. Push upward on the radiator and downward on the condenser to unsnap the condenser mounting tabs from the radiator clip.

23. Remove the condenser.

24. Remove the upper seal.

IMPORTANT: Cap all A/C components immediately to prevent system contamination.

25. Remove and discard the sealing washers.

Installation Procedure

1. Uncap A/C components.

2. Install new sealing washers.

3. Install the upper seal.

4. If replacing the condenser, add the specific amount of PAGĀ®
oil directly to the condenser.

5. Install the radiator air side seals onto the condenser mounting tabs on the radiator.

NOTE: The bolt retaining the condenser to the radiator end
tank is a special length and should be the ONLY bolt used upon reinstallation. The use of a longer bolt will damage the radiator end tank.

IMPORTANT: Replace the condenser mounting bolts and nuts.

6. Insert condenser mounting tabs into the radiator clips.

7. Install the condenser mounting nuts.

8. Install the condenser mounting bolts.
Tighten: Tighten the mounting bolts to 6 N.M (53 lb in).

9. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.

10. The radiator air side seals must be in the proper position for proper airflow.

11. Install both lower radiator mounting brackets.

12. Install both lower radiator mounting brackets bolts.
Tighten: Tighten the bolts to 60 N.M (44 lb ft).

13. Install the liquid line to the condenser.

14. Install the compressor hose to the condenser.

15. Install the liquid line and compressor hose bolt to the condenser.
Tighten: Tighten the bolt to 20 N.M (15 lb ft).

IMPORTANT: Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur.

16. Install the left radiator air deflector.

17. Install the left radiator air deflector retainers.

18. Install the right radiator air deflector.

19. Install the right radiator air deflector retainers.

20. Install the right front fender liner.

21. Install the lower radiator air deflector.

22. Install the lower radiator air deflector retainers.

23. Lower the vehicle.

24. Remove the rope attached to the radiator and upper tie bar.

25. Install both upper radiator support brackets.

IMPORTANT: Do not allow the upper bracket to twist when tightening the radiator mounting bolts or vibration may result.

26. Install both upper radiator support bracket bolts.
Tighten: Tighten the bolt to 10 N.M (89 lb in).

27. Install the right headlamp.

28. Install the left headlamp.

29. Evacuate and charge the refrigerant system.

30. Leak test the fittings using the J 39400-A.
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KHLow2008
Sep 23, 2011.
Drain Cooling System
Remove air intake tube from air filter housing to throttle body
Remove electrical connections to cooling fan(s)
Remove cooling fan assembly
Remove upper and lower radiator hose clamps and disconnect hoses from radiator
Remove transmission cooler lines from radiator
Remove radiator support brackets
Remove radiator
Evacuate & Recover refrigerant (if any) and disconnect A/C Lines from condenser
Tilt condenser forward and lift upward to remove.


Dan_K
Sep 23, 2011.
That is a for sure. Remove the radiator. Chances are it will get damaged trying to access and remove the condenser. There won't be much room.



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