GM Prizm/Nova 1985-1993 Repair Guide

Condenser

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REMOVAL & INSTALLATION



1985-88

See Figures 1 and 2


CAUTION
Please re-read the air conditioning section in Routine Maintenance so that the system may be discharged properly. Always wear eye protection and gloves when discharging the system. Observe no smoking/no open flame rules.

  1. Safely discharge the air conditioning system.
  2.  
  3. Remove the grille and the hood lock brace.
  4.  
  5. Disconnect the flexible discharge hose from the condenser inlet fitting. Use 2 wrenches, one to counterhold the fitting and one to turn. Failure to counterhold the fitting may result in damage to the lines.
  6.  
  7. Disconnect the liquid line from the condenser outlet. Again, use 2 wrenches.
  8.  
  9. Cap the open lines immediately to prevent moisture from entering the system.
  10.  
  11. Remove the 4 bolts holding the condenser and remove the condenser. Take great care not to damage the fins on the condenser during removal.
  12.  

To install:
  1. When reinstalling, make sure the rubber cushions fit on the mounting flange correctly.
  2.  
  3. Install the 4 bolts holding the condenser.
  4.  
  5. Connect the liquid line to the condenser and tighten it to 10 ft. lbs.
  6.  
  7. Connect the flexible discharge hose and tighten it to 16 ft. lbs.
  8.  

The lightweight fittings on the lines and hoses are easily damaged. Do not overtighten the threaded fittings.

  1. Install the front grille and hood lock brace.
  2.  
  3. If a different condenser was installed, add 1.4-1.7 oz. of compressor oil to the compressor.
  4.  
  5. Evacuate and recharge the system.
  6.  



Click image to see an enlarged view

Fig. Fig. 1: Liquid line - 1985-88



Click image to see an enlarged view

Fig. Fig. 2: Condenser - 1985-88

1989-92

See Figure 3


CAUTION
Please re-read the air conditioning section in Routine Maintenance so that the system may be discharged properly. Always wear eye protection and gloves when discharging the system. Observe no smoking/no open flame rules.

  1. Safely discharge the system.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the front grille, the hood lock and its brace.
  6.  
  7. Remove the front bumper.
  8.  
  9. Disconnect the liquid line and the discharge hose at the condenser. Use 2 wrenches, one to hold the assembly and one to turn the fitting. Failure to counterhold the lines may result in damage to the lines, hoses and fittings. Cap the open lines immediately to prevent moisture from entering the system.
  10.  
  11. Remove the 4 mounting bolts and remove the condenser.
  12.  

To install:
  1. When reinstalling, mount the condenser and install its 4 bolts.
  2.  
  3. Connect the liquid tube and the discharge hose to the condenser. Tighten the liquid tube to 10 ft. lbs. and the discharge hose to 18 ft. lbs.
  4.  

The lightweight fittings on the lines and hoses are easily damaged. Do not overtighten the threaded fittings.

  1. Reinstall the front bumper.
  2.  
  3. Install the hood lock and center brace. Install the grille.
  4.  
  5. If the condenser has been replaced with a different unit, add 1.4-1.7 ounces of compressor oil to the compressor.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Evacuate and recharge the system.
  10.  



Click image to see an enlarged view

Fig. Fig. 3: Condenser - 1989-92

1993

See Figure 4


CAUTION
Please re-read the air conditioning section in Routine Maintenance so that the system may be discharged properly. Always wear eye protection and gloves when discharging the system. Observe no smoking/no open flame rules.

  1. Disconnect the negative battery cable.
  2.  
  3. Recover refrigerant (discharge system) from refrigeration system.
  4.  
  5. Remove the following parts:
    1. radiator grille
    2.  
    3. horn
    4.  
    5. hood lock
    6.  
    7. center brace
    8.  
    9. battery
    10.  
    11. radiator reserve tank
    12.  

  6.  
  7. Remove the condenser fan assembly.
  8.  
  9. Remove the oxygen sensor.
  10.  
  11. Remove all refrigerant system connections. Remove the receiver with bracket. Cap open fittings immediately.
  12.  
  13. Remove the radiator support brackets - remove the condenser mounting bolts lean the radiator back and pull out the condenser.
  14.  

To install:
  1. Install the condenser assembly to the vehicle. Install radiator support brackets. Make sure all rubber cushions fit on the mounting flanges correctly.
  2.  
  3. Reconnect all refrigerant system connections. Install receiver with bracket. Replace O-rings, as required.
  4.  
  5. Install the oxygen sensor, torque the nuts to 15 ft. lbs. Install condenser fan.
  6.  
  7. Install all other remaining components in reverse order of removal procedure.
  8.  
  9. If condenser assembly was replaced, add 1.4-1.7 fl. oz. of compressor oil.
  10.  
  11. Reconnect battery cable. Evacuate, charge and test refrigerant system. Check system for leaks.
  12.  



Click image to see an enlarged view

Fig. Fig. 4: Condenser - 1989-92

 
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