Montana, Silhouette, Venture 2000-2005

Removal & Installation

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WARNING
Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

  1. Recover the refrigerant from the A/C system. Refer to the Heating & Air Conditioning Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove the cooling fans with the cooling fan shroud.
    NOTE
    Use the special tool J38185 to gently release tension on the hose clamp until the hose clamp lock feature engages allowing removal of the hose.



    Click image to see an enlarged view

    Fig. Release tension from the hose clamp at the water pump housing using the special tool J38185.

  6.  
  7. Release tension from the hose clamp at the water pump housing using the special tool J38185.
  8.  
  9. Disconnect the radiator outlet hose from the water pump housing.
  10.  
  11. Disconnect the lower TOC line from the radiator.

    Click image to see an enlarged view

    Fig. Remove the nut which secures the A/C discharge hose to the condenser block

  12.  
  13. Remove the nut which secures the A/C discharge hose to the condenser block.
  14.  
  15. Disconnect the A/C discharge hose from the condenser block.
  16.  
  17. Remove and discard the sealing washer.
    NOTE
    Cap or tape off the open A/C hose immediately to prevent system contamination.

  18.  
  19. Cap or tape off the A/C discharge hose.
  20.  
  21. Remove the bolt which secures the evaporator inlet tube to the condenser block.
  22.  
  23. Disconnect the evaporator inlet tube from the condenser block.
  24.  
  25. Cap or tape off the evaporator inlet tube.

    Click image to see an enlarged view

    Fig. Remove the radiator and condenser assembly

  26.  
  27. Remove the radiator and condenser assembly.
  28.  
  29. Release tension from the hose clamp at the radiator using the special tool J38185 .
  30.  
  31. Remove the lower radiator hose.
  32.  
  33. Remove the condenser tube clip bolt.
  34.  
  35. Remove the mounting bolts that secure the condenser to the radiator.
  36.  
  37. Remove the condenser from the radiator.
  38.  

To install:

  1. Install the condenser to the radiator.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2.  
  3. Install the mounting bolts that secure the condenser to the radiator and tighten the bolts to 53 inch lbs. (6 Nm).
  4.  
  5. Install the condenser tube clip bolt and tighten the bolt to 22 inch lbs. (2.5 Nm).
  6.  
  7. Install the lower radiator hose.
    NOTE
    Release the hose clamp retention lock by using a small flat bladed screwdriver.

  8.  
  9. Release the hose clamp retention lock at the radiator to secure the hose.
  10.  
  11. Install the radiator and condenser assembly.
  12.  
  13. Remove the cap or the tape from the evaporator inlet tube.
  14.  
  15. Install a new sealing washer to the evaporator inlet tube.
  16.  
  17. Install the evaporator inlet tube and the bolt to the condenser block and tighten bolt to 12 ft. lbs. (16 Nm).
  18.  
  19. Remove the cap or the tape from the A/C discharge hose.
  20.  
  21. Install a new sealing washer to the A/C discharge hose.
  22.  
  23. Install the A/C discharge hose and the nut to the condenser block and tighten the nut to 12 ft. lbs. (16 Nm).
  24.  
  25. Connect the lower TOC line to the radiator.
  26.  
  27. Connect the radiator outlet hose to the water pump housing.
  28.  
  29. Release the hose clamp retention lock at the water pump housing to secure the hose.
  30.  
  31. Install the cooling fans with the cooling fan shroud.
  32.  
  33. Fill the cooling system.
  34.  
  35. Evacuate and recharge the A/C system
  36.  
  37. Leak test the fittings of the component using the special tool J39400-A.
  38.  
  39. Inspect the transmission fluid level.
  40.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the lower transmission oil cooler (TOC) line from the radiator.
  4.  
  5. Remove the cooling fans and shroud.
  6.  
  7. Remove the radiator inlet hose.
  8.  
  9. Remove the radiator outlet hose.
  10.  
  11. Remove the bolt that secures the radiator to the condenser.
  12.  
  13. Remove the condenser tube clip screw.
  14.  
  15. Tilt the radiator and condenser inward toward the engine and remove the radiator.
  16.  

To install:

  1. Install the radiator.
  2.  
  3. Install the condenser tube clip screw.
  4.  
  5. Install the bolt that secures the radiator to the condenser.
  6.  
  7. Install the radiator hoses.
  8.  
  9. Install the cooling fan and shroud.
  10.  
  11. Connect the lower transmission oil cooler (TOC) line to the radiator.
  12.  
  13. Refill the cooling system.
  14.  
  15. Inspect the transmission fluid level.
  16.  

 
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