Roadmaster 1992

Removal & Installation

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  1. Before servicing the vehicle, refer to the Precautions Section.
    NOTE
    Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer systems and may require the computer to undergo a relearning process, once the negative battery cable is reconnected.


    NOTE
    If working near and/or around the SRS system and components, be sure to properly disable the SRS system. See disarming/arming the SRS system.


    NOTE
    For vehicles equipped with OnStar (RPO UE1), with battery backup, the backup battery is a redundant power supply to allow limited ONStar functionality in the event of a main battery power disruption to the OnStar module (VCIM). Do not disconnect the main vehicle battery or remove the OnStar fuse with the ignition key in any position other than OFF. Retained accessory power should be allowed to time out or be disabled by opening the driver-s side door before disconnecting power. Disconnecting power to the module in any way while the ignition is ON or with the retained accessory power activated may cause activation of the OnStar backup battery system and will discharge and permanently damage the backup battery. Once the backup battery is activated it will stay on until it has completely discharged. The backup battery is not rechargeable and once it is activated, it must be replaced.

  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air intake duct and resonators.
  6.  
  7. Properly discharge the air conditioning system.
    NOTE
    On some vehicle configurations it will be necessary to remove the radiator.

  8.  
  9. Drain the cooling system, as required. Be sure to properly dispose of used coolant.
  10.  
  11. On 1994-1996 vehicles, if equipped with manual cooling fan, remove the upper radiator shroud and upper radiator hose and pipe. Remove the electric cooling fans, if equipped. Remove the radiator upper mounting panel, if equipped with electric cooling fans.
  12.  
  13. Disconnect and plug the freon lines.
  14.  
  15. Remove the condenser from its mounting.
  16.  
  17. Remove the fixed orifice tube.

    Click image to see an enlarged view

    Fig. Air conditioning expansion tube (fixed orifice tube) and related components



    Click image to see an enlarged view

    Fig. Air conditioning condenser and related components-1994-1996



    Click image to see an enlarged view

    Fig. Air conditioning condenser mounting and related components-exploded view-1991-1993

  18.  

To install:


NOTE
Be sure to use new fasteners, as required.


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 sealer are identified. 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.

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to use new O-rings coated with clean refrigerant oil.
  4.  
  5. Be sure to properly evacuate the air conditioning system.
  6.  
  7. Be sure to fill the cooling system with the proper grade and type coolant, as required.
  8.  
  9. Using the GM diagnostic scan tool or aftermarket equivalent reprogram the necessary systems and components. Be sure to follow the scan tool manufacturer-s directions.
  10.  

 
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