GM Service Manual Online
For 1990-2009 cars
Makes 🢒 Chevrolet 🢒 2004 🢒 Tahoe - 2WD 🢒 Engine 🢒 Engine Electrical 🢒 Air Conditioning Condenser Replacement

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure

    Object Number: 401547 Size: SH
  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. Remove the grille. Refer to Grille Replacement in Exterior Trim.
  3. Remove the tie bar to radiator brace bolts (1). Access the bolts from the rear of the upper radiator support.

    4. Object Number: 373069 Size: SH
  4. Remove the lower bolts from the hood latch support bracket.

    5. Object Number: 363062 Size: SH
  5. Remove the compressor discharge hose assembly bolt from the condenser.
  6. Disconnect the compressor discharge hose assembly from the condenser.

    7. Object Number: 363033 Size: SH
  7. Remove the evaporator tube nut from the condenser.
  8. Disconnect the evaporator tube from the condenser.

    9. Object Number: 281181 Size: SH
  9. Remove the insulator retainer bolts and the upper insulator retainers.
  10. Remove the condenser from the vehicle.

Installation Procedure

    Important: If replacing the condenser, add the refrigerant oil to the condenser. Refer to Refrigerant System Capacities for system capacity information.


    Object Number: 281181 Size: SH
  1. Install the condenser to the vehicle.

    2. Notice: Refer to Fastener Notice in the Preface section.

  2. Install the upper insulator retainers and the insulator retainer bolts.

    3. Tighten
    Tighten the bolts to 2.4 N·m (21 lb in).


    Object Number: 363033 Size: SH
  3. Connect the evaporator tube to the condenser using new sealing washers. Refer to Sealing Washer Replacement .
  4. Install the evaporator tube nut to the condenser.

    5. Tighten
    Tighten the nut to 16 N·m (12 lb ft).


    Object Number: 363062 Size: SH
  5. Connect the compressor discharge hose to the condenser using new sealing washers. Refer to Sealing Washer Replacement
  6. Install the compressor discharge hose nut to the condenser.

    7. Tighten
    Tighten the nut to 16 N·m (12 lb ft).


    Object Number: 373069 Size: SH
  7. Install the lower bolts to the hood latch support bracket.

    8. Tighten
    Tighten the bolts to 9 N·m (80 lb in).


    Object Number: 401547 Size: SH
  8. Install the tie bar to radiator brace bolts (1). Access the bolts from the rear of the upper radiator support.

    9. Tighten
    Tighten the bolts to 9 N·m (80 lb in).

  9. Install the grille. Refer to Grille Replacement in Exterior Trim.
  10. Evacuate and recharge the system. Refer to Refrigerant Recovery and Recharging .
  11. Leak test the fittings of the component using the J 39400-A .