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HOMESERVICE MANUALSCHEVROLET1999PICKUP K1500, 5.7 RREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 449 (HEATING, VENTILATION AND AIR CONDITIONING)REPAIR INSTRUCTIONSCONDENSER REPLACEMENTINSTALLATION PROCEDURE
1999 Chevrolet Pickup K1500, 5.7 R

Installation Procedure

1999 Chevrolet Pickup K1500, 5.7 RSECTION Installation Procedure
WARNING: This page is about a different car, the 2003 Pontiac Aztek and 2003 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
  1. If replacing the condenser add the specified amount of PAG oil directly to the condenser. Refer to Refrigerant System Capacities .
  2. Install new sealing washers to the receiver dehydrator. Refer to Sealing Washer Replacement .
    3. Fig 1: View Of Receiver Dehydrator Upper/Lower Bracket Bolts
    GM887653Courtesy of GENERAL MOTORS CORP.
  3. Connect the receiver dehydrator to the condenser.
    4. NOTE: Refer to Fastener Notice in Cautions and Notices.
  4. Install the receiver dehydrator lower mounting bolts.

    Tighten:  Tighten the bolts to 6 N.m (53 lb in).

  5. Install the receiver dehydrator upper bracket bolt.

    Tighten:  Tighten the bolt to 6 N.m (53 lb in).

  6. Install the condenser to the radiator.
    7. Fig 2: Identifying Condenser Mounting Bolts
    GM825405Courtesy of GENERAL MOTORS CORP.
  7. Install the condenser mounting bolts.

    Tighten:  Tighten the bolts to 6 N.m (53 lb in).

  8. Install the condenser tube clip.
  9. Install the condenser tube clip bolt.

    Tighten:  Tighten the bolt to 2.5 N.m (22 lb in).

  10. Install the radiator and condenser assembly.
  11. Remove cap or tape from the evaporator inlet tube.
  12. Install a new sealing washer to the evaporator inlet tube fitting. Refer to Sealing Washer Replacement .
    13. Fig 3: Identifying Evaporator Inlet Tube From The Condenser & Bolt
    GM825404Courtesy of GENERAL MOTORS CORP.
  13. Install the evaporator inlet tube and bolt to the condenser block.

    Tighten:  Tighten the bolt to 16 N.m (12 lb ft).

  14. Remove cap or tape from the A/C discharge hose.
  15. Install a new sealing washer to the A/C discharge hose fitting. Refer to Sealing Washer Replacement .
    16. Fig 4: Discharge Hose To Condenser Nut
    GM628885Courtesy of GENERAL MOTORS CORP.
  16. Install the A/C discharge hose and nut to the condenser block.

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

  17. Connect the lower TOC line to the radiator. Refer to Transmission Fluid Cooler Line Quick Connect Fitting in Automatic Transaxle - 4T65-E.
    18. Fig 5: Aligning Radiator Outlet Hose Clamp At The Water Pump Housing
    GM825403Courtesy of GENERAL MOTORS CORP.
  18. Install the radiator outlet hose.
  19. Connect the radiator outlet hose to the radiator.
  20. Reposition the radiator outlet hose clamp at the radiator to secure the hose using the J 38185  .
  21. Connect the radiator outlet hose to the water pump housing.
  22. Reposition the radiator outlet hose clamp at the water pump housing to secure the hose using the J 38185  .
  23. Install the cooling fans with the cooling fan shroud. Refer to Cooling Fan Replacement - Electric (LA1) or Cooling Fan Replacement - Electric (LY7) in Engine Cooling.
  24. Fill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
  25. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
  26. Leak test the fittings of the component using J 39400-A  .
RENDER: 1.0x

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Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.