Heating, Ventilation, and Air Conditioning Cadillac ELR I

Fastener Tightening Specifications

Fastener Tightening Specifications

Adhesives, Fluids, Lubricants, and Sealers

Adhesives, Fluids, Lubricants, and Sealers

Refrigerant System Specifications

Refrigerant System Specifications

Handling of Refrigerant Lines and Fittings

1. Keep all metal tubing lines free of dents or kinks. Any line restrictions will cause the loss of system capacity.
2. Never bend a flexible hose line to a radius of less than four times the diameter of the hose.
3. Never allow a flexible hose line to come within 65 mm (2-1/2 in) of the exhaust manifold.
4. Inspect flexible hose lines regularly for leaks or brittleness.
5. Replace flexible hose lines with new lines if you find signs of deterioration or leaking.
6. Discharge the refrigeration system of all refrigerant before disconnecting any fitting in the refrigeration system.
7. Proceed very cautiously regardless of the gauge readings.
8. Open the fittings very slowly.
9. If you notice pressure when you loosen a fitting, allow the pressure to bleed off as described Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System .
10. Cap or tape any refrigerant line immediately after it is opened. This will prevent the entrance of moisture and dirt, which can cause internal compressor wear or plugged lines in the condenser, the evaporator core, the expansion valve, or the compressor inlet screens. NOTE: Use two proper wrenches to connect the fittings.
11. Back up the opposing fitting to prevent distortion of the connecting lines or the components.
12. Keep the sealing surfaces in perfect condition. A burr or a piece of dirt may cause a refrigerant leak.
13. When seal washers are used, always install the seal washer without lubrication.
14. When O-rings are used, always lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil prior to installation.

Leak Testing

Special Tools

1. GE-50078 Infrared Refrigerant Leak Detector
2. GE-42220 Universal 12V Leak Detection Lamp
3. GE-43872 Fluorescent Dye Cleaner

For equivalent regional tools, refer to Special Tools .

Refrigerant Leak Testing

Note. All A/C system repairs must be verified using electronic leak detection. Dye detection may take up 2 or 3 days to be reliable.

Note. General Motors vehicles are now manufactured with fluorescent dye installed directly into the air conditioning (A/C) system.

The fluorescent dye mixes and flows with the refrigerant oil throughout the refrigerant system.

Verifying some passive leaks may require using the GE-50078 detector , even though the A/C system contains fluorescent dye.

Visual Inspection

Visually trace the entire refrigerant system and look for signs of lubricant leakage, damage, and corrosion on all lines hoses and components (Oil can be an indication of a leak). Each questionable area should be checked for leaks using an electronic leak detector.

Fluorescent Leak Detector

Note. Always use UV protective eyewear when working with UV light.

Fluorescent dye will assist in locating any leaks in the A/C system.

1. Condensation on the evaporator core or the refrigerant lines may wash the POE oil and fluorescent dye away from the actual leak. Condensation may also carry dye through the HVAC module drain.
2. Leaks in the A/C system will be indicated in a light green or yellow color when using the leak detection lamp. Use the leak detection lamp in the following areas: All fittings or connections that use seal washers or O-rings All of the A/C components The A/C hoses and pressure switches The HVAC module drain tube, if the evaporator core is suspected of leaking The service port sealing caps The sealing cap is the primary seal for the service ports.
3. Follow the instructions supplied with the GE-42220 lamp.
4. To prevent false diagnosis in the future, thoroughly clean the residual dye from any area where leaks were found. Use a rag and the approved GE-43872 cleaner.

Replacing System Dye After Flushing

Note. Do not add dye to the refrigerant system equipped with high voltage electric compressors. The only means of replenishing dye after flushing is by replacing component containing the dye. Currently a compatible dye wafer is contained in the O.E. desiccant package. Adding dye that is not compatible with the high voltage electric compressor may cause compressor damage and high voltage isolation faults.

To prevent false diagnosis, thoroughly clean any residual dye from the service port with a rag and the approved fluorescent dye cleaner GE-43872 cleaner.

Electronic Leak Detection

Infrared detectors operate differently than heated sensor type detectors. They detect changes in concentration of refrigerant rather than absolute concentration. If the tip is held at a detected leak for more than 5 seconds the detector will saturate and zero to that concentration and will no longer detect leaks at that concentration or less. Move tip away from the leak saturation area for 30 seconds to reset the sensitivity of the detector.

Adequate system pressure is required for effective leak detection.

1. If system is empty install 10% of system charge.
2. Temperature must be above 60 F.

Do not use

1. Soap solutions (not effective for leak detection)
2. Shop air (will introduce contamination to the refrigerant system)
3. High pressure gasses i.e nitrogen (May cause system damage

Air movement from the engine cooling fan can affect the detectors ability to detect leaks. Always leak test with engine off and if possible after engine has reached normal operating temperature.

1. All fittings and components should be checked.
2. Take care not to contaminate the probe tip if the part being tested is contaminated.
3. No cleaners containing solvents should be used prior to using electronic leak detector.
4. Always follow the refrigerant system around in a continuous path so that no areas of potential leaks are missed. Move the tip along the refrigerant system at a rate of no more than 75 mm per second and a distance of 10 mm from the surface being tested. If a leak is found, always continue to test the remainder of the system.

Follow the instructions supplied with the GE-50078 detector.

Air Conditioning (A/C) System Performance Test

This test measures the operating efficiency of the A/C system under the following conditions

1. The current ambient air temperature
2. The current relative humidity
3. The high side pressure of the A/C system
4. The low side pressure of the A/C system
5. The temperature of the air being discharged into the passenger compartment

Test Description

The numbers below refer to the step numbers on the diagnostic table.

1. 1 This step determines if the A/C system has at least the minimum refrigerant charge required to operate the system without damage.
2. 2 This step measures the performance of the A/C system.
3. 3 This step is to allow for vehicle variations as well as high ambient temperatures.

Air Conditioning (A/C) System Performance Test

A/C Performance Table

A/C Diagnostics Chart

A/C Diagnostics Chart

Heating Performance Diagnostic

Heating Performance Diagnostic

Defrosting Insufficient

Defrosting Insufficient

Noise Diagnosis - Blower Motor

Noise Diagnosis - Blower Motor

Air Conditioning Compressor Oil Diagnosis

Note. To avoid repeat compressor failure, always inspect the condition of the refrigerant oil and take the appropriate corrective action before installing the replacement compressor.

Air Conditioning Compressor Oil Diagnosis

Noise Diagnosis - HVAC Module

Noise Diagnosis - HVAC Module

Odor Diagnosis

Odor Diagnosis

Eliminating Air Conditioning (A/C) Odor

Odors may be emitted from the air conditioning system primarily at start up in hot, humid climates. The following conditions may cause the odor

1. Debris is present in the HVAC module
2. Microbial growth on the evaporator core

When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. To remove odors of this type, the microbial growth must be eliminated. Perform the following procedure

Deodorize the evaporator core using Deodorizing Aerosol Kit.

Perform the following steps in order to deodorize the A/C system

1. Ensure that the plenum which draws outside air into the HVAC module is clear of debris.
2. Disable the air conditioning (A/C) compressor clutch operation by disconnecting the clutch coil electrical connector.
3. Dry the evaporator core by performing the following steps: Start the engine. Select the warmest temperature setting. Select the recirculation mode. Run the blower motor on high for 10 minutes.
4. Locate an area in the air conditioning duct between the blower motor and the evaporator core downstream of the blower motor.
5. Drill a 3.175 mm (0.125 in) hole where the hole will not interfere with or damage the following components: The blower motor The evaporator core Any other operating part the of system
6. Wear safety goggles and latex gloves in order to perform the following actions: Select the maximum blower speed. Insert the deodorizer extension tube into the hole to the mark on the extension tube. Use short spray bursts and vary the direction of spray for a 2-3 minute period of time.
7. Shut the engine OFF. Allow the vehicle to sit for 3-5 minutes.
8. Seal the 3.175 mm (0.125 in) hole with body sealer or RTV gasket compound.
9. Start the engine.
10. Operate the blower motor on high for 15-20 minutes to dry.
11. Reconnect the A/C compressor clutch coil electrical connector.
12. Verify proper A/C clutch operation.

Refrigerant Recovery and Recharging

Special Tools

1. GE 48997 Hybrid A/C Oil Injector Adapter Hose
2. GE 43600 ACR 2000 A/C Recovery/Recharge Machine
3. GE-48800 CoolTech A/C Recovery/Recharge Machine
4. GE-45037-A A/C Oil Injector

For equivalent regional tools, refer to Special Tools .

Both the GE 43600 ACR 2000 A/C Recovery/Recharge Machine and GE-48800 CoolTech A/C Recharge Machine are a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. Both units automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant.

The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system.

The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain.

GE-48800 CoolTech A/C Recharge Machine is released as a required replacement for the previously essential GE 43600 ACR 2000 A/C Recovery/Recharge Machine. The GE-48800 CoolTech A/C Recharge Machine is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil.

Refer to the GE 43600 ACR 2000 A/C Recovery/Recharge Machine and GE-48800 CoolTech A/C Recharge Machine ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Specifications for the correct amount.

A/C Refrigerant System Oil Charge Replenishing

If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. If no oil was removed from the A/C system during recovery, do not charge any POE oil into the A/C system. POE refrigerant oil can be injected into a charged A/C system using GE-45037-A injector along with GE 48997 adapter. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Specifications .

Flushing

Special Tools

1. GE-42220 Universal 12V Leak Detection Lamp
2. GE-43600-50 Flush Loop Hose
3. GE-45268 Flush Adapter Kit
4. GE-48800 CoolTech A/C Recharge Machine

For equivalent regional tools. Refer to Special Tools .

ACR2000 (GE-48800) Hose Flush Procedure

Note. The following hose flushing procedure must be performed every time the ACR2000 (GE-48800) is used on the hybrid vehicles. It must be completed before the ACR2000 (GE-48800) is connected to the vehicle to begin a diagnostic or service procedure. The high voltage (HV) electric air conditioning (A/C) compressor uses a polyolester (POE) refrigerant oil instead of a polyalkylene glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. The following hose flush procedure is required to prevent oil cross-contamination. Laboratory testing has shown that flushing the ACR2000 (GE-48800) using the following procedure will minimize oil cross-contamination to a negligible amount (<500ppm). Failure to flush the ACR2000 (GE-48800) hoses before adding refrigerant to a hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may also cause a battery energy control module hybrid battery voltage system isolation lost diagnostic trouble code (DTC P1AE7) to be set. Additionally the A/C system warranty will be voided. The ACR2000 (GE-48800) will need to be retrofitted with a GE-43600-50 (Hose-ACR2000 Oil Flush Loop) to be able to perform the following procedure. All hybrid dealers will receive a GE-43600-50, with installation instructions, which is a component of the hybrid essential tool package. Dealers not included in the hybrid marketing plan and needing to service a hybrid vehicle can obtain the GE-43600-50 from SPX Kent Moore, 1-800-GM-TOOLS (1-800-468-6657). The GE-43600-50 Retrofit Kit replaces the existing hose mount fittings on the ACR2000. Installation instructions are included to properly update the ACR2000 for hybrid vehicle A/C service. New hybrid compliant A/C refrigerant recharging equipment (GE-48800) will replace current ACR2000 equipment. GE-48800 meets new SAE refrigerant recovery standard J-2788 and is specially designed for GM hybrid vehicle A/C service.

Before Beginning the Hose Flushing Procedure

1. Always allow the ACR2000 to complete the hose flush cycle to assure that all oil and refrigerant is removed from the hoses and the ACR2000 flow control circuit.
2. Assure the ACR2000 has at least 4.08 kg (9 lb) of chargeable refrigerant before proceeding.
3. A Low Filter Flow message displayed during the hose flushing process indicates that the hose couplers are not connected or open.

Hose Flushing Procedure

1. Connect the ACR2000 service hose couplers to the GE-43600-50 hose flush adapter fittings and open the service hose coupler valves.
2. Power on the ACR2000.
3. If there is positive pressure in the ACR2000 service hoses, press START to recover the service hoses. If there is 88-98 kPa (26-29 Hg) of vacuum showing on the display screen, skip to step 7.
4. Press Vacuum.
5. Press Start. Allow the vacuum program to run until the display screen shows between 88-98 kPa (26-29 Hg).
6. Press Pause.
7. Press Main Menu.
8. Press Scroll Menu.
9. Press Oil Flush.
10. Press Next.
11. Enter 03:00 (for a three minute flush) and press Start.
12. The ACR2000 will now flush the service hoses for three minutes and then recover the refrigerant
13. Close the ACR2000 service hose couplers and remove the GE-43600-50 hose flush adapter.
14. The ACR2000 can now be connected to the hybrid vehicle to perform the A/C system diagnostic or service procedures.

ACR2000 (GE-48800) A/C System Procedure

Note. Flushing with the ACR 2000 is not intended to remove metal from the A/C system.

Flushing is intended to remove the following contaminants

1. Contaminated polyolester (POE) oil
2. Desiccant, following a desiccant bag failure
3. Overcharge of POE oil
4. Refrigerant contamination

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the air conditioning refrigerant desiccant. Refer to «Air Conditioning Refrigerant Desiccant Replacement»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Remove the air conditioning refrigerant desiccant plug from the desiccant cartridge.
4. Install the air conditioning refrigerant desiccant plug without the desiccant cartridge.
5. Remove the evaporator thermal expansion valve. Refer to «Air Conditioning Evaporator Thermal Expansion Valve Replacement (A/C Evaporator)»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) , «Air Conditioning Evaporator Thermal Expansion Valve Replacement (Drive Motor Battery Coolant Cooler)»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning)
6. Install GE-45268-115 to the evaporator.
7. Remove the drive motor battery cooler thermal expansion valve. Refer to «Air Conditioning Evaporator Thermal Expansion Valve Replacement (A/C Evaporator)»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) , «Air Conditioning Evaporator Thermal Expansion Valve Replacement (Drive Motor Battery Coolant Cooler)»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning)
8. Install another GE-45268-115 to the drive motor battery cooler.
9. Install A/C evaporator tube to both GE-45268-115.
10. Install A/C evaporator TXV tube to both GE-45268-115 using an oversized seal washer.
11. Remove the A/C and drive motor battery cooling compressor. Refer to «Air Conditioning and Drive Motor Battery Cooling Compressor Replacement»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning)
12. Inspect the end of the suction hose for a suction screen.
13. Remove the suction screen, if installed.
14. Install GE-45268-4 to the A/C compressor suction hose.
15. Install GE-452688-5 to the A/C compressor discharge hose.
16. Forward flow refrigerant flushing is recommended for contaminated refrigerant or POE oil.
17. Perform the following procedure: NOTE: The filter inside the GE-45268-1 is serviceable. Remove and discard the check valve from the filter. Service the filter with ACDelco P/N GF 470, before each flush. Connect the GE-45268-1 flush filter to the suction port of the GE-45268-4 flush adapter. Connect the blue hose from the GE-48800 ACR 2000 Air Conditioning Service Center to the J 45268-1 flush filter adapter. Connect the red hose from the GE-48800 ACR 2000 Air Conditioning Service Center to the GE-45268-5 flush adapter.
18. Reverse flow refrigerant flushing is recommended for desiccant cartridge failure. NOTE: The filter inside the J 45268-1 is serviceable. Remove and discard the check valve from the filter. Service the filter with AC P/N GF 470, before each flush. Connect the J 45268-1 flush filter to the discharge port of the GE-45268-5 flush adapter. Connect the blue hose from the GE-48800 ACR 2000 Air Conditioning Service Center to the J 45268-1 flush filter adapter. Connect the red hose from the GE-48800 ACR 2000 Air Conditioning Service Center to the suction port of the GE-45268-4 flush adapter.
19. Flush the front A/C system. Follow the instructions supplied with the GE-48800 ACR 2000 Air Conditioning Service Center.
20. Flush the A/C system. Follow the instructions supplied with the GE-48800 ACR 2000 Air Conditioning Service Center
21. Remove the GE-45268-4 from the A/C compressor suction hose.
22. Remove the GE-45268-5 from the A/C compressor discharge hose.
23. If the removed A/C compressor is being reinstalled, perform the following procedure: Drain the POE oil from the A/C compressor. Add the total system capacity of POE oil to the A/C compressor. Refer to «Refrigerant System Specifications»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-specifications) .
24. If you will replace the A/C compressor after flushing the system, perform the following procedure: Refer to the «Refrigerant System Specifications»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-specifications) . DO NOT drain the new POE oil from the compressor. Deduct the amount of POE oil shipped with the service compressor from the amount of POE oil listed in the capacities table. Refer to «Refrigerant System Specifications»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-specifications) . Add the calculated amount to the compressor, as needed.
25. Install the air conditioning and drive motor battery cooling compressor. Refer to «Air Conditioning and Drive Motor Battery Cooling Compressor Replacement»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning)
26. Replace the air conditioning refrigerant desiccant. Refer to «Air Conditioning Refrigerant Desiccant Replacement»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
27. Remove A/C evaporator TXV tube from both GE-45268-115.
28. Remove A/C evaporator tube from both GE-45268-115.
29. Remove both GE-45268-115.
30. Install the drive motor battery cooler thermal expansion valve. Refer to «Air Conditioning Evaporator Thermal Expansion Valve Replacement (A/C Evaporator)»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) , «Air Conditioning Evaporator Thermal Expansion Valve Replacement (Drive Motor Battery Coolant Cooler)»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning)
31. Install the evaporator thermal expansion valve. Refer to «Air Conditioning Evaporator Thermal Expansion Valve Replacement (A/C Evaporator)»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) , «Air Conditioning Evaporator Thermal Expansion Valve Replacement (Drive Motor Battery Coolant Cooler)»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning)
32. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging)
33. Leak test the fittings using GE-42220 Universal 12V Leak Detection Lamp

Scheme 1

Air Conditioning and Drive Motor Battery Cooling Compressor Replacement

Removal Procedure

1. Remove the air conditioning and drive motor battery cooling compressor. Refer to «Air Conditioning and Drive Motor Battery Cooling Compressor Replacement»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the 3 air conditioning compressor bolts (1).
3. Remove the air conditioning compressor bracket (2).

Installation Procedure

1. Install the air conditioning compressor bracket (2).
2. Install the 3 air conditioning compressor bolts (1) and tighten to 22 (16 lb ft).
3. Install the air conditioning and drive motor battery cooling compressor. Refer to «Air Conditioning and Drive Motor Battery Cooling Compressor Replacement»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure
2. Remove the O-ring seal from the A/C refrigerant component.
3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure.
4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary.
5. Cap or tape the A/C refrigerant components.
6. Discard the O-ring seal.

1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary.
2. Remove the cap or tape from the A/C refrigerant components.
3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components.
4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil.
5. Carefully slide the new O-ring seal onto the A/C refrigerant component.
6. The O-ring seal must be fully seated.
7. Assemble the A/C components. Refer to the appropriate repair procedure.

Scheme 2

Air Conditioning Condenser Hose Replacement

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/cadillac/elr/i-2013-2015/remont/testing-diagnostics/#engine-controls-and-fuel-14l-luu-repair-instructions) .
3. Remove the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(/cadillac/elr/i-2013-2015/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Remove the right headlamp. Refer to «Headlamp Replacement»(/cadillac/elr/i-2013-2015/remont/exterior-lights/#lighting-system) .
5. Remove the air conditioning evaporator hose assembly. Refer to «Air Conditioning Evaporator Hose Assembly Replacement»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. Disconnect electrical connectors.
7. Remove the air conditioning condenser tube (1) from the air conditioning evaporator air conditioning evaporator thermal expansion valve and the drive motor battery coolant cooler air conditioning evaporator thermal expansion valve.
8. Remove and discard the old sealing washers (2).
9. Remove the air conditioning condenser tube nut (1) from the stud.
10. Remove the air conditioning condenser tube (2) from the retainers.
11. Remove the air conditioning condenser hose nut (1) from the air conditioning condenser.
12. Remove the air conditioning condenser hose (3) from the air conditioning condenser.
13. Remove and discard the old sealing washers (4).
14. Remove the air conditioning condenser tube (1) from the air conditioning condenser.
15. Remove and discard the old sealing washers (4).
16. Remove the air conditioning condenser tube (1) from the vehicle.

1. Install the air conditioning condenser tube (1) to the vehicle.
2. Install NEW sealing washer (2) to the air conditioning condenser tube (1). Refer to «Air Conditioning O-Ring Seal Replacement»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the air conditioning condenser tube (1) to the air conditioning condenser.
4. Install NEW sealing washer (2) to the air conditioning condenser hose (4).
5. Install the air conditioning condenser hose (3) to the air conditioning condenser.
6. Install the air conditioning condenser hose nut (1) to the air conditioning condenser and tighten to 22 (16 lb ft).
7. Install the air conditioning condenser tube (2) to the retainers.
8. Install the air conditioning condenser tube nut (1) to the stud.
9. Install NEW sealing washers (2) to the air conditioning condenser tube (1). Install the air conditioning condenser tube (1) to the air conditioning evaporator air conditioning evaporator thermal expansion valve and the drive motor battery coolant cooler air conditioning evaporator thermal expansion valve.
10. Install the air conditioning evaporator hose assembly. Refer to «Air Conditioning Evaporator Hose Assembly Replacement»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
11. Connect electrical connectors.
12. Install the right headlamp. Refer to «Headlamp Replacement»(/cadillac/elr/i-2013-2015/remont/exterior-lights/#lighting-system) .
13. Install the coolant recovery reservoir. Refer to «Coolant Recovery Reservoir Replacement»(/cadillac/elr/i-2013-2015/remont/cooling-system-mechanical/#engine-cooling-system) .
14. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/cadillac/elr/i-2013-2015/remont/testing-diagnostics/#engine-controls-and-fuel-14l-luu-repair-instructions) .
15. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .

Scheme 3

Air Conditioning Compressor Front Hose Replacement

Scheme 4

Air Conditioning Evaporator Hose Assembly Replacement

Air Conditioning Refrigerant Service Valve Core Replacement

Special Tools

1. GE-39400-A Halogen Leak Detector
2. GE-46246 Valve Core Removal Tool

For equivalent regional tools, Refer to Special Tools

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Use GE-46246 Valve Core Removal Tool or equivalent to remove the valve core.

1. Use GE-46246 Valve Core Removal Tool or equivalent to install and tighten the valve core.
2. Evacuate and charge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
3. Test the affected A/C fittings for leaks using GE-39400-A Halogen Leak Detector.

Scheme 5

Air Conditioning Refrigerant Desiccant Replacement

Scheme 6

Air Conditioning Evaporator Thermal Expansion Valve Replacement (A/C Evaporator)

Scheme 7

Air Conditioning Evaporator Thermal Expansion Valve Replacement (Drive Motor Battery Coolant Cooler)

Scheme 8

Air Conditioning Refrigerant Pressure Sensor Replacement - Low Pressure

Scheme 9

Air Conditioning Refrigerant Pressure Sensor Replacement - High Pressure

Scheme 10

Air Conditioning Condenser Replacement

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/cadillac/elr/i-2013-2015/remont/body-electrical/#battery-charging-system-and-starting-system) .
2. Recover the air conditioning (A/C) refrigerant. Refer to «Refrigerant Recovery and Recharging»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
3. Drain the engine coolant system. Refer to «Cooling System Draining and Filling»(/cadillac/elr/i-2013-2015/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling) .
4. Remove the heater water shutoff valve actuator inlet hose (3) from the heater core tube. Refer to «Heater Water Shutoff Valve Actuator Inlet Hose Replacement»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Remove the heater inlet hose (3) from the heater core tube. Refer to «Heater Inlet Hose Replacement»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. Remove the air conditioning evaporator hose (2) from the thermal expansion valve. Refer to «Air Conditioning Evaporator Hose Assembly Replacement»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
7. Remove the air conditioning condenser tube (1) from the thermal expansion valve. Refer to «Condenser Tube Replacement»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
8. Temporarily support heater and air conditioning evaporator and blower module assembly (HVAC).
9. Remove the instrument panel tie bar (2) assembly. Refer to «Instrument Panel Tie Bar Replacement»(/cadillac/elr/i-2013-2015/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
10. Remove the air conditioning evaporator and blower module drain hose (1) from the HVAC module assembly.
11. Remove the HVAC module assembly bolt, (2) securing the HVAC module assembly to the cowl panel.
12. Remove the HVAC module assembly (3) from the vehicle.
13. Transfer all necessary components.

1. Position the HVAC module assembly (3) into the vehicle and temporarily support it.
2. Install the HVAC module assembly bolt (2) securing the HVAC module assembly to the cowl panel, and tighten to 9 (7 lb ft).
3. Install the air conditioning evaporator and blower module drain hose (1) to the HVAC module assembly.
4. Install the instrument panel tie bar (2) assembly. Refer to «Instrument Panel Tie Bar Replacement»(/cadillac/elr/i-2013-2015/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
5. Install the air conditioning condenser tube (1) on to the thermal expansion valve. Refer to «Condenser Tube Replacement»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. Install the air conditioning evaporator hose (2) on to the thermal expansion valve. Refer to «Air Conditioning Evaporator Hose Assembly Replacement»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
7. Install the heater inlet hose (3) on to the heater core tube. Refer to «Heater Inlet Hose Replacement»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
8. Install the heater water shutoff valve actuator inlet hose (3) on to the heater core tube. Refer to «Heater Water Shutoff Valve Actuator Inlet Hose Replacement»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
9. Fill the engine coolant system. Refer to «Cooling System Draining and Filling»(/cadillac/elr/i-2013-2015/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling) .
10. Recharge the A/C refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/cadillac/elr/i-2013-2015/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
11. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(/cadillac/elr/i-2013-2015/remont/body-electrical/#battery-charging-system-and-starting-system) .
12. Visually inspect for coolant leaks.
13. Visually inspect for A/C refrigerant leaks.

Scheme 11

Blower Lower Case Replacement

Scheme 12

Blower Upper Case Replacement

Scheme 13

Air Conditioning Evaporator Replacement

Scheme 14

Air Conditioning Evaporator and Blower Module Drain Hose Replacement

Scheme 15

Heater Inlet Hose Replacement

Heater Inlet And Outlet Pipe Replacement

Special Tools

BO-38185 Hose Clamp Pliers

For equivalent regional tools, refer to Special Tools .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling»(/cadillac/elr/i-2013-2015/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling) .
2. Remove the front wheelhouse liner on passenger side. Refer to «Front Wheelhouse Liner Replacement»(/cadillac/elr/i-2013-2015/remont/frames-subframes-crossmembers/#frame-and-underbody) .
3. Remove the heater inlet and outlet pipe clamps (1) at heater water auxiliary pump using BO-38185 pliers.
4. Remove the heater inlet and outlet pipe (2) from the heater water auxiliary pump.
5. Remove the heater inlet and outlet pipe clamps (1) at the heater water auxiliary pump inlet hose and the heater outlet hose using BO-38185 pliers.
6. Remove the heater inlet and outlet pipe bolts (2) from the cradle.
7. Remove the heater inlet and outlet pipe (3) from the vehicle.

1. Install the heater inlet and outlet pipe (3) to the vehicle.
2. Install the heater inlet and outlet pipe bolts (2) to the cradle and torque to 9 (80 lb in).
3. Install the heater inlet and outlet pipe clamps (1) at the heater water auxiliary pump inlet hose and the heater outlet hose using BO-38185 pliers.
4. Install the heater inlet and outlet pipe (2) to the heater water auxiliary pump.
5. Install the heater inlet and outlet pipe clamps (1) at the heater water auxiliary pump using BO-38185 pliers.
6. Install the front wheelhouse liner on passenger side. Refer to «Front Wheelhouse Liner Replacement»(/cadillac/elr/i-2013-2015/remont/frames-subframes-crossmembers/#frame-and-underbody) .
7. Fill the cooling system. Refer to «Cooling System Draining and Filling»(/cadillac/elr/i-2013-2015/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling) .

Scheme 16

Heater Outlet Hose Replacement

Scheme 17

Heater Inlet Pipe Adapter Replacement

Scheme 18

Heater Coolant Pump Replacement

Scheme 19

Air Inlet Valve Actuator Gear Replacement

Scheme 20

Passenger Compartment Air Filter Replacement

Scheme 21

Air Inlet Replacement

Scheme 22

Air Inlet Housing Replacement

Scheme 23

Blower Motor Control Module Replacement

Scheme 24

Air Inlet Valve and Inside Air Valve Control Cam Replacement

Scheme 25

Air Inlet Valve Lever Replacement

Scheme 26

Blower Motor Replacement

Scheme 27

Side Window Defogger Outlet Grille Replacement - Left Side

Scheme 28

Side Window Defogger Outlet Grille Replacement - Right Side

Scheme 29

Air Distributor Case Replacement

Scheme 30

Instrument Panel Outer Air Outlet Replacement - Left Side

Scheme 31

Instrument Panel Center Air Outlet Replacement

Scheme 32

Instrument Panel Outer Air Outlet Replacement - Right Side

Scheme 33

Floor Front Air Outlet Duct Replacement - Right Side

Scheme 34

Floor Front Air Outlet Duct Replacement - Left Side

Scheme 35

Instrument Panel Outer Air Outlet Duct Replacement

Scheme 36

Windshield Defroster Nozzle Replacement

Scheme 37

Side Window Defogger Outlet Duct Replacement - Left Side

Scheme 38

Side Window Defogger Outlet Duct Replacement - Right Side

Scheme 39

Mode Valve Lever Replacement

Scheme 40

Heater Coolant Heater Heat Shield Replacement

Scheme 41

Heater Core Replacement

Scheme 42

Heater Tube Replacement

Scheme 43

Heater Coolant Heater Air Supply Hose Replacement

Scheme 44

Heater Coolant Heater Replacement

Scheme 45

Engine Coolant Temperature Sensor Replacement - Heater Coolant Heater

Scheme 46

Heater Water Shutoff Valve Replacement

Scheme 47

Heater Water Shutoff Valve Actuator Inlet Hose Replacement

Heater Water Shutoff Valve Inlet Hose Replacement

Special Tools

BO-38185 Hose Clamp Pliers

For equivalent regional tools, refer to Special Tools .

1. Drain the cooling system. Refer to «Drive Motor Generator Power Inverter Module Cooling System Draining and Filling»(/cadillac/elr/i-2013-2015/remont/body-electrical/#hybridev-battery-heating-and-cooling-system__drive-motor-generator-power-inverter-module) .
2. Remove the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(/cadillac/elr/i-2013-2015/remont/testing-diagnostics/#engine-controls-and-fuel-14l-luu-repair-instructions) .
3. Disconnect the heater water shutoff valve inlet hose quick connect fitting (1) at the heater water shutoff valve.
4. Remove the heater water shutoff valve inlet hose (2) from the heater water shutoff valve.
5. Remove the heater water shutoff valve inlet hose clamp (1) at engine using BO-38185 pliers.
6. Remove the heater water shutoff valve inlet hose (2) from engine.
7. Remove the heater water shutoff valve inlet hose from the vehicle.

1. Install the heater water shutoff valve inlet hose to the vehicle.
2. Install the heater water shutoff valve inlet hose (2) to the engine.
3. Install the heater water shutoff valve inlet hose clamp (1) at the engine using BO-38185 pliers.
4. Install the heater water shutoff valve inlet hose (2) to the heater water shutoff valve.
5. Connect the heater water shutoff valve inlet hose quick connect fitting (1) at heater water shutoff valve.
6. Install the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(/cadillac/elr/i-2013-2015/remont/testing-diagnostics/#engine-controls-and-fuel-14l-luu-repair-instructions) .
7. Fill the cooling system. Refer to «Drive Motor Generator Power Inverter Module Cooling System Draining and Filling»(/cadillac/elr/i-2013-2015/remont/body-electrical/#hybridev-battery-heating-and-cooling-system__drive-motor-generator-power-inverter-module) .

Heater Water Auxiliary Pump Inlet Hose Replacement

Special Tools

BO-38185 Hose Clamp Pliers

For equivalent regional tools, refer to Special Tools .

1. Drain the cooling system. Refer to «Cooling System Draining and Filling»(/cadillac/elr/i-2013-2015/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling) .
2. Remove the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(/cadillac/elr/i-2013-2015/remont/testing-diagnostics/#engine-controls-and-fuel-14l-luu-repair-instructions) .
3. Remove the heater water auxiliary pump inlet hose clamp (1) at the coolant reservoir using BO-38185 pliers.
4. Remove the heater water auxiliary pump inlet hose (2) from the coolant reservoir.
5. Remove the heater water auxiliary pump inlet hose clamps (1) at engine and heater water shutoff valve using BO-38185 pliers.
6. Remove the heater water auxiliary pump inlet hose (2) from the engine and heater water shutoff valve.
7. Remove the heater water auxiliary pump inlet hose clamp (1) at the heater inlet and outlet pipe using BO-38185 pliers.
8. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/cadillac/elr/i-2013-2015/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) .
9. Remove the heater water auxiliary pump inlet hose (2) from the heater inlet and outlet pipe.
10. Remove the heater water auxiliary pump inlet hose from the vehicle.

1. Install the heater water auxiliary pump inlet hose to the vehicle.
2. Install the heater water auxiliary pump inlet hose (2) to the engine and heater water shutoff valve.
3. Install the heater water auxiliary pump inlet hose clamp (1) at the heater inlet and outlet pipe using BO-38185 pliers.
4. Install the heater water auxiliary pump inlet hose (2) to the engine and heater water shutoff valve.
5. Install the heater water auxiliary pump inlet hose clamps (1) at the engine and heater water shutoff valve using BO-38185 pliers.
6. Install the heater water auxiliary pump inlet hose (2) to the coolant reservoir.
7. Install the heater water auxiliary pump inlet hose clamp (1) at the coolant reservoir using BO-38185 pliers.
8. Lower the vehicle.
9. Install the air cleaner resonator outlet duct. Refer to «Air Cleaner Resonator Outlet Duct Replacement»(/cadillac/elr/i-2013-2015/remont/testing-diagnostics/#engine-controls-and-fuel-14l-luu-repair-instructions) .
10. Fill the cooling system. Refer to «Cooling System Draining and Filling»(/cadillac/elr/i-2013-2015/remont/cooling-system-mechanical/#engine-cooling-system__cooling-system-draining-and-filling) .

Scheme 48

Heater Outlet Hose Vapor Vent Hose Replacement

The heating system uses the engine and a high voltage heater to provide heat to the passenger compartment. The high voltage heater is used when the engine is not running and passenger compartment heat is requested. The high voltage heater provides different levels of heat depending on the amount of heat needed and outside temperature.

The HVAC Control Module turns on the coolant pump and monitors the temperature sensors in the passenger compartment, outside air, engine radiator, high voltage heater and the engine to determine the position of the coolant flow control valve and if the high voltage heater is needed. Passenger compartment heat is provided by air flowing through the heater core. The heater core is heated by coolant from either the engine or the high voltage heater.

The engine cooling system circulates a 50/50 mixture of Dex-cool and deionized water.

The A/C system uses the refrigerant R-134a which is a gas at very low temperatures and can transfer heat from the passenger compartment and high voltage battery to the outside air. The A/C system is mechanically protected with the use of a high pressure relief valve on the A/C compressor. If the refrigerant pressure sensor were to fail or if the A/C system becomes restricted and the refrigerant pressure continued to rise, the high pressure relief will open and release refrigerant from the system.

The high voltage electric A/C compressor is a self contained high voltage inverter, electric motor, and direct coupled compressor. The electric A/C compressor has the ability to run and provide cooling performance while the vehicle engine is not running. This feature enables the electric A/C compressor to run at a speed independent of the engine. The electronic climate control module and the Vehicle Integration Control Module (VICM) will command the electric A/C compressor to a speed necessary to maintain a desired cooling level rather than cycle the electric A/C compressor on and off.

The electric A/C compressor builds pressure and adds heat to the refrigerant gas. The refrigerant gas flows from the electric A/C compressor to the condenser where heat is transferred to the outside air when the refrigerant condenses from a gas to a liquid. The liquid refrigerant then flows to a thermal expansion valve (TXV) on the battery chiller. The TXV lowers the pressure of the liquid refrigerant which makes the refrigerant expand from a liquid to a vapor. The low pressure refrigerant vapor flows into the battery chiller and begins to boil and change into a gas as the refrigerant absorbs heat from the battery coolant also flowing inside the battery chiller. The battery coolant and refrigerant are separated by several plates inside the battery chiller. The liquid refrigerant also flows to a second TXV on the evaporator. The low pressure refrigerant vapor flows from the TXV into the evaporator and begins to boil and change into a gas as the refrigerant absorbs heat from the passenger compartment air that is flowing through the outside of the evaporator. The moister in the passenger compartment air condenses on the outside of the evaporator and flows down to the bottom of the HVAC module where it drains outside the passenger compartment through a drain hose. The low pressure refrigerant gas then flows from the battery chiller and the evaporator back to the electric A/C compressor where the cycle is repeated.

Special Tools

Illustration Tool Number/ Description GE 39400-A J 39400-A Halogen Leak Detector GE 42220 J 42220 Universal 12V Leak Detection Lamp GE 43872 J 43872 Fluorescent Dye Cleaner GE 45037-A J 45037-A A/C PAG/POE Oil Injector GE 45268 J 45268 Flush Adapter Kit GE 46246 J 46246 Valve Core Removal Tool GE 48800 CoolTech A/C Recharge Machine GE 48997 Hybrid A/C Oil Injector Adapter Hose

Scheme 49

Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

See also:
• Symptoms - HVAC Systems - Automatic
• Moving Parts and Hot Surfaces Warning
• Diagnostic Starting Point - Vehicle
• Instrument Panel Carrier Replacement
• Loss of Coolant
• High Voltage Disabling
• Lifting and Jacking the Vehicle
• Fastener Caution
• Headlamp Replacement
• Front Wheelhouse Liner Replacement
• Engine Ground Strap Replacement
• Drive Motor Battery Coolant Cooler Inlet Hose Assembly Replacement
• Air Cleaner Assembly Replacement
• Coolant Recovery Reservoir Replacement
• Component Fastener Tightening Caution
• Drive Motor Battery Coolant Radiator Replacement
• Cooling System Draining and Filling
• Special Tools
• Actuator Recalibration
• Instrument Panel Lower Airbag Replacement - Passenger Side
• Temperature Valve Actuator Replacement - Left Side
• Mode Control Cam Actuator Replacement
• Drive Motor Generator Power Inverter Module Cooling System Draining and Filling
• Special Tools
• Leak Testing
• A/C Diagnostics Chart
• Heating and Air Conditioning System Description and Operation
• Heating Performance Diagnostic
• Air Conditioning (A/C) System Performance Test
• Flushing
• Refrigerant System Specifications
• Refrigerant Recovery and Recharging
• Heater Inlet And Outlet Pipe Replacement
• Heater Water Shutoff Valve Inlet Hose Replacement
• Heater Water Auxiliary Pump Inlet Hose Replacement