Heating, Ventilation and Air Conditioning Chevrolet Aveo I

Fastener Tightening Specifications

Fastener Tightening Specifications

Heater Temperature Specifications

Heater Temperature Specifications

Refrigerant System Capacities

Refrigerant System Capacities

Handling of Refrigerant Lines and Fittings

Always wear goggles and wrap a clean cloth around the fittings, the valves, and the connections when performing work that involves opening the refrigerant system. Do not weld or steam clean on or near any vehicle-installed air conditioning lines or components.

All refrigerant drums are shipped with a heavy metal screw cap. The purpose of the cap is to protect the valve and the safety plug from damage. It is good practice to replace the cap after each use of the drum.

If it is necessary to transport or carry any container of refrigerant in a vehicle, do not carry it in the passenger compartment.

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 4 times the diameter of the hose.
3. Never allow a flexible hose line to come within 63.5 mm (2.5 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 gage readings.
8. Open the fittings very slowly.
9. Keep your face and your hands away from the fitting so that you will not be injured if there happens to be liquid refrigerant in the line.
10. If you notice pressure when you loosen a fitting, allow the pressure to bleed off.
11. 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.

1. Back up the opposing fitting to prevent distortion of the connecting lines or the components.
2. Back up both the swaged fitting on the flexible hose connections and the coupling to which it is attached with 2 wrenches to prevent turning the fitting and damaging the ground seat.
3. Keep the O-rings and the seats in perfect condition. A burr or a piece of dirt may cause a refrigerant leak.
4. Dip new O-rings in clean polyalkaline glycol (PAG) refrigerant oil before installation.

Leak Testing

Test for leaks whenever you suspect a refrigerant leak in the system. You should also test for leaks whenever you perform a service operation which results in disturbing the lines or the connections. Leaks are commonly found at the refrigerant fittings or at the connections. Leaks are commonly caused by the following problems

1. Improper torque
2. Damaged O-ring seals
3. Dirt or lint on the O-ring seals

Liquid Leak Detectors

Use a liquid leak detector solution on locations such as fittings. Apply the solution to the area in question with the swab that is supplied with the solution. Look for bubbles to appear. This will indicate the existence and location of any leak.

For areas where this is not practical, such as sections of the evaporator and the condenser, an electronic leak detector is more useful.

Electronic Leak Detectors

Follow the manufacturer's instructions for calibration, operation, and maintenance of an electronic leak detector. Battery condition is especially important to the accuracy of a portable model. Set the detector to R-134a before beginning the test.

Surfaces must be clean to prevent false readings. Make sure that all surfaces are dry to prevent damage to the detector.

General Testing Instructions

1. Follow the entire path of the refrigerant system.
2. Completely circle each joint at 25-50 mm (1-2 in) per second.
3. Hold the probe tip within 6 mm (0.25 in) of the surface.
4. Do not block the air intake.

The audible tone changes from 1-2 clicks per second into a solid alarm if there is a leak. Adjust the balance control to maintain 1-2 clicks per second.

Test all of the following areas, even after 1 leak has been confirmed

1. Evaporator inlet and outlet
2. Receiver-drier inlet and outlet
3. Condenser inlet and outlet
4. Brazed and welded areas
5. Damaged areas
6. Hose couplings
7. Compressor rear head
8. All fittings and joints

Testing Service Ports/Access Valves

The sealing cap is the primary seal for the service ports. This cap contains a special leak-free O-ring. Make sure that this cap is not missing or loose. Always use the correct cap.

Testing the Evaporator Core

Leaks in the evaporator core are difficult to find. Test the evaporator core using the following procedure

1. Run the blower fan at speed setting 4 for at least 15 minutes.
2. Turn the blower to the OFF position.
3. Wait for 10 minutes.
4. Remove the blower motor resistor. Refer to «Blower Motor Resistor Replacement»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Insert the leak detector probe as close as possible to the evaporator core. The detector will indicate a leak with a solid alarm.
6. Use a flashlight to search for refrigerant oil in the core surface.

Testing the Compressor Shaft Seal

1. Blow shop air behind and in front of the compressor clutch/pulley for at least 15 seconds.
2. Wait 1-2 minutes.
3. Probe the area in front of the pulley. If the detector emits a solid alarm, there is a leak.

HVAC Preliminary Checks

If you suspect a problem in the refrigerant system, inspect for the following conditions

1. Inspect the outer surfaces of the radiator and the condenser cores to be sure that the airflow is not blocked by dirt, leaves, or other foreign material. Inspect between the condenser and the radiator, as well as all outer surfaces.
2. Inspect for restrictions or kinks in the condenser core, the hoses, and the tubes.
3. Inspect the operation of the blower fan.
4. Inspect all the air ducts for leaks or restrictions. A low airflow rate may indicate a restricted evaporator core.
5. Inspect for slippage of the compressor clutch.
6. Inspect the tension on the serpentine accessory drive belt.

Insufficient Cooling - Quick Check Procedure

Perform the following hand-feel procedure to get a quick idea of whether the air conditioning (A/C) system has the proper charge of Refrigerant-134a. The air temperature must be above 21°C (70°F) for most models.

1. Warm up engine. Run the engine at idle.
2. Open the hood and all the doors.
3. Turn the A/C switch ON.
4. Set the temperature control to the full cold position.
5. Set the blower speed switch on 4.
6. Hand-feel the temperature of the evaporator outlet pipe. The pipe should be cold.
7. Inspect for other problems. Refer to «HVAC Preliminary Checks»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__hvac-preliminary-checks) .
8. Leak check the system. Refer to «Leak Testing»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__leak-testing) . If you find a leak, discharge the system and repair the leak as required. After completing the repair, evacuate and charge the system.
9. If there is no leak, refer to «Too Hot in Vehicle»(/chevrolet/aveo/i-2003-2008/remont/manual-hvac-system/#hvac-systems-manual__too-hot-in-vehicle) .

Pressure Temperature Relationship of R-134A

Air Conditioning (A/C) System Performance Test

Air Conditioning (A/C) System Performance Test

Noise Diagnosis - Blower Motor

Noise Diagnosis - Blower Motor

Tools Required

J 5403 Snap Ring Pliers. See Special Tools .

J 9553-01 O-Ring Remover. See Special Tools .

J 23128-A Seal Seat Remover and Installer. See Special Tools .

J 33011 O-Ring Installer. See Special Tools .

J 34614 Shaft Seal Protector. See Special Tools .

Disassembly Procedure

1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
3. Loosen and reposition the compressor in the mounting brackets.
4. Remove the clutch drive plate and hub assembly from the compressor. Refer to «Compressor Clutch Plate and Hub Assembly Removal»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Use the J 5403 (1) to remove the shaft seal retaining ring. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
6. Thoroughly clean the inside of the compressor housing area surrounding the shaft, the exposed portion of the seal, the shaft itself, and the O-ring groove.
7. Fully engage the knurled tangs of the J 23128-A (1) into the recessed portion of the seal by turning the handle clockwise. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Remove and discard the seal from the compressor with a rotating-pulling motion. The handle should be hand-tightened securely. Do not use a wrench or pliers to tighten the handle.
8. Remove and discard the O-ring from the compressor neck using the J 9553-01 (1). See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
9. Thoroughly clean the seal O-ring groove in the compressor housing.
10. Inspect the shaft and the inside of the compressor housing neck for dirt or foreign material. These parts must be perfectly clean before installing any new parts.

Assembly Procedure

1. Dip the new seal O-ring in clean polyalkaline glycol (PAG) refrigerant oil and assemble the O-ring onto the J 33011 (1). See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
2. Insert the O-ring installer J 33011 (1) into the compressor neck until the installer bottoms. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Lower the moveable slide of the J 33011 (1) to release the O-ring into the seal O-ring lower groove. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . The top groove of the compressor neck is for the shaft seal retainer ring. Rotate the installer to seat the O-ring and then remove the installer.
3. Attach the shaft lip seal to the J 23128-A (1). See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Dip the seal in clean PAG oil.
4. Install the J 34614 (2) in the seal. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Place it over the shaft and push the seal into place with a rotary motion.
5. Use the J 5403 (1) to install the shaft seal retaining ring with its flat side against the seal. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
6. Remove any excess oil around the shaft and the inside of the compressor housing neck.
7. Install the clutch plate and hub assembly. Refer to «Compressor Clutch Plate/Hub Assembly Install»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-platehub-assembly-install) .
8. Reposition the compressor in its mounting.
9. Adjust the tension on the drive belt.
10. Connect the negative battery cable.
11. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
12. Perform a leak test of the system. Refer to «Leak Testing»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__leak-testing) .

J 34993 Cylinder Alignment Rods. See Special Tools .

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the compressor. Refer to «Compressor Replacement»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Drain the oil from compressor into a suitable container. Measure and record the amount of oil drained from the compressor. Discard the used oil.
4. Remove the clutch plate and hub assembly. Refer to «Compressor Clutch Plate and Hub Assembly Removal»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Remove the clutch rotor and bearing. Refer to «Clutch Rotor and/or Bearing Removal»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. Remove the clutch coil. Refer to «Compressor Clutch Coil Removal»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
7. Remove the compressor through-bolts. Remove and discard the gaskets.
8. Using a wooden block and a plastic-headed hammer, tap around the edge of the rear head to disengage the head from the compressor cylinder. Separate the rear head, the head gasket, the rear valve plate, the suction reed plate, and the cylinder to rear head O-ring. Discard the head gasket and the O-ring.

1. Place the rear head on a clean, flat surface. Position the head with the control valve at the 6 o'clock position.
2. Install the J 34993 in the mounting holes at the 11 o'clock and the 5 o'clock positions. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
3. Install the head gasket over the J 34993 with the elongated hole at the upper left pin, the 11 o'clock position. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
4. Install the rear head valve plate over the J 34993 with the elongated hole at the upper left alignment rod. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Lower the rear head valve plate into place.
5. Install the suction reed plate over the J 34993 . See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Remove the alignment rod at the 5 o'clock position.
6. Lubricate the cylinder to the new rear head O-ring with clean polyalkaline glycol (PAG) refrigerant oil.
7. Install the O-ring in the cylinder O-ring groove. The O-ring seal surface of the head may be lubricated to ease assembly.
8. With the O-ring in place on the rear of the cylinder assembly, locate the relief boss for the alignment rod at the 6 o'clock position, directly above the hole in the side of the rear head. Carefully lower the cylinder and the front head assembly over the cylinder alignment rods to the rear head.
9. Press the cylinder and the compressor housing assembly down onto the rear head using both hands.
10. Add the new through-bolt gasket to the through-bolts and install it into the compressor assembly. Four of the through-bolts must thread into the rear head before removing the alignment rods. Tighten: Alternately tighten the compressor front head-to-rear head through-bolts in progressive tighten sequence to 10 N.m (89 lb in).
11. Add new PAG refrigerant oil as determined in Step 1.
12. Place the shaft nut on the shaft and rotate the compressor shaft several times.
13. Perform a leak test on the compressor. Refer to «Compressor Leak Testing»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-leak-testing) .
14. Install the clutch coil. Refer to «Compressor Clutch Coil Install»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-coil-install) .
15. Install the clutch rotor and bearing. Refer to «Clutch Rotor and/or Bearing Install»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__clutch-rotor-andor-bearing-install) .
16. Install the clutch plate and hub assembly. Refer to «Compressor Clutch Plate/Hub Assembly Install»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-platehub-assembly-install) .
17. Install the compressor. Refer to «Compressor Replacement»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
18. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .

J 34993 Cylinder Alignment Rods. See Special Tools .

J 35372 Support Block. See Special Tools .

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the compressor. Refer to «Compressor Replacement»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Drain the oil from compressor into a suitable container. Measure and record the amount of oil drained from the compressor. Discard all used oil.
4. Remove the clutch plate and hub assembly. Refer to «Compressor Clutch Plate and Hub Assembly Removal»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Remove the clutch rotor and bearing. Refer to «Clutch Rotor and/or Bearing Removal»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. Remove the clutch coil. Refer to «Compressor Clutch Coil Removal»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
7. Remove and discard the shaft seal parts. Refer to «Compressor Shaft Seal Replacement»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
8. Remove the compressor through-bolts. Remove and discard the gaskets.
9. Using a wooden block and a plastic-headed hammer, tap the compressor housing at the mounting locations to disengage the housing from the compressor cylinder.
10. Remove the thrust washer and the bearing.
11. Remove and discard the compressor housing-to-cylinder O-ring.

1. Rest the rear head on the J 35372 . See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Locate the control valve in the 6 o'clock position.
2. Install the J 34993 through the 11 o'clock and the 5 o'clock bolt holes. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
3. Lubricate the new cylinder-to-compressor housing O-ring with clean polyalkalene glycol (PAG) oil.
4. Install the new O-ring in the cylinder O-ring groove.
5. Install the thrust washer and bearing in the same order as they were removed.
6. Align the cylinder alignment rod recess in the compressor housing with the cylinder alignment rod. Press down on the compressor housing with both hands to force it over the O-ring on the cylinder assembly.
7. Add a new through-bolt gasket to the through-bolts and install them into the compressor assembly. Four through-bolts must thread into the rear head before removing the cylinder alignment rods. Tighten: Alternately tighten the compressor front head-to-rear head through-bolts in progressive tighten sequence to 10 N.m (89 lb in).
8. Install a new shaft seal. Refer to «Compressor Shaft Seal Replacement»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
9. Add new PAG oil equal to the amount drained in Step 3.
10. Install the clutch coil. Refer to «Compressor Clutch Coil Install»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-coil-install) .
11. Install the clutch rotor and bearing. Refer to «Clutch Rotor and/or Bearing Install»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__clutch-rotor-andor-bearing-install) .
12. Install the clutch plate and hub assembly. Refer to «Compressor Clutch Plate/Hub Assembly Install»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-platehub-assembly-install) .
13. Perform a leak test on the compressor. Refer to «Compressor Leak Testing»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-leak-testing) .
14. Install the compressor. Refer to «Compressor Replacement»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
15. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .

Removal Procedure

1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
3. Remove the air cleaner housing bolts and the air filter housing assembly.
4. Disconnect the electrical connector at the pressure transducer.
5. Remove the liquid evaporator pipe connector block retaining nut at the cowl.
6. Remove the liquid pipe connector block to the condenser retaining bolt.
7. Remove the refrigerant suction hose to liquid pipe block retaining nut.
8. Remove the liquid evaporator pipe support clamp bolt.
9. Remove the liquid evaporator pipe and the refrigerant suction hose.
10. Remove the refrigerant suction hose and the refrigerant discharge hose to compressor connector block retaining nut.
11. Remove the refrigerant discharge hose connector block bolt at the condenser.
12. Remove the refrigerant discharge hose support clamp bolt.
13. Remove the refrigerant discharge hose.

Installation Procedure

1. Position the refrigerant suction hose section into the vehicle.
2. Install a new O-ring on the connector block at the condenser.
3. Install a new O-ring at the liquid condenser to evaporator plate pipe connector block.
4. Install the refrigerant discharge hose support clamp bolt. Tighten: Tighten the refrigerant discharge hose support clamp bolt to 7 N.m (62 lb in).
5. Install the refrigerant discharge hose connector block bolt at the condenser. Tighten: Tighten the refrigerant discharge hose connector block bolt to 16 N.m (12 lb ft).
6. Install the refrigerant suction hose and the refrigerant discharge hose to compressor connector block retaining nut. Tighten: Tighten the refrigerant suction hose and the refrigerant discharge hose to compressor block retaining nut to 33 N.m (24 lb ft).
7. Install the refrigerant suction hose connector block retaining nut. Tighten: Tighten the refrigerant suction hose connector block retaining nut to 15 N.m (11 lb ft).
8. Install the liquid pipe connector block to condenser retaining bolt. Tighten: Tighten the liquid pipe connector block to condenser retaining bolt to 14 N.m (124 lb in).
9. Install the liquid evaporator pipe connector block retaining nut at the cowl. Tighten: Tighten the liquid evaporator pipe connector block retaining nut to 15 N.m (11 lb ft).
10. Connect the electrical connector to the pressure transducer.
11. Install the air cleaner housing assembly with the retaining bolts. Tighten: Tighten the air cleaner housing assembly retaining bolts to 12 N.m (106 lb in).
12. Connect the negative battery cable.
13. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .

Refrigerant Recovery and Recharging

The efficient operation and life of the air conditioning system is dependent upon the chemical stability of the refrigeration system. When foreign materials, such as dirt, air, or moisture, contaminate the refrigeration system, they will change the stability of the refrigerant and the polyalkaline glycol (PAG) compressor oil. They will also affect the pressure-temperature relationship, reduce efficient operation, and can possibly cause interior corrosion and abnormal wear of moving parts.

Observe the following practices to ensure chemical stability in the system

1. Wipe away dirt or oil at and near any connection before opening that connection. This will reduce the chance of dirt entering the system.
2. Cap, plug, or tape both sides of a connection as soon as possible after opening the connection. This will prevent the entry of dirt, foreign material, and moisture.
3. Keep all tools clean and dry, including the manifold gage set and all replacement parts.
4. Use a clean and dry transfer device and container to add PAG refrigerant oil. This will ensure that the oil remains as moisture-free as possible.
5. Have everything you need ready to allow you to perform all operations quickly when opening an A/C system. Do not leave the A/C system open any longer than necessary.
6. Evacuate and recharge any A/C system that has been opened.

All service parts are dehydrated and sealed before shipping. They should remain sealed until just before making connections. All the parts should be at room temperature before uncapping. This prevents condensation of moisture from the air from entering the system. Reseal all parts as soon as possible if the caps have been removed but the connections cannot be made promptly.

A charging station discharges, evacuates, and recharges an air conditioning system with one hook-up. Filtering during the recovery cycle together with filtering during the evacuation cycle ensures a supply of clean, dry refrigerant for A/C system charging.

1. Never use the R-134a charging station on a system charged with R-12. The refrigerants and the oils are not compatible and must never be mixed in even the smallest amount. Mixing refrigerant residue will damage the equipment.
2. Never use adapters which convert from one size fitting to another. This will allow contamination which may cause system failure.

Charging Station Setup and Maintenance

Refer to the manufacturer's instructions for all initial setup procedures and all maintenance procedures. There are many charging stations available. All perform the various tasks required to discharge the system and recover refrigerant, evacuate the system, add a measured amount of oil, and recharge an air conditioning system with a measured amount of refrigerant.

Control Panel Functions

A charging station will have controls and indicators to allow the operator to control and monitor the operation in progress. Refer to the manufacturer's instructions for details. These can be expected to include

1. Main power switch - The main power switch supplies electrical power to the control panel.
2. Display - The display shows the time programmed for vacuum and the weight of the refrigerant programmed for recharging. Refer to the manufacturer's instructions for detailed programming information.
3. Low-side manifold gage - This gage shows the system's low-side pressure.
4. High-side manifold gage - This gage shows the system's high-side pressure.
5. Controls - This will contain the controls that control various operating functions.
6. Low-side valve - This valve connects the low side of the A/C system to the unit.
7. Moisture indicator - This indicator shows if the refrigerant is wet or dry.
8. High-side valve - This valve connects the high side of the A/C system to the unit.

Refrigerant Recovery

1. Attach the high-side hose with the quick disconnect coupler to the high-side fitting of the vehicle's A/C system.
2. Open the coupler valve after attachment.
3. Attach the low-side hose with the quick disconnect coupler to the low-side fitting of the vehicle's A/C system.
4. Open the coupler valve after attachment.
5. Check the high-side and the low-side gages on the unit's control panel in order to ensure that the A/C system has pressure. If there is no pressure, there is no refrigerant in the system to recover.
6. Open both the high-side and the low-side valves.
7. Open the gas and the liquid valves on the tank.
8. Drain any oil that may be in the oil separator.
9. Close the oil drain valve.
10. Plug the unit into the proper voltage outlet.
11. Turn ON the main power switch.
12. Begin the recovery process. Refer to the manufacturer's instructions for the charging station in use.
13. Wait 5 minutes. Check the control panel low-side gage. If the A/C has maintained vacuum, the recovery is complete.
14. There is more refrigerant in the system if the low side gage pressure rises above zero. Recover the additional refrigerant. Repeat this step until the system maintains vacuum for 2 minutes.

Evacuation

The unit tank must contain a sufficient amount of R-134a refrigerant for charging. Check the amount of refrigerant in the tank. If there is less than 3.6 kg (8 lbs) of refrigerant, add new refrigerant to the tank. Refer to the manufacturer's instructions for adding refrigerant.

1. Verify that the high side and the low side hoses are connected to the A/C system. Open both the high side and the low side valves on the unit's control panel.
2. Open both the gas and the liquid valves on the tank.
3. Start the vacuum pump and begin the evacuation process. Non-condensable gases, mostly air, are automatically vented from the tank during the recycling process. You may hear the pressure being released.
4. Check for leaks in the system. Refer to the manufacturer's instructions for the charging station in use.

A/C System Oil Charge Replenishing

Any oil removed from the A/C system during the recovery process must be replenished at this time.

1. Use the correct graduated bottle of PAG oil for the R-134a system. Keep the oil bottles tightly capped at all times to protect the oil from moisture and contamination. Never open the oil injection valve while there is positive pressure in the A/C system. This will result in oil blow-back through the bottle vent. You must have A/C system vacuum for this operation. Never let the oil level drop below the pick-up tube while charging or replenishing the system. This will allow air into the A/C system.
2. Refer to the manufacturer's instructions for the charging station in use. Add the proper amount of PAG oil to the system.
3. Close the valve when the required oil charge has been pulled into the system.

Charging

1. Close the low-side valve on the control panel.
2. Open the high-side valve on the control panel.
3. Refer to the manufacturer's instructions for the charging station in use.
4. Enter the amount of refrigerant needed to charge the A/C. Be sure that you are using the correct system of measurement (kg, lb).
5. Begin the charging process.

Successful Transfer Complete

1. Close the high-side valve on the unit's control panel. Both valves should be closed.
2. Start the vehicle and the A/C system.
3. Let the engine run until the readings on the high-side and low-side gages stabilize.
4. Compare the readings to the system specifications.
5. Check the evaporator outlet temperature to ensure that the A/C system is operating within the system specifications.
6. Keep the A/C running.
7. Close the high side coupler valve.
8. Disconnect the high-side hose from the vehicle.
9. Open the high-side and low-side valves on the control panel.
10. The system will quickly draw in refrigerant from both hoses through the low-side hose.
11. Close the low-side coupler valve.
12. Disconnect the low-side hose from the vehicle.

Unsuccessful Transfer

Sometimes the total charge does not transfer into the A/C system. There are 2 reasons why this may occur.

1. The pressure in the unit's tank and the pressure in the A/C system are roughly equal. This will cause the transfer to proceed too slowly. Refer to the manufacturer's instructions for the charging station in use.
2. There was not enough refrigerant in the unit's tank to transfer the full charge. It is necessary to recover the partial charge of refrigerant from the vehicle and evacuate and charge the A/C system again. Refer to the manufacturer's instructions for the charging station in use.

1. Disconnect the negative battery cable.
2. Discharge and recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
3. Remove the compressor A/C hose assembly connector block fitting nut.
4. Raise and suitably support the vehicle.
5. Disconnect the electrical connector at the compressor.
6. Remove serpentine accessory drive belt.
7. Remove the A/C compressor-to-bracket bolts.
8. Remove the compressor.
9. Drain the oil from the compressor into a container. Measure the amount of oil drained and then discard the used oil.

1. Add oil to the new compressor. Use the exact amount of oil that you drained from the old compressor.
2. Install the compressor.
3. Install the compressor-to-bracket mounting bolts. Tighten: Tighten the compressor bracket bolt to 35 N.m (26 lb ft).
4. Install the serpentine accessory drive bolt.
5. Lower the vehicle.
6. Install new O-ring to the A/C hose assembly connector block fitting.
7. Install the compressor hose assembly connector block fitting and tighten the retaining nut. Tighten: Tighten the A/C system hose connector retaining nut to 33 N.m (24 lb ft).
8. Connect the electrical connector at the compressor.
9. Connect the negative battery cable.
10. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .

J 33013-B Hub and Drive Plate Remover/Installer. See Special Tools .

J 33027-A Clutch Hub Holding Tool. See Special Tools .

J 42428 Compressor Holding Fixture. See Special Tools .

1. Remove the compressor. Refer to «Compressor Replacement»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Install the J 42428 to the compressor and hold the compressor holding fixture using a bench vise. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
3. Use the J 33027-A to keep the clutch drive plate and the hub assembly from turning. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Remove the shaft nut.
4. Thread the J 33013-B (1) into the hub. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Hold the body of the remover with a wrench and turn the center screw into the remover body to remove the clutch drive plate and hub assembly.
5. Remove the clutch hub key. Retain the key for assembly (3).

J 6083 Snap Ring Pliers

J 8092 Driver Handle. See Special Tools .

J 9398-A Bearing Remover. See Special Tools .

J 33020 Pulley Puller. See Special Tools .

1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
3. Remove the compressor. Refer to «Compressor Replacement»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Remove the clutch drive plate and hub assembly. Refer to «Compressor Clutch Plate and Hub Assembly Removal»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Remove the pulley rotor and the bearing assembly retaining ring using the J 6083 .
6. Install the J 33020 (1) into the inner circle of slots in the pulley rotor. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Turn the J 33020 (1) clockwise in the slots to engage the puller tangs with the segments between the slots in the rotor. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
7. Hold the J 33020 (1) in place and tighten the puller bolt against the compressor shaft to remove the pulley rotor and the bearing assembly. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
8. Remove the puller bolt from the J 33020 . See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . With the puller tangs still engaged in the rotor slots, invert the assembly onto a solid flat surface or blocks.
9. Drive the bearing out of the rotor hub with the J 9398-A (2) and the J 8092 (1). See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .

J 8433-1 Puller Crossbar. See Special Tools .

J 8433-3 Forcing Screw. See Special Tools .

J 33023-A Puller Pilot. See Special Tools .

J 33025 Clutch Coil Puller Legs. See Special Tools .

1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
3. Remove the compressor. Refer to «Compressor Replacement»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Remove the clutch plate and hub assembly. Refer to «Compressor Clutch Plate and Hub Assembly Removal»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Remove the clutch rotor and bearing. Refer to «Clutch Rotor and/or Bearing Removal»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. Mark the clutch coil terminal location on the compressor housing.
7. Install the J 33023-A (1) on the compressor housing. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Also install the J 8433-1 (3) with the J 33025 (4). See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
8. Tighten the J 8433-3 (2) against the J 33023-A (1) to remove the clutch coil. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .

Compressor Control Valve Assembly Removal

Tools Required

J 5403 Snap Ring Pliers. See Special Tools .

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the control valve retaining ring using the J 5403 (1). See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
3. Remove the control valve assembly.

Scheme 1

Tools Required

J 5403 Snap Ring Pliers. See Special Tools .

1. Install the control valve assembly.
2. Install the control valve retaining ring using J 5403 (1). See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
3. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .

Compressor Clutch Plate/Hub Assembly Install

Tools Required

J 33013-B Hub and Drive Plate Remover/Installer. See Special Tools .

J 33022 Shaft Nut Socket. See Special Tools .

J 33027-A Clutch Hub Holding Tool. See Special Tools .

J 42428 Compressor Holding Fixture. See Special Tools .

1. Install the clutch hub key into the hub keyway. Allow the key to project approximately 3.2 mm (1/8 in) out of the keyway. The hub key is curved slightly to provide an interference fit in the hub key groove.
2. Be sure the frictional surface of the clutch plate and the pulley rotor are clean before installing the clutch drive plate and the hub assembly.
3. Align the clutch hub key with the shaft keyway. Place the clutch drive plate and hub assembly onto the compressor shaft.
4. Remove the J 33013-B (1) center bolt and reverse the body direction on the center bolt. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . The body of the J 33013-B (1) should be backed off sufficiently to allow the center bolt to be threaded onto the end of the compressor shaft. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
5. Install the J 33013-B (1) and the bearing onto the clutch drive plate. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Thread the center bolt onto the compressor shaft.
6. Hold the center bolt with a wrench. Tighten the hex portion of the J 33013-B (1) body to press the hub onto the shaft. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Tighten the body several turns.
7. Remove the J 33013-B (1) and check to see that the clutch hub key is still in place in the keyway before installing the clutch drive plate and the hub assembly to its final position. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . The air gap between frictional surfaces of the clutch drive plate and the clutch pulley rotor should be 0.38-0.64 mm (0.015-0.025 in).
8. Remove the J 33013-B . See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Check for proper positioning of the clutch hub key. It should be even or slightly above the clutch hub.
9. Install the shaft nut. Hold the clutch drive plate and the hub assembly with the J 33027-A (2). See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Use the J 33022 (1) and tighten the nut against the compressor shaft shoulder. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Tighten: Tighten the clutch plate and hub assembly nut to 17 N.m (13 lb ft).
10. Spin the pulley rotor by hand to verify that the pulley is not rubbing the clutch drive plate.
11. Remove the compressor from the bend vise and remove the J 42428 (3) on the compressor. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
12. Install the compressor. Refer to «Compressor Replacement»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Clutch Rotor and/or Bearing Install

Tools Required

J 33017 Pulley Rotor and Bearing Assembly Installer. See Special Tools .

J 33019 Bearing Staking Guide/Bearing Staking Pin. See Special Tools .

J 33023-A Puller Pilot. See Special Tools .

J 42428 Compressor Holding Fixture. See Special Tools .

J 6083 Snap Ring Pliers

J 8092 Driver Handle. See Special Tools .

J 8433-1 Puller Crossbar. See Special Tools .

J 8433-3 Forcing Screw. See Special Tools .

J 9481-A Bearing Installer. See Special Tools .

1. Invert the pulley rotor and place it on a support block to fully support the rotor hub during bearing installation.
2. Align the new bearing squarely in the pulley bore. Use the J 9481-A (2) and the J 8092 (1), drive the bearing fully into the pulley bore. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
3. Place the J 33019 (1) and the J 33019 (2) in the rotor hub core. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Shift the rotor and bearing assembly on the block to give full support to the hub under the staking pin location. A heavy-duty rubber band may be used to hold the staking tool pin in the guide. The pin should be properly positioned in the guide after each impact on the pin.
4. Strike the pin with a hammer until a metal stake, similar to the original, is formed down to, but not touching, the bearing. The metal stake should not contact the outer race of the bearing to avoid the possibility of distorting the outer race. Stake in 3 places 120° apart.
5. With the compressor mounted to the J 42428 (3), position the rotor and the bearing assembly on the compressor housing. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
6. Position the J 33017 (4) and the J 33023-A (2) directly over the inner race of the bearing. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
7. Position the J 8433-1 (5) center forcing bolt on the J 33023-A (2) and assemble the 2 through-bolts and the washers through the J 8433-1 (5) slots. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Thread them into the J 42428 (3). See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . The thread of the through-bolts should engage the full thickness of the fixture.
8. Tighten the center J 8433-3 (1) in the J 8433-1 (5) to force the pulley rotor and the bearing assembly onto the compressor housing. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
9. Install the rotor and the bearing assembly retainer ring using the J 6083 (1).
10. Reinstall the clutch drive plate and the hub assembly. Refer to «Compressor Clutch Plate/Hub Assembly Install»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-platehub-assembly-install) .
11. Install the compressor. Refer to «Compressor Replacement»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
12. Connect the negative battery cable.
13. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .

Compressor Clutch Coil Install

Tools Required

J 8433-1 Puller Crossbar. See Special Tools .

J 8433-3 Forcing Screw. See Special Tools .

J 33024 Clutch Coil Installer Adapter. See Special Tools .

J 42428 Compressor Holding Fixture. See Special Tools .

1. Place the clutch coil assembly on the compressor housing with the terminals positioned at the marked location.
2. Place the J 33024 (1) over the internal opening of the clutch coil housing and align the J 33024 (1) with the compressor housing. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
3. Center the J 8433-1 (4) in the countersunk center hole of the J 33024 (3). See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Install the J 42428 (2) through-bolts and the washers through the crossbar slots. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Thread them into the holding fixture to the full thickness of the holding fixture.
4. Turn the J 8433-3 (1), or use a suitable vise, to force the clutch coil onto the compressor housing. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
5. When the clutch coil is fully seated on the compressor housing, use a 3 mm (1/8 inch) diameter drift punch and stake the housing at 3 places, 120° apart, to ensure that the clutch coil will remain in position. Stake point size should be only one-half the area of the punch tip and approximately 0.28-0.35 mm (0.01-0.015 in) deep.
6. Install the clutch rotor and bearing assembly. Refer to «Clutch Rotor and/or Bearing Install»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__clutch-rotor-andor-bearing-install) .
7. Install the clutch plate and hub assembly. Refer to «Compressor Clutch Plate/Hub Assembly Install»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-clutch-platehub-assembly-install) .
8. Install the compressor. Refer to «Compressor Replacement»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
9. Connect the negative battery cable.
10. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .

Compressor Leak Testing

Tools Required

J 9625-A Pressure Test Set. See Special Tools .

1. Install the J 9625-A (1) connector to the suction/discharge ports on the compressor. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
2. Attach the center hose of the manifold gage set on the charging station to a refrigerant drum standing in an upright position. Open the valve on the drum.
3. Connect the charging station high and low-pressure lines to the corresponding fittings on the J 9625-A (1) connectors, or hoses equipped with valve depressors. See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . The suction port, low-side, of the compressor has a large internal opening. The discharge port, high-side, has a smaller internal opening into the compressor.
4. Open the low-pressure control, the high-pressure control, and the refrigerant control on the charging station to allow the refrigerant vapor to flow into the compressor.
5. Using a leak detector, check for leaks at the high-pressure relief valve seal, the housing seal, the rear head seal, the center cylinder seal, the through-bolt gaskets, and the compressor shaft seal. After checking for leaks, shut off the low-pressure control, the high-pressure control, and the refrigerant control lines on the charging station.
6. If an external leak is present, perform the necessary corrective measures and recheck for leaks to verify that the leak has been corrected.
7. Loosen the manifold gage hose connections to the gage adapters connected to the low and high sides. Allow the vapor pressure to release from the compressor. If the valve depressor-type hoses are used, loosen the hose connections at the gage manifold to release vapor pressure from the compressor.
8. Disconnect both gage hoses. Remove the J 9625-A (1). See «Special Tools»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .

O-Ring Replacement

Install new General Motors-approved service replacement air conditioning O-rings whenever a joint or a fitting is assembled, except when the O-rings are provided on new components.

When replacing O-rings on an air conditioning component or a joint connection, the fitting design should be identified to ensure installation of the correct air conditioning service replacement O-ring. Some joint connections and components will implement a captured O-ring design fitting that uses a groove to retain the O-ring. Others do not have a groove and use a non-captured or standard O-ring. Assembly and tightening procedures are the same for both designs, but the O-rings are different.

Before installation, verify that both O-rings and fittings have not been nicked or deformed. Deformed or nicked parts must be replaced. Failure to use the proper service replacement parts and procedures may result in excessive refrigerant leakage.

1. Disconnect the negative battery cable.
2. The relay is located in the fuse junction box in the engine compartment on the right-hand side.
3. Pull the relay straight up and out.

1. Align the relay terminal contacts with the base receptacle.
2. Push the relay into the base until it is seated.
3. Connect the negative battery cable.

1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
3. Remove the liquid evaporator pipe connector block retaining nut at the cowl.
4. Remove the expansion valve connector block retaining bolts.
5. Remove the expansion valve.
6. Discard the O-rings.

1. Clean the O-ring surface areas of dirt or contamination.
2. Install new O-rings on the evaporator tubes.
3. Install a new expansion valve onto the evaporator tubes.
4. Install the expansion valve retaining bolts. Tighten: Tighten the expansion valve retaining bolts to 12 N.m (106 lb in).
5. Install the liquid evaporator pipe connecting block retaining nut at the cowl. Tighten: Tighten the liquid evaporator pipe connecting block retaining nut to 15 N.m (11 lb in).
6. Connect the negative battery cable.
7. Evacuate and recharge the system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .

1. Disconnect the negative battery cable.
2. Remove the air cleaner housing bolts and the air filter housing assembly.
3. Release the connector lock and pull the air conditioning (A/C) pressure transducer wire connector out.
4. Hold the line fitting boss with one wrench and remove the A/C pressure transducer with another wrench.
5. Discard the O-ring seal.

1. Install the new seal on the A/C pressure transducer.
2. Install the A/C pressure transducer. Tighten: Tighten the pressure transducer, using 2 wrenches, to 8 N.m (71 lb in).
3. Install the electrical connector.
4. Install the air cleaner housing bolts and the air filter housing assembly. Tighten: Tighten the air cleaner housing assembly retaining bolts to 12 N.m (106 lb in).

1. Disconnect the negative battery cable.
2. Discharge and recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
3. Remove the radiator. Refer to «Draining and Filling Cooling System»(/chevrolet/aveo/i-2003-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system) in Engine Cooling.
4. Remove the bolt that secures the liquid evaporator pipe connector block.
5. Remove the receiver-dryer.
6. Cap all the openings to prevent contamination.
7. Remove the upper condenser mount nuts and the washers.
8. Move the condenser to the rear, away from the radiator mount support.
9. Lift the condenser up and out of the engine compartment.

1. Install new O-rings onto the receiver-dryer tube fittings.
2. Ensure that the condenser rubber mounts are in place.
3. Install the condenser into the vehicle. The lower mount shock protectors must fit into the holes provided.
4. Move the condenser forward into the radiator support mount holes.
5. Install the receiver-dryer.
6. Tighten the band clamp bolt.
7. Install the receiver-dryer to the condenser pipe connector block with the nut. Tighten: Tighten the liquid condenser pipe connector block-to-receiver-dryer nut to 10 N.m (89 lb in).
8. Install the liquid pipe connector block to condenser retaining bolt. Tighten: Tighten the liquid pipe connector block to condenser retaining bolt to 14 N.m (124 lb in).
9. Install the refrigerant discharge hose connector block bolt at the condenser. Tighten: Tighten the refrigerant discharge hose connector block bolt to 16 N.m (12 lb ft).
10. Install the radiator. Refer to «Draining and Filling Cooling System»(/chevrolet/aveo/i-2003-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system) in Engine Cooling.
11. Connect the negative battery cable.
12. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .

1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
3. Remove the screw that secures the receiver-dryer band clamp.
4. Remove the receiver-dryer with the bolts.
5. Drain the oil from the receiver-dryer into a container. Measure the amount of oil drained from the receiver dryer and then discard this used oil.

1. Add oil to the new receiver-dryer. Use the exact amount of oil that you drained from the receiver-dryer.
2. Install new O-rings in the seal area recess of the new receiver-dryer.
3. Install the receiver-dryer into the clamp position.
4. Install the connector block retaining bolt to the receiver-dryer. Tighten: Tighten the receiver-dryer bolt to 14 N.m (10 lb ft).
5. Install and tighten the band clamp bolt.
6. Connect the negative battery cable.
7. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .

1. Disconnect the negative battery cable.
2. Remove the instrument panel assembly. Refer to «Instrument Panel (I/P) Assembly Replacement (North America)»(/chevrolet/aveo/i-2003-2008/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) or «Instrument Panel (I/P) Assembly Replacement (European and Non-European)»(/chevrolet/aveo/i-2003-2008/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages, and Console.
3. Drain the cooling system. Refer to «Draining and Filling Cooling System»(/chevrolet/aveo/i-2003-2008/remont/cooling-system-mechanical/#engine-cooling-system__draining-and-filling-cooling-system) in Engine Cooling.
4. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
5. Compress the heater hose clamps at the cowl and slide the clamps toward the engine.
6. Remove the 2 heater hoses from the core lines at the cowl.
7. Turn the condensation drain hose and pull the hose off.
8. Remove the nuts that secure the A/C suction hose and liquid evaporator pipe connector block at the cowl.
9. From the engine side of the cowl, remove the screws that secure the heater/air distribution case assembly to the cowl.
10. Remove the heater/air distribution case assembly from the vehicle.

1. Clean the O-ring surface areas of dirt and contamination.
2. Install 2 new O-rings onto the A/C suction hose and the liquid evaporator pipe at the cowl in the engine compartment.
3. Install the heater/air distribution case assembly and tighten the screws. Tighten: Tighten the heater/air distribution case assembly retaining screws on the cowl side to 8 N.m (71 lb in).
4. Install the A/C suction hose and liquid evaporator pipes onto the evaporator flange connector block and tighten the nut. Tighten: Tighten the liquid evaporator pipe connector block nut to 15 N.m (11 lb ft).
5. Connect the 2 heater hoses to the heater core tubes.
6. Slide the heater hose clamps into position.
7. Install the case condensation drain hose.
8. Install the instrument panel assembly. Refer to «Instrument Panel (I/P) Assembly Replacement (North America)»(/chevrolet/aveo/i-2003-2008/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) or «Instrument Panel (I/P) Assembly Replacement (European and Non-European)»(/chevrolet/aveo/i-2003-2008/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages, and Console.
9. Fill the cooling system.
10. Connect the negative battery cable.
11. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
12. Operate the HVAC control to verify the proper function of the heating and cooling systems.

1. Disconnect the negative battery cable.
2. Remove the instrument panel assembly. Refer to «Instrument Panel (I/P) Assembly Replacement (North America)»(/chevrolet/aveo/i-2003-2008/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) or «Instrument Panel (I/P) Assembly Replacement (European and Non-European)»(/chevrolet/aveo/i-2003-2008/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages, and Console.
3. Remove the heater/air distribution case assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Remove the screws that secure the evaporator case cover.
5. Remove the cover.
6. Slide the evaporator flange support plate upward to facilitate evaporator removal.
7. Remove the evaporator from the case.

1. Install new O-rings onto the evaporator tubes.
2. Install the evaporator core into the case. Center the evaporator flange in the case opening.
3. Install the evaporator core case cover with the screws.
4. Install the heater/air distribution case. Refer to «HVAC Module Assembly Replacement»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Install the instrument panel assembly. Refer to «Instrument Panel (I/P) Assembly Replacement (North America)»(/chevrolet/aveo/i-2003-2008/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) or «Instrument Panel (I/P) Assembly Replacement (European and Non-European)»(/chevrolet/aveo/i-2003-2008/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages, and Console.
6. Connect the negative battery cable.
7. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .

1. Partially drain the cooling system.
2. Compress and slide rearward the two heater hose spring clamps at the fire wall.
3. Gently twist the hose from the left to the right and back again to loosen the bond between the hose and the tube.
4. Remove the end of the hose from the tube.
5. Repeat Steps 3 and 4 with the other hose.
6. Compress the heater hose spring clamp on the inlet coolant line and slide the clamp rearward.
7. Remove the hose from the vehicle.
8. Compress the heater hose spring clamp at the connection below the intake manifold and slide the clamp rearward.
9. Remove hose from the vehicle.

1. Install the left heater hose to the coolant inlet line fitting. Slide the end of the heater hose over the coolant fitting until the hose is seated.
2. Install the right heater hose to the fitting below the intake manifold. Slide the end of the heater hose over the fitting until it is seated.
3. Install and seat the other end of each heater hose.
4. Compress and slide the spring clamps into position on the heater hoses and release the tension on the spring clamps.
5. Filling the cooling system.
6. Check the hoses for leaks.

1. Partially drain the cooling system.
2. Compress and slide rearward the 2 heater hose spring clamps at the cowl.
3. Gently twist the hose from left to right and back again to loosen the bond between the hose and the tube.
4. Remove the end of the hose from the tube.
5. Repeat Steps 3 and 4 with the other hose.
6. Compress the heater hose spring clamp on the inlet coolant line and slide the clamp rearward.
7. Remove the hose from the vehicle.
8. Compress the heater hose spring clamp at the connection below the intake manifold and slide the clamp rearward.
9. Remove the hose from the vehicle.

1. Install the left heater hose to the coolant inlet line fitting. Slide the end of the heater hose over the coolant fitting until the hose is seated.
2. Install the right heater hose to the fitting below the intake manifold. Slide the end of the heater hose over the fitting until it is seated.
3. Install and seat the other end of each heater hose.
4. Compress and slide the spring clamps into position on the heater hoses and release the tension on the spring clamps.
5. Fill the cooling system.
6. Inspect the hoses for leaks.

1. Disconnect the negative battery cable.
2. Remove the instrument panel fuse cover.
3. Pull out the relay at the front of the relay box.

1. Align the relay contacts with the relay terminal slots.
2. Push the relay firmly into the base. The relay must be seated and flushed with the base edge.
3. Replace the instrument panel access panel.
4. Replace the remote mirror/lighting control panel.
5. Connect the negative battery cable.

1. Disconnect the negative battery cable.
2. Disconnect the electrical connector at the resistor.
3. Remove the retaining screws from the resistor.
4. Remove the resistor by gently pulling it downward.

1. Install the new resistor into the heater/air distribution case with the screws. Tighten: Tighten the blower resistor retaining screws to 6 N.m (53 lb in).
2. Connect the electrical connector at the resistor.
3. Connect the negative battery cable.
4. Confirm the proper performance of the blower.

1. Disconnect the negative battery cable.
2. Disconnect the blower motor electrical connector.
3. Remove the blower cooling hose.
4. Remove the screws that secure the motor to the heater/air distribution case.
5. Remove the motor and the seal from the heater/air distribution case by gently pulling the motor straight down and out.

1. Install the blower motor and seal, with the shock mount pads, in the heater/air distribution case. Hold the blower motor in position.
2. Install the screws to secure the blower motor to the heater/air distribution case. Tighten: Tighten the blower motor retaining screws to 6 N.m (53 lb in).
3. Install the blower motor cooling hose.
4. Connect the electrical connector.
5. Connect the negative battery cable.
6. Confirm that the blower motor operates properly.

1. Disconnect the negative battery cable.
2. Remove the instrument panel center upper cover. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Center»(/chevrolet/aveo/i-2003-2008/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages, and Console.
3. Remove the screws and the air deflectors.

1. Install the air deflectors with the screws. Tighten: Tighten the air deflector screws to 2 N.m (18 lb in).
2. Install the instrument panel center upper cover. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Center»(/chevrolet/aveo/i-2003-2008/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages, and Console.
3. Connect the negative battery cable.

1. Raise the hood.
2. Disconnect the negative battery cable.
3. Remove the instrument panel assembly from the vehicle. Refer to «Instrument Panel (I/P) Assembly Replacement (North America)»(/chevrolet/aveo/i-2003-2008/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) or «Instrument Panel (I/P) Assembly Replacement (European and Non-European)»(/chevrolet/aveo/i-2003-2008/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
4. Remove the heater/air distribution case from the vehicle. Refer to «HVAC Module Assembly Replacement»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Remove the linkage screw from the lower heater core cover post.
6. Remove the linkage lever. Note the position of all the levers to facilitate reassembly.
7. Remove the screws that secure the heater core cover.
8. Slowly separate the lower heater core cover from the rest of the assembly. Retain the sealant.
9. Remove the screw and the bracket clamp that secure the heater core lines to the case.
10. Remove the spring clamp that secures the heater core body to the case.
11. Remove the heater core from the case.

1. Install the heater core into the case.
2. Secure the heater core lines to the case with the retaining bracket clamp and the screw.
3. Install the heater core body with the retaining spring clamp.
4. Reapply the sealant to the heater core cover mounting channel flange as removed.
5. Install the heater core cover.
6. Install the retaining screws.
7. Install the linkage lever onto the cover post with the screw.
8. Confirm proper operation of the actuating levers for the heater/air distribution case doors.
9. Install the heater/air distribution case. Refer to «HVAC Module Assembly Replacement»(/chevrolet/aveo/i-2003-2008/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
10. Install the instrument panel assembly. Refer to «Instrument Panel (I/P) Assembly Replacement (North America)»(/chevrolet/aveo/i-2003-2008/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) or «Instrument Panel (I/P) Assembly Replacement (European and Non-European)»(/chevrolet/aveo/i-2003-2008/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
11. Fill the cooling system.
12. Connect the negative battery cable.

Scheme 2

Special Tools

Special Tools Illustration Tool Number/ Description J 5403 Snap Ring Pliers J 6083 Snap Ring Pliers J 8092 Drive Handle J 8433-1 Puller Crossbar J 8433-3 Forcing Screw J 9398-A Bearing Remover J 9481-A Bearing Installer J 9553-1 O-Ring Remover J 9625-A Pressure Test Set J 23128-A Seal Seat Remover and Installer J 33011 O-Ring Installer J 33013-B Hub and Drive Plate Remover and Installer J 33017 Pulley Rotor and Bearing Assembly Installer J 33019 Bearing Staking Tool Set J 33020 Pulley Puller J 33022 Shaft Nut Socket J 33023-A Puller Pilot J 33024 Clutch Coil Installer Adapter J 33025 Clutch Coil Puller Legs J 33027-A Clutch Hub Holding Tool J 34614 Shaft Seal Protector J 34993 Cylinder Alignment Rods J 35372 Support Block J 42428 Compressor Holding Fixture

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

Scheme 14

See also:
• Too Hot in Vehicle
• Battery Disconnect Caution
• Fastener Notice
• Protective Goggles and Glove Caution
• Draining and Filling Cooling System
• Instrument Panel (I/P) Assembly Replacement (North America)
• Blower Motor Resistor Replacement
• HVAC Preliminary Checks
• Leak Testing
• Special Tools
• Refrigerant Recovery and Recharging
• Compressor Clutch Plate/Hub Assembly Install
• Compressor Leak Testing
• Compressor Clutch Coil Install
• Clutch Rotor and/or Bearing Install