Heating, Ventilation, and Air Conditioning: Other Chevrolet Aveo I facelift

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.

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»(ref-300897-S07406155072008101600000) .
8. Leak check the system. Refer to «Leak Testing»(ref-300897-S30099081072008101600000) . 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»(ref-300831-S05861601612008101600000) .

Pressure Temperature Relationship of R-134A

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.

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.

Tools Required

DW-610-010 Clutch Hub Holding Tool. See Special Tools .

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

J 5403 Snap Ring Pliers. See Special Tools .

J 5403 Snap Ring Pliers. See Special Tools .

Clutch Rotor and/or Bearing Install (V5 Compressor)

Tools Required

1. J 33017 Pulley Rotor and Bearing Assembly Installer. See «Special Tools»(ref-300897-S25091623852008101600000) .
2. J 33019 Bearing Staking Guide/Bearing Staking Pin. See «Special Tools»(ref-300897-S25091623852008101600000) .
3. J 33023-A Puller Pilot. See «Special Tools»(ref-300897-S25091623852008101600000) .
4. J 42428 Compressor Holding Fixture. See «Special Tools»(ref-300897-S25091623852008101600000) .
5. J 6083 Snap Ring Pliers
6. J 8092 Driver Handle. See «Special Tools»(ref-300897-S25091623852008101600000) .
7. J 8433-1 Puller Crossbar. See «Special Tools»(ref-300897-S25091623852008101600000) .
8. J 8433-3 Forcing Screw. See «Special Tools»(ref-300897-S25091623852008101600000) .
9. J 9481-A Bearing Installer. See «Special Tools»(ref-300897-S25091623852008101600000) .

Clutch Rotor and/or Bearing Install (SP10 Compressor)

1. Locate the rotor pulley on the front head housing squarely and precisely.
2. Insert the pulley and bearing assembly by gradually increasing the force on the pulley surface.
3. Check for proper installation of the pulley by spinning it.
4. Install the retainer ring using the snap ring pliers (1).
5. Place the shim(s) on the shaft shoulder. Determine type and quantity of shim(s) to use to make an air gap of the specified size. Specification: 0.3-0.7 mm (0.012-0.028 in)
6. Install the clutch and drive assembly. Refer to «Compressor Clutch Plate/Hub Assembly Install (V5 Compressor)»(ref-300897-S20853446722008101600000) or «Compressor Clutch Plate/Hub Assembly Install (SP10 Compressor)»(ref-300897-S11462306632008101600000) .

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