Heating, Ventilation and Air Conditioning Chevrolet Cobalt I

Fastener Tightening Specifications

Fastener Tightening Specifications

Refrigerant System Capacities

Refrigerant System Capacities

The Heating, Ventilation and Air Conditioning (HVAC) system is divided into two separate sections. The first, Heating, Ventilation and Air Conditioning, has all procedures that pertain to a HVAC component or function that is not specifically associated with the manual control system. The second, HVAC Systems-Manual, has all procedures specific to the manual control system.

Begin the system diagnosis with the Symptoms - HVAC Systems - Manual in HVAC Systems-Manual.

Review the Description and Operation information to help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. The HVAC Description and Operation information is divided into

1. «Air Delivery Description and Operation»(/chevrolet/cobalt/i-2004-2010/remont/manual-hvac-system/#hvac-systems-manual__air-delivery-description-and-operation) in HVAC Systems-Manual
2. «Air Temperature Description and Operation»(/chevrolet/cobalt/i-2004-2010/remont/manual-hvac-system/#hvac-systems-manual__air-temperature-description-and-operation) in HVAC Systems-Manual

The Air Delivery Description and Operation contains the following topics

1. Air Speed
2. Air Distribution

The Air Temperature Description and Operation contains the following topics

1. Heater Mode
2. A/C Mode
3. A/C Cycle

Leak Testing

Tools Required

1. J 39400-A Halogen Leak Detector
2. J 41447 Leak Detection Dye. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
3. J 42220 Leak Detection Lamp. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
4. J 43872 Fluorescent Dye Cleaner. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
5. J 46297 A/C Dye Injector Kit. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
6. J 46297-12 Replacement Dye Cartridges. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .

Refrigerant Leak Testing

The fluorescent dye mixes and flows with the polyalkylene glycol (PAG) oil throughout the refrigerant system.

Verifying some passive leaks may require using the J 39400-A , even though the A/C system contains fluorescent dye.

The only time that adding additional fluorescent dye is required is after flushing the A/C system.

Fluorescent Leak Detector

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 PAG 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 compressor shaft seal 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 J 42220 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
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 J 43872 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .

Fluorescent Dye Injection

1. Not all of the fluorescent dyes are compatible with PAG oil. Some types of dye decrease the oil viscosity or may chemically react with the oil.
2. R-134A leak detection dye requires time to work. Depending upon the leak rate, a leak may not become visible for between 15 minutes and 7 days.
3. To prevent false diagnosis, thoroughly clean any residual dye from the service port with a rag and the approved fluorescent dye cleaner J 43872 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .

Halogen Leak Detector

Ensure that the vehicle has at least 0.45 kg (1 lb) of refrigerant in the A/C refrigeration system in order to perform a leak test. Refer to Refrigerant Recovery and Recharging for recharging the A/C system.

Clean and dry all surfaces in order to prevent a false warning. Liquids will damage the detector.

Follow the instructions supplied with the J 39400-A .

Air Conditioning (A/C) System Performance Test (L61)

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 (L61)

A/C Performance Table

Air Conditioning (A/C) System Performance Test (LSJ)

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

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 (LSJ)

A/C Performance Table

Air Conditioning (A/C) Diagnostics - Pressure Zone A

Air Conditioning (A/C) Diagnostics - Pressure Zone A

Air Conditioning (A/C) Diagnostics - Pressure Zone B

Air Conditioning (A/C) Diagnostics - Pressure Zone B

Air Conditioning (A/C) Diagnostics - Pressure Zone C

Air Conditioning (A/C) Diagnostics - Pressure Zone C

Air Conditioning (A/C) Diagnostics - Pressure Zone D

Air Conditioning (A/C) Diagnostics - Pressure Zone D

Heating Performance Diagnostic

Heating Performance Diagnostic

Defrosting Insufficient

Defrosting Insufficient

Noise Diagnosis - Blower Motor

Noise Diagnosis - Blower Motor

Noise Diagnosis - Air Conditioning (A/C) System

Noise Diagnosis - Air Conditioning (A/C) System

Noise Diagnosis - HVAC Module

Noise Diagnosis - HVAC Module

Odor Diagnosis

Odor Diagnosis

Eliminating Air Conditioning 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 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 HVAC module case 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 of the 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 clutch operation.

Refrigerant Recovery and Recharging

Tools Required

1. J 43600 ACR 2000 Air Conditioning Service Center. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
2. J 45037 A/C Oil Injector. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .

Note. R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure.

Note. To avoid system damage use only R-134a dedicated tools when servicing the A/C system.

Note. Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result.

Note. R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing.

The J 43600 is a complete air conditioning service center for R-134a. See Special Tools . 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. The ACR 2000 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.

Refer to the J 43600 ACR 2000 manual for operation and setup instruction. See Special Tools . Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities 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. Oil can be injected into a charged system using J 45037 . See Special Tools . For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities .

Flushing

Tools Required

1. J 41447 R-134a-Leak Detection Dye. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
2. J 42220 Universal 12V Leak Detection Lamp. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
3. J 43600 ACR 2000 Air Conditioning Service Center. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
4. J 45268 A/C Flush Adapter Kit. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .

Flushing is intended to remove the following

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

Forward Flushing Setup

1. Install both J 45268-9 (2) onto the J 45268-10 (3).
2. Install the J 45268-7 (4) onto the suction side of the J 45268-10 (3).
3. Install the J 45268-8 (1) onto the discharge side of the J 45268-10 (3).

Reverse Flushing Setup

1. Install both J 45268-9 (2) onto the J 45268-10 (3).
2. Install the J 45268-8 (1) onto the suction side of the J 45268-10 (3).
3. Install the J 45268-7 (4) onto the discharge side of the J 45268-10 (3).

Scheme 1

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the thermal expansion valve (TXV). Refer to «Thermal Expansion Valve Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the stud onto the J 45268-115.
4. Install new sealing washers onto the evaporator core. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Install J 45268-115 in place of the TXV.
6. Install TXV mounting bolts. Tighten: Tighten the bolts to 7 N.m (62 lb in).
7. Install new washers onto the condenser tube and evaporator hose. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
8. Connect the condenser tube and evaporator hose to the J 45268-115.
9. Install the TXV block fitting nut. Tighten: Tighten the nut to 20 N.m (15 lb ft).
10. Remove the A/C compressor. Refer to «Compressor Replacement (2.2L - L61)»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-replacement-22l-l61) or «Compressor Replacement (2.0L - LSJ)»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-replacement-20l-lsj) .
11. Remove the A/C refrigerant filter. Refer to «Air Conditioning (A/C) Refrigerant Filter Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
12. Service the filter with AC Delco P/N GF 470, before each flush.
13. Install the J 45268-10 to the compressor hose assembly.
14. Connect the J 45268-1 flush filter to the J 45268-7 flush adapter.
15. Connect the blue hose from the J 43600 to J 45268-1 flush filter adapter. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
16. Connect the red hose from the J 43600 to J 45268-8 flush adapter. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
17. Flush the A/C system. Follow the instructions supplied with the J 43600 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
18. Disconnect the red hose from the J 43600 to J 45268-8 flush adapter. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
19. Disconnect the blue hose from the J 43600 to J 45268-1 flush filter adapter. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
20. Disconnect the J 45268-1 flush filter from the J 45268-10 flush adapter.
21. Remove the J 45268-10 from the compressor hose assembly.
22. If you will reinstall the removed A/C compressor, perform the following procedure: Remove the A/C compressor drain plug. Drain the PAG oil from the A/C compressor. Rotate the compressor input shaft to assist in draining the PAG oil from the compressor. Add the total system capacity of PAG oil to the crankcase of the A/C compressor. Refer to «Refrigerant System Capacities»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-capacities) . IMPORTANT: Flushing will remove the fluorescent leak detection dye from the A/C system. Add one bottle of J 41447 directly into the A/C compressor. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Install the A/C compressor drain plug. Tighten: Tighten the drain plug to 15 N.m (11 lb ft).
23. Install the A/C compressor. Refer to «Compressor Replacement (2.2L - L61)»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-replacement-22l-l61) or «Compressor Replacement (2.0L - LSJ)»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-replacement-20l-lsj) .
24. Install the A/C refrigerant filter. Refer to «Air Conditioning (A/C) Refrigerant Filter Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
25. Remove the TXV block fitting nut.
26. Disconnect the condenser tube and evaporator hose from the J45268-115.
27. Remove the TXV bolts retaining the J 45268-115.
28. Remove the J 45268-115.
29. Inspect the TXV for debris. Clean or replace as needed.
30. Install the TXV. Refer to «Thermal Expansion Valve Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
31. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
32. Leak test the fittings using J 42220 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .

Draining Procedure

1. Remove the compressor crankcase oil drain plug and drain the crankcase into a clean, graduated container.
2. Drain the oil from both the suction and discharge ports of the removed compressor into the same container. Rotate the compressor shaft to assist in draining the compressor.
3. Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor.
4. Properly discard the used refrigerant oil.

Balancing Procedure

1. The replacement compressor is shipped with 74 ml (2.5 oz) of refrigerant oil.
2. Compare the amount of refrigerant oil recorded during compressor removal to the amount of refrigerant oil shipped in the replacement compressor. If the amount of refrigerant oil drained and recorded from the removed compressor is: Less than 74 ml (2.5 oz) Leave the 74 ml (2.5 oz) in the replacement compressor. More than 74 ml (2.5 oz) Add to the compressor the difference between the 74 ml (2.5 oz) and the amount drained.

Compressor Replacement (2.2L - L61)

Tools Required

1. J 39400-A Halogen Leak Detector
2. J 44811 Accessory Belt Tensioner Unloader

Removal Procedure

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cobalt/i-2004-2010/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
3. Remove the front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/cobalt/i-2004-2010/remont/exterior-body-panels/#body-front-end) in Body Front End.
4. Use J 44811 to rotate the drive belt tensioner counterclockwise to release the spring tension.
5. Remove the drive belt.
6. Disconnect the electrical connector from the compressor.
7. Remove the compressor and condenser hose assembly bolt from the compressor.
8. Remove the compressor and condenser hose assembly from the compressor.
9. Remove and discard the sealing washers.
10. Remove the compressor mounting bolts.
11. Remove the compressor.

Installation Procedure

1. If you are replacing the compressor, refer to «Compressor Oil Balancing»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Install the compressor and the bolts to the engine. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
3. Install new sealing washers on the hose fittings. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Install the hose assembly to the compressor.
5. Install the assembly bolt. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
6. Connect the compressor electrical connector.
7. Use J 44811 to rotate the drive belt tensioner counterclockwise to release the spring tension.
8. Install the drive belt.
9. Install the front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/cobalt/i-2004-2010/remont/exterior-body-panels/#body-front-end) in Body Front End.
10. Lower the vehicle.
11. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
12. Leak test the fittings using J 39400-A .

Compressor Replacement (2.0L - LSJ)

Tools Required

1. J 39400-A Halogen Leak Detector
2. J 44811 Accessory Belt Tensioner Unloader

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cobalt/i-2004-2010/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
3. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/cobalt/i-2004-2010/remont/exterior-body-panels/#body-front-end) in Body Front End.
4. Remove the drive belt. Refer to «Drive Belt Replacement»(/chevrolet/cobalt/i-2004-2010/remont/mechanical/#engine-mechanical-20l) .
5. Disconnect the electrical connector from the compressor.
6. Remove the compressor and condenser hose assembly bolt from the compressor.
7. Remove the compressor and condenser hose assembly from the compressor.
8. Remove and discard the sealing washers.
9. Remove the auxiliary intercooler pump bolts and position the pump toward the driver side of the vehicle.
10. Remove the compressor mounting bolts.
11. Remove the compressor.

1. If you are replacing the compressor, refer to «Compressor Oil Balancing»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Install the compressor and the bolts to the engine. Tighten: Tighten the bolts to 25 N.m (18 lb ft).
3. Install new sealing washers on the hose fittings. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Install the hose assembly to the compressor.
5. Install the assembly bolt. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
6. Connect the compressor electrical connector.
7. Install the auxiliary intercooler pump. Tighten: Tighten the pump bolt to 10 N.m (88 lb in).
8. Use J 44811 to rotate the drive belt tensioner counterclockwise to release the spring tension.
9. Install the drive belt.
10. Install the front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/cobalt/i-2004-2010/remont/exterior-body-panels/#body-front-end) in Body Front End.
11. Lower the vehicle.
12. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
13. Leak test the fittings using J 39400-A .

Compressor Clutch Assembly Replacement

Tools Required

1. J 37872 Universal Spanner Wrench. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
2. J 6083 Snap Ring Pliers. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .

1. Remove the compressor. Refer to «Compressor Replacement (2.2L - L61)»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-replacement-22l-l61) or «Compressor Replacement (2.0L - LSJ)»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-replacement-20l-lsj) .
2. Remove and discard the compressor clutch plate bolt. Use the J 37872 to hold the compressor clutch plate from turning. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
3. Remove the compressor clutch plate from the compressor.
4. Remove the compressor pulley snap ring using the J 6083 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
5. Remove the compressor pulley from the compressor.
6. Remove the compressor clutch coil snap ring using the J 6083 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
7. Remove the compressor clutch coil from the compressor.

1. Carefully clean the clutch plate bolt threads with a M6x1.0 tap. Carefully blow out debris with compressed air.
2. Install the compressor clutch coil to the compressor.
3. Install the compressor clutch coil snap ring using the J 6083 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
4. Install the compressor pulley to the compressor.
5. Install the compressor pulley snap ring using the J 6083 . See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .
6. Place a small amount of oil on the 0.4 mm (0.016 in) air gap shim and place inside the clutch drive plate.
7. Install the compressor clutch plate to the compressor.
8. Measure the air gap between the pulley and the drive plate. Adjust the shims to achieve a 0.3-0.6 mm (0.012-0.024 in) air gap.
9. Install the clutch drive plate bolt.
10. Tighten the compressor clutch drive plate bolt. Use the J 37872 to hold the compressor clutch plate from turning. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Tighten: Tighten the bolt to 12 N.m (9 lb ft).
11. Install the compressor. Refer to «Compressor Replacement (2.2L - L61)»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-replacement-22l-l61) or «Compressor Replacement (2.0L - LSJ)»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__compressor-replacement-20l-lsj) .
12. Leak test the fittings using the J 39400-A .

Tools Required

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cobalt/i-2004-2010/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
3. Remove the pressure relief valve from the compressor.

1. Install the pressure relief valve and seal to the compressor. Tighten: Tighten the compressor pressure relief valve to 7 N.m (62 lb in).
2. Lower the vehicle.
3. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
4. Leak test the fittings using the J 39400-A .

1. Remove the seal washer from the A/C refrigerant component.
2. Inspect the seal washer for signs of damage to help determine the root cause of the failure.
3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary.
4. Discard the sealing washer.

1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer.
2. Remove the cap or tape from the A/C refrigerant components.
3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components.
4. Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting.
5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure.

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the compressor hose from the evaporator hose.
3. Remove and discard the seal washer.
4. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cobalt/i-2004-2010/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
5. Remove the lower right radiator mount.
6. Drain the intercooler system. Refer to «Draining and Filling Cooling System - Charge Air Cooling System»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
7. Remove the auxiliary intercooler pump. Refer to «Coolant Pump Replacement - Charge Air Cooler»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
8. Remove the mounting cover from the charge air cooler pump and position the pump forward.
9. Disconnect the electrical connector from the pressure transducer.
10. Remove the compressor and condenser hose assembly bolt from the compressor.
11. Remove the compressor and condenser hose assembly from the compressor.
12. Remove and discard the sealing washers.
13. Remove the compressor hose from the condenser.
14. Remove and discard the seal washer.

1. Route the compressor hose to the evaporator hose.
2. Install new sealing washers on the compressor and condenser hose fittings. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the A/C compressor and condenser hose assembly to the compressor.
4. Install the A/C compressor and condenser hose assembly bolt. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
5. Install a new seal washer to the compressor hose. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. Install the compressor hose and bolt to the condenser. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
7. Connect the pressure transducer electrical connector.
8. Install the auxiliary intercooler pump. Refer to «Coolant Pump Replacement - Charge Air Cooler»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
9. Install the lower right radiator mount.
10. Install the charge cooler pump. Tighten: Tighten the bolts to 10 N.m (88 lb in).
11. Lower the vehicle.
12. Install a new seal washer to the compressor hose. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
13. Install the compressor hose and nut to the evaporator hose. Tighten: Tighten the nut to 20 N.m (15 lb ft).
14. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
15. Leak test the fittings using the J 39400-A .
16. Fill the intercooler system with coolant. Refer to «Draining and Filling Cooling System - Charge Air Cooling System»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cobalt/i-2004-2010/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
3. Disconnect the electrical connector from the pressure transducer.
4. Remove the compressor and condenser hose assembly bolt from the compressor.
5. Remove the compressor and condenser hose assembly from the compressor.
6. Remove and discard the sealing washers.
7. Remove the compressor hose from the condenser.
8. Remove and discard the seal washer.
9. Lower the vehicle.
10. Remove the compressor hose from the evaporator hose.
11. Remove and discard the seal washer.

1. Install new sealing washers on the compressor and condenser hose fittings. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Install the A/C compressor and condenser hose assembly to the compressor.
3. Install the A/C compressor and condenser hose assembly bolt. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
4. Install new seal washer to the compressor hose. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Install the compressor hose and nut to the evaporator hose. Tighten: Tighten the nut to 20 N.m (15 lb ft).
6. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cobalt/i-2004-2010/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
7. Install new seal washer to the compressor hose. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
8. Install the compressor hose and bolt to the condenser. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
9. Connect the pressure transducer electrical connector.
10. Lower the vehicle.
11. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
12. Leak test the fittings using the J 39400-A .

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cobalt/i-2004-2010/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
3. Remove the condenser tube bolt and tube from the condenser.
4. Remove and discard the sealing washers.
5. Lower the vehicle.
6. Remove the condenser tube from the frame rail.
7. Remove the condenser tube from the front of dash.
8. Remove the condenser tube and evaporator hose from the thermal expansion valve (TXV).
9. Remove and discard the seal washer.

1. Install new sealing washers on the condenser tube and evaporator hose fittings. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Install the condenser tube and evaporator hose to the TXV.
3. Install the TXV nut. Tighten: Tighten the nut to 20 N.m (15 lb ft).
4. Install the condenser tube to the front of dash. Tighten: Tighten the nut to 10 N.m (88 lb in).
5. Install the condenser tube to the frame rail.
6. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cobalt/i-2004-2010/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
7. Install a new seal washer to the condenser tube. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
8. Install the condenser tube and bolt to the condenser. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
9. Lower the vehicle.
10. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
11. Leak test the fittings using the J 39400-A .

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cobalt/i-2004-2010/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
3. Remove the condenser tube bolt and tube from the condenser.
4. Remove and discard the sealing washers.
5. Lower the vehicle.
6. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/cobalt/i-2004-2010/remont/testing-diagnostics/#engine-controls-22l-introduction) in Engine Controls - 2.2L - L61.
7. Remove the condenser tube from the frame rail.
8. Remove the condenser tube from the front of dash.
9. Remove the condenser tube and evaporator hose from the thermal expansion valve (TXV).
10. Remove and discard the seal washer.

1. Install new sealing washers on the condenser tube and evaporator hose fittings. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Install the condenser tube and evaporator hose to the TXV.
3. Install the TXV nut. Tighten: Tighten the nut to 20 N.m (15 lb ft).
4. Install the condenser tube to the front of dash. Tighten: Tighten the nut to 10 N.m (88 lb in).
5. Install the condenser tube to the frame rail.
6. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/cobalt/i-2004-2010/remont/testing-diagnostics/#engine-controls-22l-introduction) in Engine Controls - 2.2L - L61.
7. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cobalt/i-2004-2010/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
8. Install a new seal washer to the condenser tube. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
9. Install the condenser tube and bolt to the condenser. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
10. Lower the vehicle.
11. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
12. Leak test the fittings using the J 39400-A .

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the compressor hose from the evaporator hose.
3. Remove and discard the seal washer.
4. Remove the retainer clamp from the evaporator hose.
5. Remove the condenser tube and the evaporator hose from the thermal expansion valve (TXV).
6. Remove and discard the seal washers.

1. Install new sealing washers on the condenser tube and evaporator hose fittings. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Install the condenser tube and evaporator hose to the TXV.
3. Install the TXV nut. Tighten: Tighten the nut to 20 N.m (15 lb ft).
4. Install the new seal washer to the compressor hose. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Install the compressor hose and nut to the evaporator hose. Tighten: Tighten the nut to 20 N.m (15 lb ft).
6. Install the retainer clamp to the evaporator hose.
7. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
8. Leak test the fittings using the J 39400-A .

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the compressor hose from the evaporator hose.
3. Remove and discard the seal washer.
4. Remove the condenser tube and evaporator hose from the thermal expansion valve (TXV).
5. Remove and discard the seal washers.

1. Install new sealing washers on the condenser tube and evaporator hose fittings. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Install the condenser tube and evaporator hose to the TXV.
3. Install the TXV nut. Tighten: Tighten the nut to 20 N.m (15 lb ft).
4. Install new seal washer to the compressor hose. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Install the compressor hose and nut to the evaporator hose. Tighten: Tighten the nut to 20 N.m (15 lb ft).
6. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
7. Leak test the fittings using the J 39400-A .

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the condenser tube and evaporator hose from the thermal expansion valve (TXV).
3. Remove and discard the seal washer.
4. Remove the refrigerant filter from the condenser tube.

1. Install the refrigerant filter into the condenser tube.
2. Install new sealing washers on the condenser tube and evaporator hose fittings. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the condenser tube and evaporator hose to the TXV.
4. Install the TXV nut. Tighten: Tighten the nut to 20 N.m (15 lb ft).
5. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
6. Leak test the fittings using the J 39400-A .

J 44551 Suction Screen Kit. See Special Tools .

The suction screens are available in 3 different sizes.

1. Insert the J 44551-6 Sizing Tool (1) into the suction hose to select the correct size suction screen.
2. Insert the suction screen into the compressor end of the suction hose.
3. Install the correct mandrel (1) to the J 44551-5 Screen Installation Tool.
4. Install the J 44551-5 (3) over the end of the suction hose and the suction screen (2).
5. Tighten the forcing screw of the J 44551-5. The suction screen is fully installed when the screen is flush with the end of the suction hose fitting.
6. Remove the J 44551-5 from the suction hose.
7. Install the J 44551-1 Suction Screen Notification Label.

Service Port Valve Core Replacement

Tools Required

1. J 39400-A Halogen Leak Detector
2. J 46246 Valve Core Tool. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the service port valve core using J 46246 or equivalent. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) .

1. Install the service port valve core using J 46246 or equivalent. See «Special Tools»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__special-tools) . Tighten: Tighten the service port valve core to 2.5 N.m (22 lb in).
2. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
3. Leak test the fittings using the J 39400-A .

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the condenser tube and evaporator hose from the thermal expansion valve (TXV).
3. Remove and discard the seal washers.
4. Remove the TXV bolts.
5. Remove the TXV.
6. Remove and discard the seal washers.

1. Install new seal washers to the evaporator core fittings. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Install the TXV.
3. Install the TXV bolts. Tighten: Tighten the bolts to 7 N.m (62 lb in).
4. Install new sealing washers on the condenser tube and evaporator hose fittings. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Install the condenser tube and evaporator hose to the TXV.
6. Install the TXV nut. Tighten: Tighten the nut to 20 N.m (15 lb ft).
7. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
8. Leak test the fittings using the J 39400-A .

J 39400-A Halogen Leak Detector

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cobalt/i-2004-2010/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Disconnect the electrical connector from the pressure sensor.
3. Remove the pressure sensor from the compressor hose.
4. Remove and discard the seal.

1. Install a new seal in the pressure sensor.
2. Install the pressure sensor to the compressor hose. Tighten: Tighten the pressure sensor to 5 N.m (44 lb in).
3. Connect the pressure sensor electrical connector.
4. Lower the vehicle.
5. Leak test the fittings using the J 39400-A .

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cobalt/i-2004-2010/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
3. Remove the compressor hose from the condenser.
4. Remove the condenser tube from the condenser.
5. Remove the condenser bolts.
6. Slide the condenser down to disengage the upper mounting tabs from the radiator.
7. Remove the right and left radiator side baffles.

1. If replacing the condenser add the specified amount of PAG oil directly to the condenser. Refer to «Refrigerant System Capacities»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-capacities) .
2. Install the right and left radiator side baffles.
3. Slide the condenser up to engage the upper mounting tabs into the radiator brackets.
4. Install the condenser bolts. Tighten: Tighten the bolts to 10 N.m (88 lb in).
5. Install the compressor hose and new seal washer to the condenser. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . Tighten: Tighten the bolt to 20 N.m (15 lb ft).
6. Install the condenser tube and new seal washer to the condenser. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . Tighten: Tighten the bolt to 20 N.m (15 lb ft).
7. Lower the vehicle.
8. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
9. Leak test the fittings using the J 39400-A .

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cobalt/i-2004-2010/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
3. Remove the compressor hose from the condenser.
4. Remove the condenser tube from the condenser.
5. Remove the condenser bolts.
6. Slide the condenser down to disengage the upper mounting tabs from the radiator.
7. Remove the right and left radiator side baffles.

1. If replacing the condenser add the specified amount of PAG oil directly to the condenser. Refer to «Refrigerant System Capacities»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-capacities) .
2. Install the right and left radiator side baffles.
3. Slide the condenser up to engage the upper mounting tabs into the radiator.
4. Install the condenser bolts. Tighten: Tighten the bolts to 10 N.m (88 lb in).
5. Install the compressor hose and new seal washer to the condenser. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . Tighten: Tighten the bolt to 20 N.m (15 lb ft).
6. Install the condenser tube and new seal washer to the condenser. Refer to «Sealing Washer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . Tighten: Tighten the bolt to 20 N.m (15 lb ft).
7. Lower the vehicle.
8. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
9. Leak test the fittings using the J 39400-A .

1. Remove the HVAC module from the vehicle. Refer to «HVAC Module Assembly Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__hvac-module-assembly-replacement) .
2. Remove the heat stakes from the heater core cover using a small chisel and remove the cover.
3. Remove the heater core.
4. Remove the heat stakes that secure the lower HVAC case to the HVAC module using a small chisel.
5. Unsnap and open the passenger compartment filter door.
6. Remove the lower HVAC case.
7. Remove the evaporator core.

1. Install the evaporator core into the HVAC module assembly.
2. Install the lower HVAC case.
3. Install the lower HVAC case screws. Tighten: Tighten the screws to 1.8 N.m (16 lb in).
4. Close and secure the passenger compartment filter door.
5. Inspect the foam heater core seal on the lower HVAC case. If damaged, replace using Kent Industries adhesive black foam tape P/N 46480 or equivalent.
6. Install the heater core into the HVAC module.
7. Install the heater core cover and the screws. Tighten: Tighten the screws to 1.8 N.m (16 lb in).
8. Replace the drain tube seal.
9. Replace the front of dash seal.
10. Inspect and replace the following HVAC module seals if damaged: The defrost duct seal The HVAC module to cross car duct seal The center air outlet duct seal The center floor air outlet duct seal The air inlet seal
11. Install the HVAC module in the vehicle. Refer to «HVAC Module Assembly Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__hvac-module-assembly-replacement) .
12. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
13. Leak test the fittings using J 39400-A .
14. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.0L - LSJ)»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (2.2L - L61)»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) .

1. Remove the HVAC module from the vehicle. Refer to «HVAC Module Assembly Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__hvac-module-assembly-replacement) .
2. Remove the heater core cover heat stakes.
3. Remove the heater core cover.
4. Remove the heater core.
5. Remove the lower HVAC case heat stakes.
6. Unsnap and open the passenger compartment filter door.
7. Remove the lower HVAC case.

1. Install the lower HVAC case.
2. Install the new lower HVAC case screws. Tighten: Tighten the screws to 1.8 N.m (15 lb in).
3. Close and secure the passenger compartment filter door.
4. Inspect the foam heater core seal on the lower HVAC case. If damaged, replace using Kent Industries adhesive black foam tape P/N 46480 or equivalent.
5. Install the heater core into the HVAC module.
6. Install the heater core cover. Tighten: Tighten the screws to 1.8 N.m (15 lb in).
7. Install new heater core cover screws
8. Replace the drain tube seal.
9. Replace the front of dash seal.
10. Inspect and replace the HVAC module seals if damaged: The defrost duct seal The HVAC module to cross car duct seal The center air outlet duct seal The center floor air outlet duct seal The air inlet seal
11. Install the HVAC module in the vehicle. Refer to «HVAC Module Assembly Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__hvac-module-assembly-replacement) .
12. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.0L - LSJ)»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (2.2L - L61)»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) .

HVAC Module Assembly Replacement

Tools Required

1. J 39400-A Halogen Leak Detector
2. SA9111E Hose Clamp Pliers

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/cobalt/i-2004-2010/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
2. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
3. Drain the cooling system. Refer to «Draining and Filling Cooling System (2.0L - LSJ)»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (2.2L - L61)»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
4. Reposition the heater outlet hose clamp at the heater core using SA9111E .
5. Remove the heater outlet hose from the heater core.
6. Position the hose upright against the front of dash.
7. Reposition the heater inlet hose clamp at the heater core using SA9111E .
8. Remove the heater inlet hose from the heater core.
9. Position the hose upright against the front of dash.
10. Remove the condenser tube and evaporator hose from the thermal expansion valve (TXV).
11. Remove and discard the seal washers.
12. Raise the center floor outlet duct while pushing the floor ducts down to disengage the ducts.
13. Rotate the center floor outlet duct forward in the vehicle and pull down to disengage the duct from the HVAC module.
14. Disconnect the blower motor connector.
15. Disconnect the blower motor resistor electrical connector.
16. Remove the instrument panel (I/P) retainer. Refer to «Instrument Panel (I/P) Retainer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages, and Console.
17. Disconnect the recirculation actuator electrical connector.
18. Remove the cross car beam retaining bolts.
19. Remove the cross car beam.
20. Remove the HVAC module from the vehicle.

1. Replace the drain tube seal.
2. Replace the front of dash seal.
3. Inspect and replace the HVAC module seals if damaged: The defrost duct seal The HVAC module to cross car duct seal The center air outlet duct seal The center floor air outlet duct seal The air inlet seal
4. Place the HVAC module in the vehicle. Align the HVAC module drain tube and front of dash studs to the vehicle.
5. Install the cross car beam.
6. Install the cross car beam retaining bolts.
7. Connect the recirculation actuator electrical connector.
8. Install the I/P retainer. Refer to «Instrument Panel (I/P) Retainer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages, and Console.
9. Connect the blower motor connector.
10. Connect the blower motor resistor electrical connector.
11. Align the center floor duct with the HVAC module.
12. Push the center floor duct up while rotating rearward in the vehicle to install on the HVAC module.
13. Push down on the floor duct while rotating the center floor outlet ducts to align the ducts.
14. Slide the center floor outlet duct down into position in the floor ducts.
15. Install the heater outlet hose to the heater core.
16. Reposition the hose clamp to secure the hose using SA9111E .
17. Install the heater inlet hose to the heater core.
18. Reposition the hose clamp to secure the hose using SA9111E .
19. Install new sealing washers on the condenser tube and evaporator hose fittings.
20. Install the condenser tube and evaporator hose to the TXV.
21. Install the TXV nut. Tighten: Tighten the nut to 20 N.m (15 lb ft).
22. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
23. Leak test the fittings using the J 39400-A .
24. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/cobalt/i-2004-2010/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
25. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.0L - LSJ)»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (2.2L - L61)»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.

J 39400-A Halogen Leak Detector

Scheme 2

1. Remove the HVAC module from the vehicle. Refer to «HVAC Module Assembly Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__hvac-module-assembly-replacement) .
2. Remove the heater core cover heat stakes with a small chisel.
3. Remove the heater core.
4. Unsnap and open the passenger compartment filter door.
5. Remove the lower HVAC case screws.
6. Remove the lower HVAC case.
7. Remove the evaporator core.

1. If replacing the evaporator core, add polyalkylene glycol (PAG) oil to the evaporator core. Refer to «Refrigerant System Capacities»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-capacities) .
2. Install new seal washers to the evaporator core fittings.
3. Install the thermal expansion valve (TXV).
4. Install the TXV bolts. Tighten: Tighten the TXV bolts to 7 N.m (62 lb in).
5. Install the foam seals to the evaporator core.
6. Install the evaporator core into the HVAC module assembly.
7. Install the lower HVAC case.
8. Install the lower HVAC case screws. Tighten: Tighten the screws to 1.8 N.m (15 lb in).
9. Close and secure the passenger compartment filter door.
10. Inspect the foam heater core seal on the lower HVAC case. If damaged, replace using Kent Industries adhesive black foam tape P/N 46480 or equivalent.
11. Install the heater core into the HVAC module.
12. Install the heater core cover.
13. Install the heater core cover screws. Tighten: Tighten the screws to 1.8 N.m (15 lb in).
14. Install the HVAC module into the vehicle. Refer to «HVAC Module Assembly Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__hvac-module-assembly-replacement) .
15. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
16. Leak test the fittings using the J 39400-A .
17. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/cobalt/i-2004-2010/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
18. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.0L - LSJ)»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (2.2L - L61)»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.

J 38185

1. Remove the surge tank cap.
2. Slide a drain pan under the front of the dash under the heater inlet hose.
3. Remove the dash panel exterior sound barrier.
4. Reposition the heater inlet hose clamp at the heater core using J 38185 .
5. Remove the heater inlet hose from the heater core.
6. Reposition the heater inlet hose clamp at the engine using J 38185 .
7. Remove the heater inlet hose from the engine.

1. Install the heater inlet hose to the heater core.
2. Reposition the hose clamp to secure the hose using J 38185 .
3. Install the heater inlet hose to the engine.
4. Reposition the hose clamp to secure the hose using J 38185 .
5. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.0L - LSJ)»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (2.2L - L61)»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
6. Remove the drain pan from under the vehicle.
7. Install the dash panel exterior sound barrier.

J 38185 Hose Clamp Pliers

1. Remove the surge tank cap.
2. Slide a drain pan under the front of the dashboard under the heater inlet hose.
3. Reposition the heater inlet hose clamp at the heater core using J 38185 .
4. Remove the heater inlet hose from the heater core and tilt the hose downward toward the drain pan to drain the coolant from the hose.
5. Reposition the heater inlet hose clamp at the engine using J 38185 .
6. Remove the heater inlet hose from the engine.

1. Install the heater inlet hose to the heater core.
2. Reposition the hose clamp to secure the hose using J 38185 .
3. Install the heater inlet hose to the engine.
4. Reposition the hose clamp to secure the hose using J 38185 .
5. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.0L - LSJ)»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (2.2L - L61)»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
6. Remove the drain pan from under the vehicle.

J 38185 Hose Clamp Pliers

1. Remove the surge tank cap.
2. Place a drain pan under the heater hoses near the front of the dash.
3. Remove the dash panel exterior sound barrier.
4. Reposition the heater outlet hose clamp at the heater core using J 38185 .
5. Remove the heater outlet hose from the heater core.
6. Reposition the hose heater outlet hose clamp at the engine using J 38185 .
7. Remove the heater outlet hose from the engine.

1. Install the heater outlet hose to the heater core.
2. Reposition the hose clamp to secure the hose using J 38185 .
3. Install the heater outlet hose to the engine.
4. Reposition the hose clamp to secure the hose using J 38185 .
5. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.0L - LSJ)»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (2.2L - L61)»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
6. Remove the drain pan from under the vehicle.
7. Install the dash panel exterior sound barrier.

J 38185 Hose Clamp Pliers

1. Remove the surge tank cap.
2. Place a drain pan under the heater hoses near the front of the dash.
3. Remove the dash panel exterior sound barrier.
4. Reposition the heater outlet hose clamp at the heater core using J 38185 .
5. Remove the heater outlet hose from the heater core and tilt the hose downward toward the drain pan to drain the coolant from the hose.
6. Reposition the hose heater outlet hose clamp at the engine using J 38185 .
7. Remove the heater outlet hose from the engine.

1. Install the heater outlet hose to the heater core.
2. Reposition the hose clamp to secure the hose using J 38185 .
3. Install the heater outlet hose to the engine.
4. Reposition the hose clamp to secure the hose using J 38185 .
5. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.0L - LSJ)»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (2.2L - L61)»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
6. Remove the drain pan from under the vehicle.
7. Install the dash panel exterior sound barrier.

1. Open the I/P compartment. The access door for the passenger compartment air filter is located behind the glove box.
2. Tilt the I/P compartment door down by squeezing in on each side of the bin until the door stops can be removed from the tracks.
3. Lower the I/P compartment completely.
4. Open the passenger compartment filter door by reaching through the opening in the rear of the I/P compartment and raising the tab until the door can be opened downward.
5. Remove the filter by sliding the filter out of the passenger compartment filter housing.

1. Install the new filter by sliding the filter into the passenger compartment filter housing.
2. Close the passenger compartment filter door and snap the tab down to latch the door.
3. Raise the I/P compartment door until the door stops contact the frame. Slowly raise the door until the doorstops snap into their tracks.

1. Disconnect the blower motor resistor electrical connector.
2. Unsnap the blower motor resistor from the HVAC module and remove.

1. Snap the blower motor resistor into the HVAC module.
2. Connect the blower motor electrical connector.

1. Disconnect the blower motor electrical connector.
2. Remove the lower blower motor cover retaining screws.
3. Remove the lower blower motor cover.
4. Remove the blower motor nuts.
5. Remove the blower motor and cup from the lower case by cutting through the case between the circular ribs around the motor with a sharp utility knife.
6. Release the blower motor retaining tab and remove the motor from the cup.

1. Install the blower motor (1) into the motor cup (2) that was cut out of the lower case.
2. Install the blower motor nuts (3). Tighten: Tighten the nuts to 2.4 N.m (21 lb in).
3. Attach the service ring (4) to the motor cup (2) with the screws (5) included in the kit. Tighten: Tighten the screws to 1.8 N.m (15 lb in).
4. Install the blower motor and service ring into the HVAC module using the screws (5) included in the kit. Make certain the blower motor electrical connector is pointing rearward in the vehicle. Tighten: Tighten the screws to 1.8 N.m (15 lb in).
5. Install the lower blower motor cover.
6. Install the lower blower motor cover retaining screws. Tighten: Tighten the screws to 1.8 N.m (15 lb in).
7. Connect the blower motor electrical connector.

1. Remove the instrument panel (I/P) upper trim panel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Upper»(/chevrolet/cobalt/i-2004-2010/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages, and Console.
2. Remove the nut from the side window defog outlet grille.
3. Use a small, flat-bladed tool to release the tabs on the outlet grille. Remove the grille from the I/P top panel.

1. Install the side window defog grille to the instrument panel (I/P) upper trim panel.
2. Install a new nut to the outlet grille.
3. Check the outlet grille for proper fit and appearance.
4. Install the I/P upper trim panel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Upper»(/chevrolet/cobalt/i-2004-2010/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages, and Console.

1. Remove the instrument panel (I/P) upper trim panel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Upper»(/chevrolet/cobalt/i-2004-2010/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) .
2. Remove the screws from the outlet.
3. Remove the outlet from the vehicle.

1. Install the outlet to the I/P top panel.
2. Install the screws to the outlet.
3. Tighten the screws. Tighten: Tighten the screws to 2.2 N.m (19 lb in).
4. Install the I/P upper trim panel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Upper»(/chevrolet/cobalt/i-2004-2010/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) .

1. Remove the instrument panel (I/P) upper trim panel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Upper»(/chevrolet/cobalt/i-2004-2010/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) .
2. Remove the screws from the outlet.
3. Remove the outlet from the vehicle.

1. Install the outlet to the I/P top panel.
2. Install the screws to the outlet.
3. Tighten the screws. Tighten: Tighten the screws to 2.2 N.m (19 lb in).
4. Install a new pal nut to the air outlet.
5. Install the I/P upper trim panel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Upper»(/chevrolet/cobalt/i-2004-2010/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) .

1. Remove the left instrument panel (I/P) trim panel. Refer to «Instrument Panel (I/P) Trim Panel Replacement - Left»(/chevrolet/cobalt/i-2004-2010/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages, and Console.
2. Remove the outer air duct screw and duct.

1. Install the outer air duct.
2. Install the outer air duct screw. Tighten: Tighten the air outlet duct screw to 2.5 N.m (22 lb in).
3. Install the left instrument panel (I/P) trim panel. Refer to «Instrument Panel (I/P) Trim Panel Replacement - Left»(/chevrolet/cobalt/i-2004-2010/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages, and Console.

1. Remove the right instrument panel (I/P) trim panel. Refer to «Instrument Panel (I/P) Trim Panel Replacement - Right»(/chevrolet/cobalt/i-2004-2010/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages, and Console.
2. Remove the outer air duct screw and duct.

1. Install the outer air duct.
2. Install the outer air duct screw. Tighten: Tighten the air outlet duct screw to 2.5 N.m (22 lb in).
3. Install the right instrument panel (I/P) trim panel. Refer to «Instrument Panel (I/P) Trim Panel Replacement - Right»(/chevrolet/cobalt/i-2004-2010/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages, and Console.

1. Raise the center floor outlet duct while pushing the floor ducts down to disengage the ducts.
2. Rotate the center floor outlet duct forward in the vehicle and pull down to disengage the duct from the HVAC module.

1. Align the center floor duct with the HVAC module.
2. Push the center floor duct up while rotating rearward in the vehicle to install on the HVAC module.
3. Push down on the floor duct while rotating the center floor outlet ducts to align the ducts.
4. Slide the center floor outlet duct down into position in the floor ducts.

1. Remove the instrument panel (I/P) center trim panel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Center»(/chevrolet/cobalt/i-2004-2010/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages, and Console.
2. Remove the center air outlet duct screws and duct.

1. Install the center air outlet duct.
2. Install the center air outlet screws. Tighten: Tighten the center air outlet duct screws to 2.5 N.m (22 lb in).
3. Install the instrument panel (I/P) center trim panel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Center»(/chevrolet/cobalt/i-2004-2010/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages, and Console.

1. Remove the instrument panel (I/P) retainer. Refer to «Instrument Panel (I/P) Retainer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages, and Console.
2. Unsnap the defroster duct from the HVAC module and cross car beam. Bend the cluster wire harness tab on the cross car beam in order to remove the duct.

1. Align the defroster duct with the HVAC module and snap into place.
2. If the cluster wire harness tab on the cross car beam was bent during removal, bend the tab back into position.
3. Install the I/P retainer. Refer to «Instrument Panel (I/P) Retainer Replacement»(/chevrolet/cobalt/i-2004-2010/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages, and Console.

1. Remove the front seat. Refer to «Seat Replacement - Front Bucket»(/chevrolet/cobalt/i-2004-2010/remont/seats/#seat-system) in Seats.
2. Remove the front carpet retainer.
3. Pull the carpet up to access the floor duct.
4. Unsnap the floor duct from the floor support beam. Disengage the floor duct from the center floor outlet duct and remove from the vehicle.

1. Align the floor duct with the center floor outlet duct.
2. Align the floor duct with the floor support beam and snap into place.
3. Reposition the carpet.
4. Install the carpet retainer.
5. Install the front seat. Refer to «Seat Replacement - Front Bucket»(/chevrolet/cobalt/i-2004-2010/remont/seats/#seat-system) in Seats.

1. Remove the front seat. Refer to «Seat Replacement - Front Bucket»(/chevrolet/cobalt/i-2004-2010/remont/seats/#seat-system) in Seats.
2. Remove the front carpet retainer.
3. Remove the front floor console. Refer to «Console Replacement - Front Floor»(/chevrolet/cobalt/i-2004-2010/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
4. Pull the carpet up to access the floor duct.
5. Unsnap the floor duct from the floor support beam. Disengage the floor duct from the center floor outlet duct and remove from the vehicle.

1. Align the floor duct with the center floor outlet duct.
2. Align the floor duct with the floor support beam and snap into place.
3. Reposition the carpet.
4. Install the front floor console. Refer to «Console Replacement - Front Floor»(/chevrolet/cobalt/i-2004-2010/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
5. Install the carpet retainer.
6. Install the front seat. Refer to «Seat Replacement - Front Bucket»(/chevrolet/cobalt/i-2004-2010/remont/seats/#seat-system) in Seats.

1. Remove the body control module (BCM) from the vehicle. Refer to «Body Control Module Replacement»(/chevrolet/cobalt/i-2004-2010/remont/communication-devices/#computerintegrating-systems) in Computer/Integrating Systems.
2. Remove the front floor console left side extension panel. Refer to «Extension Replacement - Floor Console - Side»(/chevrolet/cobalt/i-2004-2010/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
3. Pull back the carpet at the bottom of the left instrument panel (I/P) center support bracket and remove the left I/P center support bracket nuts.
4. Remove the left I/P center support bracket.
5. Remove the accelerator control pedal from the front of the dash and position out of the way. Refer to «Accelerator Controls Pedal Replacement»(/chevrolet/cobalt/i-2004-2010/remont/testing-diagnostics/#engine-controls-20l-introduction) in Engine Controls - 2.2L - L61 or «Accelerator Controls Pedal Replacement»(/chevrolet/cobalt/i-2004-2010/remont/testing-diagnostics/#engine-controls-20l-introduction) in Engine Controls - 2.0L.
6. Raise the center floor outlet duct while pushing the floor ducts down to disengage the ducts.
7. Rotate the center floor outlet duct forward in the vehicle and pull down to disengage it from the HVAC module.
8. Remove the heater core cover heat stakes with a small chisel.
9. Loosen the nut that is behind the fuel line bracket and remove the stud from the dash panel at the heater hoses.
10. Pull the heater core cover down just enough to clear the locating pins from the HVAC module. Slide the heater core cover rearward until the drain tube clears the front of dash. Slide the heater core cover down, rearward, and to the right to remove.

1. Install a new drain tube seal onto the drain tube.
2. Install the heater core cover from the right side. Slide up and forward into position. Align the drain tube with the hole in the front of dash. Raise the heater core cover into position while aligning holes with the locating pins from the HVAC module.
3. Cut the sound insulator at the cowl near the center screw (1) approximately 76 mm (3 in) and fold the sound insulator back to ease in installation of the screw. Ensure the sound insulator is positioned back after the screws are tightened.
4. Install the heater core cover screws. Tighten: Tighten the heater core cover screws to 1.8 N.m (15 lb in).
5. Install the stud into the dash panel at the heater hoses and tighten the nut that is behind the fuel line bracket.
6. Align the center floor duct with the HVAC module.
7. Push the center floor duct up while rotating rearward in the vehicle to install on the HVAC module.
8. Push down on the floor duct while rotating the center floor outlet ducts to align the ducts.
9. Slide the center floor outlet duct down into position in the floor ducts.
10. Install the accelerator control pedal. Refer to «Accelerator Controls Pedal Replacement»(/chevrolet/cobalt/i-2004-2010/remont/testing-diagnostics/#engine-controls-20l-introduction) in Engine Controls - 2.2L - L61 or «Accelerator Controls Pedal Replacement»(/chevrolet/cobalt/i-2004-2010/remont/testing-diagnostics/#engine-controls-20l-introduction) in Engine Controls - 2.0L.
11. Pull back the carpet and place the left center support bracket into position.
12. Install the left center support bracket nuts. Tighten: Tighten the left center support bracket nuts to 10 N.m (88 lb in).
13. Install the left side front floor console extension panel. Refer to «Extension Replacement - Floor Console - Side»(/chevrolet/cobalt/i-2004-2010/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
14. Install the BCM to the vehicle. Refer to «Body Control Module Replacement»(/chevrolet/cobalt/i-2004-2010/remont/communication-devices/#computerintegrating-systems) in Computer/Integrating Systems.

SA9111E Hose Clamp Pliers

1. Drain the cooling system. Refer to «Draining and Filling Cooling System (2.0L - LSJ)»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (2.2L - L61)»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/cobalt/i-2004-2010/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
3. Place a drain pan under the water pump drain port.
4. Loosen the water pump drain bolt and drain the coolant from the water pump.
5. Close and tighten the water pump drain bolt. Tighten: Tighten the water pump drain bolt to 10 N.m (88 lb in).
6. Lower the vehicle.
7. Reposition the heater outlet hose clamp at the heater core using SA9111E .
8. Remove the heater outlet hose from the heater core.
9. Reposition the heater inlet hose clamp at the heater core using SA9111E .
10. Remove the heater inlet hose from the heater core.
11. Remove the heater core cover. Refer to «Heater Core Cover Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
12. Remove the heater core.

1. Inspect the foam heater core seal on the lower HVAC case. If damaged, replace using Kent Industries adhesive black foam tape P/N 46480 or equivalent.
2. Install the heater core into the HVAC module.
3. Install the heater core cover. Refer to «Heater Core Cover Replacement»(/chevrolet/cobalt/i-2004-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Install the heater outlet hose to the heater core.
5. Install the hose clamp to secure the hose using SA9111E .
6. Install the heater inlet hose to the heater core.
7. Install the hose clamp to secure the hose using SA9111E .
8. Fill the cooling system. Refer to «Draining and Filling Cooling System (2.0L - LSJ)»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) or «Draining and Filling Cooling System (2.2L - L61)»(/chevrolet/cobalt/i-2004-2010/remont/cooling-system-mechanical/#engine-cooling-system) in Engine Cooling.

Special Tools

Special Tools Illustration Tool Number/Description J 37872 Universal Spanner Wrench J 38185 Hose Clamp Pliers J 39400-A Halogen Leak Detector J 41447 R-134A A/C Tracer Dye-Box of 24 J 42220 Universal 12V Leak Detection Lamp J 43600 ACR 2000 Air Conditioning Service Center J 43872 Fluorescent Dye Cleaner J 44551 Suction Screen Kit J 45037 A/C Oil Injector J 45268 A/C Flushing Adapter Kit J 46246 Valve Core Tool J-46297 R-134A A/C Tracer Dye Injector J-46297-12 Replacement Dye Cartridges J 6083 Snap Ring Pliers

Scheme 3

Scheme 4

Scheme 5

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

See also:
• Symptoms - HVAC Systems - Manual
• Air Delivery Description and Operation
• Air Temperature Description and Operation
• Moving Parts and Hot Surfaces Caution
• Cooling System Description and Operation
• Cooling Fan Inoperative
• Diagnostic System Check - Vehicle
• Engine Fails To Reach Normal Operating Temperature
• Drive Belt Excessive Wear Diagnosis
• Drive Belt Tensioner Diagnosis
• Oil Leak Diagnosis
• Drive Belt Replacement
• Vibration Analysis - Engine
• Trim Panel Replacement - Instrument Panel (I/P) Center
• Loss of Coolant
• Fluid Leak Diagnosis
• Lifting and Jacking the Vehicle
• Front Fender Liner Replacement
• Fastener Notice
• Air Cleaner Assembly Replacement
• Battery Negative Cable Disconnect/Connect Procedure
• Seat Replacement - Front Bucket
• Body Control Module Replacement
• Accelerator Controls Pedal Replacement
• Special Tools
• Refrigerant Recovery and Recharging
• Leak Testing
• Air Conditioning (A/C) Diagnostics - Pressure Zone A
• Air Conditioning (A/C) System Performance Test (L61)
• Flushing
• Refrigerant System Capacities
• Thermal Expansion Valve Replacement
• Compressor Replacement (2.2L (L61))
• Compressor Replacement (2.0L (LSJ))
• Heating Performance Diagnostic
• Compressor Clutch Assembly Replacement
• Noise Diagnosis - Blower Motor
• HVAC Module Assembly Replacement