Heating, Ventilation, and Air Conditioning Chevrolet Impala IX

Fastener Tightening Specifications

Refrigerant System Specifications

Refrigerant System Capacities

Special Tools

1. J 39400-A: Halogen Leak Detector
2. J 41447: R 134a A/C Tracer Dye-Box of 24
3. J 42220: Universal 12V Leak Detection Lamp
4. J 43872: Fluorescent Dye Cleaner
5. J 46297: A/C Dye Injector Kit
6. J 46297-12: Replacement Dye Cartridges

Refrigerant Leak Testing

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

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

Verifying some passive leaks may require using the J 39400-A: Halogen Leak Detector, 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.

Note. PAG oil is water soluble.

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: Universal 12V Leak Detection Lamp.
4. To prevent false diagnosis in the future, thoroughly clean the residual dye from any area where leaks were found. Use a rag and the approved J 43872: Fluorescent Dye Cleaner.

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: Fluorescent Dye Cleaner

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.

Note. Halogen leak detectors are sensitive to the following items: Windshield washing solutions Many solvents and cleaners Some adhesives used in the vehicle

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

Note. Follow a continuous path in order to ensure that you will not miss any possible leaks. Test all areas of the system for leaks.

Follow the instructions supplied with the J 39400-A: Halogen Leak Detector.

Test Description

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 number(s) below refer to the step number(s) 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 air temperatures.

Scheme 1

A/C Performance Table

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

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

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

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

Heating Performance Diagnostic

Defrosting Insufficient

Noise Diagnosis - Blower Motor

Air Conditioning Compressor Oil Diagnosis

Noise Diagnosis - Air Conditioning (A/C) System

Noise Diagnosis - HVAC Module

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 air conditioning duct between the blower motor and the evaporator core downstream of the blower motor.
5. Drill a 3.175 mm (0.125 in) hole where the hole will not interfere with or damage the following components: The blower motor The evaporator core Any other operating part the of system
6. Wear safety goggles and latex gloves in order to perform the following actions: Select the maximum blower speed. Insert the deodorizer extension tube into the hole to the mark on the extension tube. Use short spray bursts and vary the direction of spray for a 2-3 minute period of time.
7. Shut the engine OFF. Allow the vehicle to sit for 3-5 minutes.
8. Seal the 3.175 mm (0.125 in) hole with body sealer or RTV gasket compound.
9. Start the engine.
10. Operate the blower motor on high for 15-20 minutes to dry.
11. Reconnect the A/C compressor clutch coil electrical connector.
12. Verify proper clutch operation.

1. J 43600: ACR 2000 Air Conditioning Service Center
2. J 45037: A/C Oil Injector

The J 43600: ACR 2000 Air Conditioning Service Center is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. 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 Air Conditioning Service Center ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Specifications for the correct amount.

A/C Refrigerant System Oil Charge Replenishing

If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037: A/C Oil Injector. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Specifications .

1. J 41447: Leak Detection Dye
2. J 42220: Universal 12V Leak Detection Lamp
3. J 43600: ACR 2000 Air Conditioning Service Center
4. J 45268: Flush Adapter Kit

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

Flushing is intended to remove the following

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

Scheme 2

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the A/C refrigerant filter. Refer to «Air Conditioning (AC) Refrigerant Filter Replacement»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Remove the thermal expansion valve (TXV). Refer to «Air Conditioning Evaporator Thermal Expansion Valve Replacement»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Install the stud for the J 45268: Flush Adapter Kit kit onto the J 45268-115.
5. Install the J 45268-115 in place of the TXV.
6. Install the TXV mounting bolts and tighten to 7 N.m (62 lb in).
7. Connect the evaporator line to the J 45268-115.
8. Install the TXV block fitting nut and tighten to 17 N.m (12.5 lb ft).
9. Remove the A/C compressor. Refer to «Air Conditioning Compressor Replacement (LZE, LGD)»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
10. Install J 45268-10 to the A/C compressor hose assembly.
11. Install the nut and bolt from the J 45268: Flush Adapter Kit kit to the J 45268-10 and compressor hose assembly and tighten the bolts to 17 N.m (12.5 lb ft).
12. Forward flow refrigerant flushing is recommended for contaminated refrigerant or PAG oil. Perform the following procedure: NOTE: The filter inside J 45268-1 is serviceable. Remove and discard the check valve from the filter. Service the filter with ACDelco P/N GF 470, before each flush. Install the port plugs J 45268-9 onto the J 45268-10. Install the fitting J 45268-7 onto the J 45268-10. Install the fitting J 45268-8 onto the J 45268-10. Connect J 45268-1 flush filter to the suction port of J 45268-7 flush adapter. Connect the blue hose from the J 43600: ACR 2000 Air Conditioning Service Center to the J 45268-1 flush filter adapter. Connect the red hose from the J 43600: ACR 2000 Air Conditioning Service Center to the J 45268-8 flush adapter.
13. Reverse flow refrigerant flush is recommended for desiccant bag failure. Replace the A/C condenser when the A/C flush is complete and perform the following procedure: NOTE: The filter inside J 45268-1 is serviceable. Remove and discard the check valve from the filter. Service the filter with ACDelco P/N GF 470, before each flush. Install the port plugs J 45268-9 onto the J 45268-10. Install the fitting J 45268-7 onto the J 45268-10. Install the fitting J 45268-8 onto the J 45268-10. Connect J 45268-1 flush filter to the discharge port of J 45268-7 flush adapter. Connect the blue hose from J 43600: ACR 2000 Air Conditioning Service Center to the J 45268-1 flush filter adapter. Connect the red hose from J 43600: ACR 2000 Air Conditioning Service Center to the J 45268-8 flush adapter.
14. Flush the A/C system. Follow the instructions supplied with the J 43600: ACR 2000 Air Conditioning Service Center.
15. Disconnect the red hose on the J 43600: ACR 2000 Air Conditioning Service Center from the J 45268-10.
16. Disconnect the blue hose on the J 43600: ACR 2000 Air Conditioning Service Center from the J 45268-1.
17. Remove J 45268-1 from the J 45268-10.
18. Remove the J 45268-10 from the A/C compressor hose assembly.
19. 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. Install the A/C compressor drain plug and tighten to 16 N.m (12 lb ft). Add the total system capacity of PAG oil to the A/C compressor. Refer to «Refrigerant System Specifications»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-specifications) .
20. If you will replace the A/C compressor after flushing the system, perform the following procedure: Determine if the new service compressor is shipped with PAG oil. Refer to the «Refrigerant System Specifications»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-specifications) . If the service compressor is shipped with PAG oil, DO NOT drain the new PAG oil from the compressor. Deduct the amount of PAG oil shipped with the service compressor from the amount of PAG oil listed in the capacities table. Refer to «Refrigerant System Specifications»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-specifications) . Add the calculated amount to the compressor, as needed.
21. Add one bottle of J 41447: Leak Detection Dye directly to the A/C Compressor.
22. Install the A/C compressor. Refer to «Air Conditioning Compressor Replacement (LZE, LGD)»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
23. Remove J 45268-115.
24. Inspect the TXV for debris. Clean or replace as needed.
25. Install the TXV. Refer to «Air Conditioning Evaporator Thermal Expansion Valve Replacement»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
26. Install the A/C refrigerant filter. Refer to «Air Conditioning (AC) Refrigerant Filter Replacement»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
27. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
28. Leak test the fittings using J42220: Universal 12V Leak Detection Lamp.

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. Inspect the oil drained from the compressor. Refer to «Air Conditioning Compressor Oil Diagnosis»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__air-conditioning-compressor-oil-diagnosis) .
5. Properly discard the used refrigerant oil.

Balancing Procedure

1. The replacement compressor is shipped with the total system capacity of refrigerant oil.
2. Before installing the compressor, the refrigerant oil may have to be partially drained: Refer to the amount of refrigerant oil recorded during the compressor removal. Subtract the amount recorded from the total system capacity. Refer to «Refrigerant System Specifications»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-specifications) . The difference between the total system capacity and the recorded amount is the calculated amount to be drained from the replacement compressor.
3. Drain the calculated amount of refrigerant oil from the replacement compressor.

Scheme 3

1. J 6083: Snap Ring Pliers
2. J 37872: Compressor Clutch Holding Tool
3. J 39400-A: Halogen Leak Detector

Removal Procedure

1. Remove the compressor. Refer to «Air Conditioning Compressor Replacement (LZE, LGD)»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove and discard the compressor clutch plate bolt. Use the J 37872: Compressor Clutch Holding Tool to hold the compressor clutch plate from turning.
3. Remove the compressor clutch plate from the compressor.
4. Remove the compressor pulley snap ring using the J 6083: Snap Ring Pliers.
5. Remove the compressor pulley from the compressor.
6. Remove the compressor clutch coil snap ring using the J 6083: Snap Ring Pliers.
7. Remove the compressor clutch coil from the compressor.

Installation Procedure

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: Snap Ring Pliers.
4. Install the compressor pulley to the compressor.
5. Install the compressor pulley snap ring using the J 6083: Snap Ring Pliers.
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 to 12 N.m (106 lb in). Use the J 37872: Compressor Clutch Holding Tool to hold the compressor clutch plate from turning.
11. Install the compressor. Refer to «Air Conditioning Compressor Replacement (LZE, LGD)»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
12. Leak test the fittings using the J 39400-A: Halogen Leak Detector.

J 39400-A: Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/impala/ix-2006-2016/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
3. Remove the high pressure relief valve.
4. Cap or tape the A/C compressor.

1. Remove the cap or tape from the A/C compressor.
2. Lubricate the O-ring on the high pressure relief valve. Refer to «Air Conditioning O-Ring Seal Replacement»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the high pressure relief valve and tighten to 8 N.m (70 lb in).
4. Lower the vehicle.
5. Evacuate and recharge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. Leak test the fittings of the component using J 39400-A: Halogen Leak Detector.

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.

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

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

J 39400-A: Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Locate the A/C coupling assembly's locking tab access slots (1).
3. Carefully insert a small flat bladed screwdriver into the first locking tab access slot and gently lift the locking tab to release the lock.
4. Carefully insert a small flat bladed screwdriver into the second locking tab access slot and gently lift the locking tab to release the lock.
5. Open and remove the A/C coupling assembly from the A/C refrigerant component.

1. Install the A/C coupling assembly to the A/C refrigerant component.
2. Close the A/C coupling assembly.
3. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Leak test the fittings of the component using J 39400-A: Halogen Leak Detector.

Scheme 4

Scheme 5

J 39400-A: Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/impala/ix-2006-2016/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) for the 3.5L engine or to «Air Cleaner Assembly Replacement»(/chevrolet/impala/ix-2006-2016/remont/testing-diagnostics/#engine-controls-and-fuel-39l-repair-instructions) for the 3.9L engine.
3. Remove the A/C line coupling from the evaporator tube to condenser tube. Refer to «Air Conditioning Line/Tube Connector Removal/Replacement»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Disconnect the evaporator tube from the condenser.
5. Remove and discard the O-ring seals. Refer to «Air Conditioning O-Ring Seal Replacement»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. Remove the refrigerant filter from the evaporator tube.

1. Replace the O-ring seals on the evaporator tube. Refer to «Air Conditioning O-Ring Seal Replacement»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Install a new refrigerant filter to the evaporator tube.
3. Connect the evaporator tube to the condenser.
4. Install the A/C line coupling to the evaporator tube and condenser tube. Refer to «Air Conditioning Line/Tube Connector Removal/Replacement»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/impala/ix-2006-2016/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) for the 3.5L engine or to «Air Cleaner Assembly Replacement»(/chevrolet/impala/ix-2006-2016/remont/testing-diagnostics/#engine-controls-and-fuel-39l-repair-instructions) for the 3.9L engine.
6. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
7. Leak test the fittings of the component using J 39400-A: Halogen Leak Detector.

Scheme 6

J 39037: Charge Valve Octagon Socket

1. Remove the service port cap.
2. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Use the J 39037: Charge Valve Octagon Socket to remove the service port.

1. Replace the O-ring. Refer to «Air Conditioning O-Ring Seal Replacement»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Install the service port valve and tighten to 11 N.m (98 lb in).
3. Evacuate and charge the system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Leak test the A/C service port. Refer to «Leak Testing»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Install the service port cap.

J 39400-A: Halogen Leak Detector

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the evaporator tube to thermal expansion valve (TXV) nut (1).
3. Disconnect the evaporator outlet and inlet tube from the TXV.
4. Remove and discard the sealing washers.
5. Cap off the evaporator inlet and outlet tube.
6. Remove the TXV to evaporator bolts.
7. Remove the TXV from the evaporator core.
8. Remove and discard the sealing washers.

1. Install the new sealing washers onto the evaporator core. Refer to «Air Conditioning System Seal Replacement»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Install the TXV to the evaporator core.
3. Install the TXV to evaporator bolts and tighten to 7 N.m (62 lb in).
4. Remove the cap or tape from the evaporator inlet and outlet tubes.
5. Install the new sealing washers onto the evaporator inlet and outlet tubes. Refer to «Air Conditioning System Seal Replacement»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. Install the evaporator outlet and inlet tube to the TXV.
7. Install the evaporator tube nut (1) and tighten to 17 N.m (13 lb ft).
8. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
9. Leak test the fittings of the component using J 39400-A: Halogen Leak Detector.

J 39400-A: Halogen Leak Detector

1. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/impala/ix-2006-2016/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) for the 3.5L engine or «Air Cleaner Assembly Replacement»(/chevrolet/impala/ix-2006-2016/remont/testing-diagnostics/#engine-controls-and-fuel-39l-repair-instructions) for the 3.9L engine.
2. Disconnect the electrical connector from the A/C refrigerant pressure sensor.
3. Remove the A/C refrigerant pressure sensor from the evaporator tube.

1. Replace the O-ring seal for the A/C refrigerant pressure sensor. Refer to «Air Conditioning O-Ring Seal Replacement»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Install the A/C refrigerant pressure sensor to the evaporator tube and tighten to 4.7 N.m (41 lb in).
3. Connect the electrical connector to the A/C refrigerant pressure sensor.
4. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/impala/ix-2006-2016/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) for the 3.5L engine or «Air Cleaner Assembly Replacement»(/chevrolet/impala/ix-2006-2016/remont/testing-diagnostics/#engine-controls-and-fuel-39l-repair-instructions) for the 3.9L engine.
5. Leak test the fittings of the component using J 39400-A: Halogen Leak Detector.

J 39400-A: Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the radiator. Refer to «Radiator Replacement»(/chevrolet/impala/ix-2006-2016/remont/cooling-system-mechanical/#engine-cooling-system) .
3. Remove the A/C line coupling from the condenser tube to evaporator tube. Refer to «Air Conditioning Line/Tube Connector Removal/Replacement»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Remove the A/C compressor line nut from the condenser and position the A/C compressor line aside.
5. Remove the condenser from the vehicle.
6. Remove and discard the O-ring seals and seal washer.

1. If replacing the condenser, add refrigerant oil to the condenser. Refer to «Refrigerant System Specifications»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-specifications) for system capacity information.
2. Install the condenser to the vehicle.
3. Install a new seal washer onto the A/C compressor hose. Refer to «Air Conditioning System Seal Replacement»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Install new O-ring seals onto the evaporator tube. Refer to «Air Conditioning O-Ring Seal Replacement»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Install the radiator. Refer to «Radiator Replacement»(/chevrolet/impala/ix-2006-2016/remont/cooling-system-mechanical/#engine-cooling-system) .
6. Install the evaporator tube to the condenser.
7. Install the A/C line coupling to the evaporator tube and condenser tube. Refer to «Air Conditioning Line/Tube Connector Removal/Replacement»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
8. Install the A/C compressor hose to the condenser.
9. Install the A/C compressor hose block fitting nut to the condenser and tighten to 17 N.m (12.5 lb ft).
10. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
11. Leak test the fittings of the component using J 39400-A: Halogen Leak Detector.

Scheme 7

Scheme 8

Scheme 9

J 38185: Hose Clamp Pliers

1. Drain the coolant. Refer to «Cooling System Draining and Filling (9C1, 9C3 Static Fill)»(/chevrolet/impala/ix-2006-2016/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (LZE, LGD Static Fill)»(/chevrolet/impala/ix-2006-2016/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (LZE, LGD GE47716 Fill)»(/chevrolet/impala/ix-2006-2016/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the surge tank from the surge tank bracket.
3. Reposition the heater inlet hose clamp at the heater core using the J 38185: Hose Clamp Pliers.
4. Reposition the heater inlet hose clamp at the engine using the J 38185: Hose Clamp Pliers.
5. Remove the heater inlet hose from the heater core.
6. Remove the heater inlet hose from the engine.
7. Remove both heater inlet hose clamps from the heater inlet hose.

1. Install both heater inlet hose clamps to the heater inlet hose.
2. Install the heater inlet hose to the engine.
3. Install the heater inlet hose to the heater core.
4. Reposition the heater inlet hose clamp at the engine using the J 38185: Hose Clamp Pliers.
5. Reposition the heater inlet hose clamp at the heater core using the J 38185: Hose Clamp Pliers.
6. Install the surge tank to the surge tank bracket.
7. Fill the coolant. Refer to «Cooling System Draining and Filling (9C1, 9C3 Static Fill)»(/chevrolet/impala/ix-2006-2016/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (LZE, LGD Static Fill)»(/chevrolet/impala/ix-2006-2016/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (LZE, LGD GE47716 Fill)»(/chevrolet/impala/ix-2006-2016/remont/cooling-system-mechanical/#engine-cooling-system) .

J 38185: Hose Clamp Pliers

1. Drain the coolant. Refer to «Cooling System Draining and Filling (9C1, 9C3 Static Fill)»(/chevrolet/impala/ix-2006-2016/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (LZE, LGD Static Fill)»(/chevrolet/impala/ix-2006-2016/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (LZE, LGD GE47716 Fill)»(/chevrolet/impala/ix-2006-2016/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the surge tank from the surge tank bracket.
3. Reposition the heater outlet hose clamp at the heater core using the J 38185: Hose Clamp Pliers.
4. Reposition the heater outlet hose clamp at the engine using the J 38185: Hose Clamp Pliers.
5. Remove the heater outlet hose from the heater core.
6. Remove the heater outlet hose from the engine.
7. Remove both heater outlet hose clamps from the heater outlet hose.

1. Install both heater outlet hose clamps to the heater outlet hose.
2. Install the heater outlet hose to the engine.
3. Install the heater outlet hose to the heater core.
4. Reposition the heater outlet hose clamp at the engine using the J 38185: Hose Clamp Pliers.
5. Reposition the heater outlet hose clamp at the heater core using the J 38185: Hose Clamp Pliers.
6. Install the surge tank to the surge tank bracket.
7. Fill the coolant. Refer to «Cooling System Draining and Filling (9C1, 9C3 Static Fill)»(/chevrolet/impala/ix-2006-2016/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (LZE, LGD Static Fill)»(/chevrolet/impala/ix-2006-2016/remont/cooling-system-mechanical/#engine-cooling-system) or «Cooling System Draining and Filling (LZE, LGD GE47716 Fill)»(/chevrolet/impala/ix-2006-2016/remont/cooling-system-mechanical/#engine-cooling-system) .

Scheme 10

1. Reposition rear hood seal halfway to the center. Refer to «Hood Rear Seal Replacement»(/chevrolet/impala/ix-2006-2016/remont/exterior-body-panels/#bolted-exterior-body-panels-and-closures) .
2. Remove the washer hose from the right air inlet grill panel and position aside.
3. Remove the 2 push pin retainers from the right air inlet grill panel.
4. Reposition the right air inlet grill panel on to the windshield.
5. Remove the water deflector cover.
6. Remove the passenger compartment air filter.

1. Install the passenger compartment air filter.
2. Install the water deflector cover. Ensure the three tabs of the water deflector engage the rear cowl edge.
3. Install the air inlet grill panel.
4. Install the air inlet grill panel push pin retainers.
5. Install the washer hose through the right air inlet grill panel clips.
6. Install the rear hood seal. Refer to «Hood Rear Seal Replacement»(/chevrolet/impala/ix-2006-2016/remont/exterior-body-panels/#bolted-exterior-body-panels-and-closures) .

Scheme 11

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Scheme 16

1. Remove the floor carpet. Refer to «Floor Panel Carpet Replacement (Impala)»(/chevrolet/impala/ix-2006-2016/remont/exteriorinterior-trim/#floor-coverings-and-headlinings) .
2. Remove the rear floor air outlet duct (1) from the holes in the floor reinforcement.
3. Disconnect the rear floor air outlet duct from the heater outlet cover.
4. Remove the rear floor air outlet duct.

1. Install the rear floor air outlet duct.
2. Connect the rear floor air outlet duct to the heater outlet cover.
3. Position the rear floor air outlet duct (1) into the holes in the floor reinforcement.
4. Install the floor carpet. Refer to «Floor Panel Carpet Replacement (Impala)»(/chevrolet/impala/ix-2006-2016/remont/exteriorinterior-trim/#floor-coverings-and-headlinings) .

Scheme 17

1. Remove the HVAC module assembly. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the screws that secure the recirculation housing to the HVAC module assembly.
3. Remove the recirculation housing from the HVAC module assembly.
4. Remove the screws that secure the mode actuator to the HVAC module assembly.
5. Remove the mode actuator from the HVAC module assembly.
6. Remove the screws that secure HVAC module assembly upper case to the HVAC module assembly lower case.
7. Remove the heat stakes that secure the HVAC module assembly upper case to the HVAC module lower case using a small chisel.
8. Separate the HVAC module assembly case (1).
9. Remove the screws that secure the air temperature actuator to the HVAC module assembly upper case.
10. Remove the air temperature actuator from the HVAC module assembly upper case.
11. Remove the air temperature door from the HVAC module assembly upper case.

1. Install the air temperature door to the HVAC module assembly upper case.
2. Install the air temperature actuator to the HVAC module assembly upper case.
3. Install the screws that secure the air temperature actuator to the HVAC module assembly upper case. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
4. From the inside of the upper case, drill the dimples adjacent to the heat stakes using a 5.5 mm (7/32 in) drill bit.
5. Align and attach the upper and lower HVAC module assembly case.
6. Install the removed screws that secure the HVAC module assembly upper case to the HVAC module assembly lower case to their original position. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
7. Install new screws that will secure the HVAC module assembly upper case to the HVAC module assembly lower case in the locations adjacent to the heat stakes. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
8. Install the mode actuator.
9. Install the screws that secure the mode actuator to the HVAC module assembly. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
10. Install the recirculation housing to the HVAC module assembly.
11. Install the screws that secure the recirculation housing to the HVAC module assembly. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
12. Install the HVAC module assembly. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation»(/chevrolet/impala/ix-2006-2016/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 18

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Scheme 20

Engine Coolant

Engine coolant is the key element of the heating system. The engine thermostat controls the normal engine operating coolant temperature. The thermostat also creates a restriction for the cooling system that promotes a positive coolant flow and helps prevent cavitation. Coolant enters the heater core through the inlet heater hose, in a pressurized state. The heater core is located inside the HVAC module. The ambient air drawn through the HVAC module absorbs the heat of the coolant flowing through the heater core. The HVAC module distributes heated air to the passenger compartment for consistent passenger comfort. Opening or closing the HVAC module temperature door controls the amount of heat delivered to the passenger compartment. The coolant exits the heater core through the return heater hose and is recirculated back through the engine cooling system.

A/C Cycle

Refrigerant is the key element in an air conditioning system. R-134a is presently the only EPA approved refrigerant for automotive use. R-134a is an very low temperature gas that can transfer the undesirable heat and moisture from the passenger compartment to the outside air.

The A/C compressor is belt driven and operates when the magnetic clutch is engaged. The compressor builds pressure on the vapor refrigerant. Compressing the refrigerant also adds heat to the refrigerant. The refrigerant is discharged from the compressor, through the discharge hose, and forced to flow to the condenser and then through the balance of the A/C system. The A/C system is mechanically protected with the use of a high pressure relief valve. If the high pressure switch were to fail or if the refrigerant system becomes restricted and refrigerant pressure continued to rise, the high pressure relief will pop open and release refrigerant from the system.

Compressed refrigerant enters the condenser in a high temperature, high pressure vapor state. As the refrigerant flows through the condenser, the heat of the refrigerant is transferred to the ambient air passing through the condenser. Cooling the refrigerant causes the refrigerant to condense and change from a vapor to a liquid state.

The condenser is located in front of the radiator for maximum heat transfer. The condenser is made of aluminum and aluminum cooling fins, which allows rapid heat transfer for the refrigerant. The semi-cooled liquid refrigerant exits the condenser and flows through the liquid line, to the thermal expansion valve.

The thermal expansion valve is located in the liquid line between the condenser and the evaporator. The thermal expansion valve is the dividing point for the high and the low pressure sides of the A/C system. As the refrigerant passes through the thermal expansion valve, the pressure of the refrigerant is lowered. Due to the pressure differential of the liquid refrigerant, the refrigerant will begin to vaporize at the thermal expansion valve. The thermal expansion valve also meters the amount of liquid refrigerant that can flow into the evaporator.

Refrigerant exiting the thermal expansion valve flows into the evaporator core in a low pressure, liquid state. Ambient air is drawn through the HVAC module and passes through the evaporator core. Warm and moist air will cause the liquid refrigerant boil inside of the evaporator core. The boiling refrigerant absorbs heat from the ambient air and draws moisture onto the evaporator. The refrigerant exits the evaporator back through the thermal expansion valve and into the suction line and back to the compressor, in a vapor state completing the A/C cycle of heat removal. At the compressor, the refrigerant is compressed again and the cycle of heat removal is repeated.

The conditioned air is distributed through the HVAC module for passenger comfort. The heat and moisture removed from the passenger compartment will also change form, or condense, and is discharged from the HVAC module as water under the vehicle.

Illustration Tool Number/ Description J 6083 External Snap Ring Pliers J 37872 Universal Spanner Wrench J 38185 Hose Clamp Pliers J 39037 Charge Valve Octagon Socket J 39400-A Halogen Leak Detector J 41447 R134A 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 45037 A/C Oil Injector J 45268 A/C Flushing Adapter Kit J 46297 A/C Dye Injector Kit J 46297 12 Replacement Dye Cartridges

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See also:
• Symptoms - HVAC Systems - Manual
• Diagnostic Starting Point - Vehicle
• Moving Parts and Hot Surfaces Warning
• Cooling System Description and Operation
• Diagnostic System Check - Vehicle
• Engine Fails To Reach Normal Operating Temperature
• Air Conditioning Compressor Malfunction
• Drive Belt Falls Off and Excessive Wear Diagnosis
• Drive Belt Falls Off and Excessive Wear Diagnosis
• Drive Belt Tensioner Diagnosis
• Drive Belt Tensioner Diagnosis
• Drive Belt Replacement
• Drive Belt Replacement
• Vibration Analysis - Engine
• Instrument Panel Lower Trim Panel Replacement
• Loss of Coolant
• Fluid Leak Diagnosis
• Power Steering Fluid Leaks
• Fastener Caution
• Lifting and Jacking the Vehicle
• Engine Splash Shield Replacement (Right)
• Air Cleaner Assembly Replacement
• Air Cleaner Assembly Replacement
• Brake Pressure Modulator Valve Bracket Replacement
• Battery Disconnect Warning
• Battery Negative Cable Disconnection and Connection (LGD/LZE)
• Hood Rear Seal Replacement
• Control Module References
• Floor Panel Carpet Replacement (Impala)
• Refrigerant Recovery and Recharging
• Air Conditioning (A/C) Diagnostics - Pressure Zone A
• Refrigerant System Specifications
• Heating Performance Diagnostic
• Noise Diagnosis - Blower Motor
• Air Conditioning Compressor Oil Diagnosis