HVAC System - Automatic: Other Chevrolet Malibu VI facelift

Sensor Resistance Table (Ambient Air Temp Sensor)

The Tech 2 will display sensor value as a voltage. This gives the approximate voltage expected at different ambient temperatures as well as what should be read with an ohmmeter connected to the sensor. Since this is raw data any heat from underhood that changes ambient temp around the sensor might skew the reading, so let the engine compartment cool.

Sensor Resistance Table (Ambient Air Temp Sensor)

Sensor Resistance Table (Duct Temp conversion temp to counts)

Sensor Resistance Table (Duct Temp conversion temp to counts)

Sensor Resistance Table (Inside Air Temperature Sensor)

Sensor Resistance Table (Inside Air Temperature Sensor)

Sensor Resistance Table (Upper and Lower Duct Temp Sensors)

Sensor Resistance Table (Upper and Lower Duct Temp Sensors)

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

A/C Compressor Clutch Connector Part Information

A/C Compressor Clutch Connector Terminal Identification

Scheme 53

A/C Refrigerant Pressure Sensor Connector Part Information

A/C Refrigerant Pressure Sensor Connector Terminal Identification

Scheme 54

Air Temperature Actuator Connector Part Information

Air Temperature Actuator Connector Terminal Identification

Scheme 55

Air Temperature Sensor Connector Part Information (Lower)

Air Temperature Sensor Connector Terminal Identification (Lower)

Air Temperature Sensor - Upper

Air Temperature Sensor Connector Part Information (Upper)

Air Temperature Sensor Connector Terminal Identification (Upper)

Scheme 56

Ambient Air Temperature Sensor Connector Part Information

Ambient Air Temperature Sensor Connector Terminal Identification

Scheme 57

Blower Motor Connector Part Information

Blower Motor Connector Terminal Identification

Scheme 58

Blower Motor Control Module Connector Part Information

Blower Motor Control Module Connector Terminal Identification

Scheme 59

HVAC Control Module Connector Part Information

HVAC Control Module Connector Terminal Identification

Scheme 60

Mode Actuator Connector Part Information

Mode Actuator Connector Terminal Identification

Recirculation Actuator

Recirculation Actuator Connector Part Information

Recirculation Actuator Connector Terminal Identification

Scheme 61

Sunload Sensor Connector Part Information

Sunload Sensor Connector Terminal Identification

2A and 61

Sets after 2 occurrences of the test fail code setting conditions listed below in the same ignition cycle.

51 and 04

Sets after one occurrence of the test fail code setting conditions listed below in the same ignition cycle.

2A, 04, 51 and 61

The following failures occur and set the DTC

1. The HVAC control module does not detect any movement of the actuator.
2. The HVAC control module detects a measured actuator range that exceeds the calibratible value.
3. The HVAC control module detects a measured actuator range that is less than the calibratible value.
4. The HVAC control module detects a calibratible procedure time that exceeds the calibratible value.
5. The HVAC control module detects the actuator motor as stalled before the actuator motor reaches the expected stall at the end of the travel. When the drive voltage is reversed, the motor is unable to move more than a calibratible amount in the other direction.
6. The HVAC control module detects the actuator motor as stalled before the actuator motor reaches the expected stall at the end of the travel. But, when the drive voltage is reversed, the motor is able to move more than a calibratible amount in the other direction.

2A

The HVAC control module will use a default range to retry calibration procedure when the ignition is OFF.

61

The HVAC control module will stop trying to move the air temperature actuator motor during the current ignition cycle.

04

The HVAC control module will retry the command to move the actuator in a certain direction in 5-minute intervals.

51

The HVAC control module will retry calibration when the ignition is OFF.

Intermittent

Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections .

HVAC Compressor Clutch Does Not Disengage

HVAC Compressor Clutch Does Not Disengage

Blower Motor Always On

Blower Motor Always On

Blower Motor Inoperative

Blower Motor Inoperative

Blower Motor Malfunction

Blower Motor Malfunction

Afterblow Enabling

The afterblow mode can be enabled using the scan tool. The afterblow mode allows the blower motor to operate after the engine has been turned off. This operation of the blower motor dries the evaporator core, which reduces the amount of microbial growth which can create undesirable odors.

Use the following procedure in order to enable the afterblow mode

1. Connect the Scan Tool.
2. Turn ON the ignition, with the engine OFF.
3. Select HVAC Module.
4. Select HVAC Systems Automatic.
5. Select Special Functions.
6. Select HVAC.
7. Select Afterblow Option.
8. Select ENTER to enable the afterblow.
9. When done, use the soft key to save changes.

When afterblow has been enabled by the scan tool the blower motor will operate at high speed for 4 minutes after the engine has been turned off.

The following conditions must be met for the HVAC module to operate the afterblow

1. The outside air temperature must be at least 21°C (70°F).
2. The A/C compressor must operate for more than 2 minutes.
3. The engine must be turned off for at least 45 minutes.
4. The system voltage must be at least 12 volts.

Re-Calibrating Actuators

When replacing the HVAC control module it will be necessary to allow the HVAC control module to perform a calibration process. When installing the HVAC control module be sure to perform the following

1. Place the ignition switch to the OFF position.
2. Disconnect the scan tool.
3. Install the HVAC control module.
4. Connect all previously disconnected components.
5. Start the vehicle.
6. Wait 40 seconds for the HVAC control module to self-calibrate.
7. Verify that no DTCs have set as current DTCs.

When replacing the HVAC actuator it will be necessary to allow the HVAC control module to perform a calibration process. When installing the HVAC actuator be sure to perform the following

Calibration Procedure

1. Clear all DTCs.
2. Place the ignition switch to the OFF position.
3. Install the HVAC actuator.
4. Connect all previously disconnected components.
5. Remove the HVAC (BATT) fuse for a minimum of 10 seconds.
6. Install the HVAC (BATT) fuse.
7. Start the vehicle.
8. Wait 40 seconds for the HVAC control module to self-calibrate.
9. Verify that no DTCs have set as current DTCs.

HVAC Control Module

The HVAC control module is a GMLAN device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The control module communicates on the low-speed data bus. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, then all HVAC DTCs and settings will be erased from KAM. The temperature display reading at the control head can be converted from °C to °F by pressing the Auto button for a minimum of 3 seconds. The ignition 3 voltage circuit provides a device on signal. The control module supports the following features

Air Delivery Description and Operation

Mode/Recirculation Actuator

The mode or recirculation actuator is a 2-wire bi-directional electric motor. Two control circuits enable the actuator to operate. The control circuits use either a 0 or 12-volt value to co-ordinate the actuator movement. When the actuator is at rest, both control circuits have a value of 0 volts. In order to move the actuator, the HVAC control module grounds the appropriate control circuit for the commanded direction. The HVAC control module reverses the polarity of the control circuits to move the actuator in the opposite direction.

The HVAC control module determines the door position by counting motor pulses on one of the control circuits. These pulses are small voltage fluctuations that occur when the brush is shorted across 2 commutator contacts as the motor rotates. As the actuator shaft rotates, the HVAC control module monitors the voltage drop across an internal resistance to detect the pulses. The HVAC control module converts the pulses to counts with a range of 0-255 counts. The HVAC control module uses a range of 0-255 counts to index the actuator position.

Blower Motor Control Processor

The blower motor control processor is an interface between the HVAC control module and the blower motor. The blower motor speed control, battery positive voltage and ground circuits enable the control processor to operate. The HVAC control module provides a pulse width modulation (PWM) signal to the control processor in order to command the blower motor speed. The processor supplies 12 volts to the blower motor through the blower motor voltage supply circuit. The control processor uses the blower motor ground as a low side control to adjust the blower motor speed.

Air Speed

The blower motor forces air to circulate within the vehicles interior. The vehicle operator determines the blower motors speed by placing the blower motor switch in a desired speed position. The blower motor will only operate if the blower motor switch is in any position other than OFF, and the ignition switch is in the RUN position.

Once a blower speed is selected, the blower speed remains constant until a new speed is selected.

As the requested blower speed increases, the following conditions occur

1. The HVAC control module increases the amount of time that the blower motor speed control circuit is modulated to ground.
2. The voltage and duty cycle, measured between the blower motor speed control circuit and ground, decrease.

As the requested blower speed decreases, the following conditions occur

1. The HVAC control module decreases the amount of time that the blower motor speed control circuit is modulated to ground.
2. The voltage and duty cycle, measured between the blower motor speed control circuit and ground, increase.

Afterblow

Afterblow is a feature that dries the evaporator core by operating the blower motor after the engine is turned off. This reduces the amount of microbial growth that can create undesirable odors. The vehicle does not come equipped with the afterblow feature turned on. If the afterblow feature is required due to an odor concern, it must be turned on by the scan tool.

The following conditions must be met for afterblow to operate

1. The A/C compressor operated for more than 10 seconds.
2. The A/C compressor, after operating for more than 10 seconds has not been deactivated for more than 10 minutes.
3. The system voltage is at least 11 volts to start and 10 volts to continue to run.
4. The ignition has been in the OFF position for at least 20 minutes.

Once the above conditions have been met the following sequence of events will occur

1. The blower will run for 4 minutes at 59 percent blower speed.
2. The recirculation door moves to outside air position.
3. The mode valve moves to the floor position.

Air Distribution

The HVAC control module controls the mode actuator in order to distribute airflow to a desired outlet. The mode switch provides the vehicle operator with the ability to override the automatic setting. When the mode switch is moved to the bi-level through defrost positions, the A/C compressor clutch engages and the recirculation actuator will be moved to the outside air position. When VENT is pressed, the following will occur

1. The mode valve will be moved to the panel position.
2. The recirculation actuator will follow user request if blower is on and power mode is in run.
3. The A/C compressor will follow user request if blower is on and power mode is in run.

Radio Display

This vehicle is equipped with a driver information center and it displays outside temperature through the radio display. If an outside temperature display concern occurs please refer to Outside Air Temperature Display Inaccurate or Inoperative .

The HVAC control module is a GMLAN device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The control module communicates on the low-speed data bus. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, then all HVAC DTCs and settings will be erased from KAM. The temperature display reading at the control head can be converted from °C to °F by pressing the Auto button for a minimum of 3 seconds. The HVAC control module during defrost modes will change the A/C compressor LED status from on to off. The ignition 3 voltage circuit provides a device on signal. The control module supports the following features

Air Temperature Description and Operation

Air Temperature Actuators

The air temperature actuator is a 2-wire bi-directional electric motor. Two control circuits enable the actuator to operate. The control circuits use either a 0 or 12-volt value to co-ordinate the actuator movement. When the actuator is at rest, both control circuits have a value of 0 volts. In order to move the actuator, the HVAC control module grounds the appropriate control circuit for the commanded direction. The HVAC control module reverses the polarity of the control circuits to move the actuator in the opposite direction. The HVAC control module determines the door position by counting motor pulses on one of the control circuits. These pulses are small voltage fluctuations that occur when the brush is shorted across 2 commutator contacts as the motor rotates. As the actuator shaft rotates, the HVAC control module monitors the voltage drop across an internal resistance to detect the pulses. The HVAC control module converts the pulses to counts with a range of 0-255 counts. The HVAC control module uses a range of 0-255 counts to index the actuator position.

Air Temperature Sensors

The air temperature sensors are 2-wire negative temperature co-efficient thermistors. The vehicle uses the following air temperature sensors

1. Ambient
2. Inside
3. Upper duct air temperature sensor
4. Lower duct air temperature sensor

A signal and low reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases, the sensor resistance decreases. The sensor signal decreases as the resistance decreases. The sensor signal varies between 0-5 volts. The HVAC control module converts the signal to a range between 0-255 counts.

The inside air temperature sensor is located within the HVAC control module. Replacement of this sensor involves the replacement of the HVAC control module. The inside air temperature sensor operates within a temperature range between -40 to +185°C (-40 to +365°F). If the sensor is shorted to ground, voltage, or an open, the system will operate using an estimated default value to allow the system to operate. The ambient temperature sensor operates within a temperature range between -40 to +87.5°C (-40 to +189.5°F). The sensor signal is read by the BCM, scaled appropriately and transmitted to the HVAC Control Module through the Low Speed bus. If the sensor is shorted to ground, voltage, or an open, the system will operate using a signal scaled appropriately to allow the system to operate.

The duct temperature sensor temperature response is different from the ambient and inside sensors. A signal and low reference circuit enables the sensor to operate. As the air temperature surrounding the sensor increases the sensor resistance decreases. The sensor operates within a temperature range between -40 to +80°C (-40 to +176°F).

Sunload Sensor

The sunload sensor is a 2-wire photo diode. The vehicle uses a single sunload sensor. The sensor is integrated into the ambient light sensor assembly along with the ambient light sensor. Low reference and signal circuits enable the sensor to operate. As the sunload increases, the sensor signal decreases. The sensor operates within an intensity range between completely dark and bright. The sensor signal varies between 0-5 volts. The sensor signal is read by the BCM, scaled appropriately and transmitted to the HVAC control module through the GM LAN Low Speed bus. Bright, or high intensity, light causes the vehicles inside temperature to increase. The HVAC system compensates for the increased temperature by diverting additional cool air into the vehicle.

A/C Refrigerant Pressure Sensor

The A/C refrigerant pressure sensor is a 3-wire piezoelectric pressure transducer. A 5-volt reference, low reference, and signal circuits enable the sensor to operate. The A/C pressure signal can be between 0-5 volts. When the A/C refrigerant pressure is low, the signal value is near 0 volts. When the A/C refrigerant pressure is high, the signal value is near 5 volts.

The A/C refrigerant pressure sensor prevents the A/C system from operating when an excessively high or low pressure condition exists.

If the powertrain control module (PCM) or engine control module (ECM) detects a failure in the A/C refrigerant pressure sensor or A/C High Side Pressure sensor circuit, the GM LAN Low Speed bus message sent to the HVAC control module will be invalid.

The afterblow function is not enabled from the factory. To enable function the following must occur. As soon as ignition is turned off, and all active processes are complete, the controller is put into sleep or low power mode. A high voltage wakeup is generated on the low speed GMLAN by the body control module (BCM) and the HVAC virtual network is activated. Embedded in GMLAN message is Afterblow control logic bit (Aftrblw_Active). The afterblow resides in the BCM. The BCM has a timer that tells the HVAC Control module to go to Hi blower. The HVAC afterblow function is used to eliminate the odor associated with A/C usage. The "After Blow" is a method where by the HVAC blower is run for a few minutes after the vehicle is turned OFF in order to physically blow off excess condensation and eliminate odors.

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.