O-RING REPLACEMENT
Note. Even though O-rings may look identical, it is extremely important that only recommended service replacement air conditioning O-rings be used or excessive leakage of refrigerant may occur.
Note. Always slip O-ring onto flange tube to ensure proper locating and sealing.
Install new DAEWOO approved service replacement air conditioning O-rings whenever a joint or a fitting is disassembled except when O-rings are provided on new components. When replacing O-rings on an air conditioning component or a joint connection, fitting design should be identified to ensure installation of correct air conditioning service replacement O-ring.
Some joint connections and components will implement a "captured" O-ring design fitting that uses a groove to retain O-ring. Others do not have a groove and use a non-captured or standard O-ring. Assembly and tightening procedures are same for both designs, but O-rings are different.
Before installation, verify that both O-rings and fittings have not been nicked or deformed. Deformed or nicked parts must be replaced. Failure to use proper service replacement parts and procedures may result in excessive refrigerant leakage.
REMOVAL & INSTALLATION
| WARNING | Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See appropriate AIR BAG RESTRAINT SYSTEMS article in RESTRAINTS. |
| CAUTION | When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. |
Note. For removal and installation procedures not covered in this article, see appropriate HEATER SYSTEMS article or COMPRESSOR SERVICING article in GENERAL SERVICING.
- Remove nut that secures air filter cover to fire wall. (Scheme 25) Remove cover. Pull air filter out of cavity in fire wall. (Scheme 26)
- Install air filter into its cavity in fire wall. Align fins on plastic frame of filter with grove in holder before attempting to insert filter into place.
- Install air filter cover with arrow pointing up. Install nut to secure air filter cover to fire wall. Tighten air filter cover nut to 35 INCH lbs. (4 N.m).
Scheme 24
Scheme 25
- Disconnect negative battery cable. Disconnect electrical connector. Remove motor retaining bolts. Slide Air Mix Door (AMD) motor off door shaft and remove AMD motor. (Scheme 27)
- To install, position AMD motor onto door shaft. Install AMD motor retaining bolts and tighten. Connect electrical connector. Connect negative battery cable.
Scheme 26
- Disconnect negative battery cable. Disconnect ambient air temperature sensor electrical connector. Remove retaining nut from bracket. Remove ambient air temperature sensor. (Scheme 28)
- Position ambient air temperature sensor into its bracket. Install retaining nut to bracket. Tighten ambient air temperature retaining bracket nut to 53 INCH lbs. (6 N.m). Connect electrical connector. Connect negative battery cable.
Scheme 27
- Disconnect negative battery cable. Remove l/P center molding. Remove Automatic Temperature Control (ATC) controller assembly retaining screws. (Scheme 29)
- Pull out ATC controller to gain access to rear. Disconnect electrical connectors. Remove Aspirator tube. Remove ATC controller assembly.
- To install, connect Aspirator tube. Connect electrical connectors. Position ATC controller assembly and install retaining screws. Tighten control assembly retaining screws to 35 INCH lbs. (1.65 N.m). Install I/P center molding. Connect negative battery cable.
Scheme 28
- Disconnect negative battery cable. Remove right console extension. Remove console assembly. Remove heater/air distributor case assembly lower cover screws. (Scheme 30) Remove heater/air distributor case assembly lower cover to gain access to coolant temperature sensor. Turn sensor to release it from heater/air distributor case housing. Disconnect electrical connector. (Scheme 31)
- Install coolant temperature sensor into heater/air distributor case housing and turn sensor to lock it. Connect electrical connector. Install heater/air distributor case assembly lower cover into position. Install heater/air distributor case assembly lower cover retaining screws and tighten. Install console assembly. Install right console extension. Connect negative battery cable.
Scheme 29
Scheme 30
- Remove heater/air distributor case assembly from vehicle. Remove motor lever and actuator rod. (Scheme 32) Remove motor screws and motor to access a hidden heater core cover bolt. Remove foam insulation from tube base. Remove remaining actuator rod from motor lever. Remove retaining screws that secure heater core cover to heater/air distributor case assembly.
- Slowly separate lower heater core cover from rest of assembly. Remove screw and bracket clamp that secure heater core lines to case. Remove spring clamp that secures heater core body to case. Remove heater core from case.
- Install heater core into case. Secure heater core lines to case with retaining bracket clamp and screw. (Scheme 33) Install heater core cover. Install and tighten screws that secure heater core cover to heater/air distributor case assembly. Install motor and screws for floor diverter. Install heater/air distributor case.
Scheme 31
Scheme 32
Scheme 33
Removal
- Disconnect negative battery cable. Remove instrument panel carrier assembly. Drain cooling system. Recover refrigerant. Remove retaining nuts that secure suction hose and liquid evaporator pipe blocks at fire wall. (Scheme 35)
- Loosen clamp bolts from suction hose and liquid evaporator pipe to allow movement of hose and pipe. Remove evaporator drain hose. Compress heater hose clamps at fire wall and slide clamps toward engine. Remove 2 heater hoses from core lines at fire wall. (Scheme 36)
- Remove screws that secure heater/air distributor case assembly to fire wall on either side of heater hoses. Remove heater/air distributor case screw, that is located adjacent to fuel filter, from engine compartment side of fire wall. (Scheme 37) Have an assistant support heater/air distributor case from inside vehicle.
- Remove heater/air distributor case screws from evaporator flange on engine compartment side of fire wall. (Scheme 38) The heater/air distributor case assembly will start to drop. Pull case straight away from fire wall. Remove heater/air distributor case assembly from vehicle.
Installation
- Position heater/air distributor case assembly in vehicle. NOTE: To avoid damaging heater core tubes, make sure they do not contact fire wall opening.
- Slowly raise heater/air distributor case assembly into position and hold it against fire wall while screws are installed and tightened from engine side of fire wall. Align and install heater/air distributor case assembly screws above fuel filter and at evaporator flange. Tighten heater/air distributor case assembly screws to 71 INCH lbs. (8 N.m).
- Install heater/air distributor case assembly screws adjacent to heater hoses. Tighten heater/air distributor case assembly screws to 71 INCH lbs. (8 N.m). Install evaporator drain hose. Install 2 heater hoses. Slide heater hose clamps into position.
- Install instrument panel carrier assembly. Install new O-rings on suction hose and liquid evaporator pipe at fire wall and put pipes back in place. Install retaining nuts that secure suction hose and liquid evaporator pipe blocks at fire wall.
- Tighten suction hose and liquid evaporator pipe retaining nuts to 89 INCH lbs. (10 N.m). Fill cooling system. Recharge A/C system. Connect negative battery cable.
Scheme 34
Scheme 35
Scheme 36
Scheme 37
- Disconnect negative battery cable. Remove Aircon cover. (Scheme 39) Disconnect electrical connector. Remove actuating rod by snapping it out of lever with needle-nose pliers. Remove motor lever from its shaft by pulling lever off. Remove motor retaining bolts. Remove heater/defroster door motor. (Scheme 40)
- Install heater/defroster door motor. Install retaining bolt and tighten. Press lever onto motor shaft. Install actuating rod onto lever. Connect electrical connector. Install Aircon cover. Connect negative battery cable.
Scheme 38
Scheme 39
- Disconnect negative battery cable. The relay is located in front of blower motor. Slide relay and connector up and out of its retaining track. Separate relay from connector.
- To install, align high-blower relay contacts with high-blower relay terminal slots. (Scheme 41) Push relay firmly into base. The relay must be seated and flush with edge of base. Connect negative battery cable.
Scheme 40
- Disconnect negative battery cable. Remove automatic temperature control assembly. Remove screws securing in-car temperature sensor. (Scheme 42) Disconnect electrical connector and remove sponge cover. Remove in-car temperature sensor from controller.
- Install in-car temperature sensor into controller. Install sponge cover and connect electrical connector. Install in-car sensor retaining screws and tighten. Install automatic temperature control assembly. Connect battery negative cable.
Scheme 41
- Disconnect negative battery cable. Remove glove box. Remove actuating rod by snapping rod out of lever with needle-nose pliers. Remove actuating lever. Disconnect electrical connector. Remove motor retaining bolts. Remove motor.
- Install motor. Install motor retaining bolts and tighten. Install actuating lever. Install actuating rod. Connect electrical connector. Install glove box. Connect negative battery cable.
Scheme 42
- Disconnect negative battery cable. Remove Aircon cover. Disconnect electrical connector. Remove motor actuating rod by snapping out it out of lever with needle-nose pliers. Remove motor lever. Remove motor retaining bolts. Remove mode door motor.
- Install mode door motor. Install motor retaining bolts and tighten. (Scheme 44)Install motor lever by pressing it onto its shaft. Install actuating rod. Connect electrical connector. Install Aircon cover. Connect negative battery cable.
Scheme 43
- Disconnect negative battery cable. Disconnect electrical connector at resistor. Remove screws from resistor. Remove resistor from heater/air distributor case assembly by gently pulling resistor downward.
- Install new resistor into heater/air distributor case assembly with screws. (Scheme 46) Tighten blower motor resistor screws to 53 INCH lbs. (6 N.m). Connect electrical connector at resistor. Connect negative battery cable. Confirm proper performance of blower.
Scheme 44
Scheme 45
- Disconnect negative battery cable. Gently pry up on sun sensor to remove it. Secure electrical connector to prevent it from falling beneath dash. Disconnect electrical connector.
- To install, connect electrical connector. Insert and press sun sensor into position in dash. Connect negative battery cable.
