Fluorescent Leak Detector
Fluorescent dye will assist in locating any leaks in the A/C system.
- 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.
- 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.
- Follow the instructions supplied with the J 42220 . See «Special Tools»(ref-197012-S41925114452005101000000) .
- To prevent false diagnosis in the future, thoroughly clean the residual dye from any area where leaks were found. Clean any refrigerant dye on components with brake and choke cleaner, Saturn P/N 21007432.
- If any refrigerant dye contacts an exterior paint surface, remove it by performing the following steps: Carefully wash affected surfaces according to the Saturn Owner's Handbook to remove any dirt and to ensure that paint is not scratched during dye removal. Mix water and isopropyl alcohol to obtain 50/50 mixture. Soak a soft 100 percent cotton cloth towel with the solution and wet down the affected areas to remove dye. After dye has been removed, wash affected areas and inspect to make sure that the dye has been removed.
Fluorescent Dye Injection
- 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.
- 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.
- With the A/C system charged, add J 41447 to the A/C system using J 46297 . See «Special Tools»(ref-197012-S41925114452005101000000) . Follow the instructions provided with J 46297 . See «Special Tools»(ref-197012-S41925114452005101000000) .
- To prevent false diagnosis in the future, thoroughly clean the residual dye from any area where leaks were found. Clean any refrigerant dye on components with brake and choke cleaner, Saturn P/N 21007432.
- The dye injection package contains a notice sticker. Complete the leak detection information and place the sticker near the charge label.
Halogen Leak Detector
| CAUTION | Do not operate the detector in a combustible atmosphere since its sensor operates at high temperatures or personal injury and/or damage to the equipment may result. |
Ensure that the vehicle has at least 0.41 kg (0.9 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.
| IMPORTANT | 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.
| IMPORTANT | 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 . See Special Tools .
Defrosting Insufficient
| Step | Action | Yes | No |
|---|---|---|---|
| DEFINITION: Time required to defrost the windshield is longer than usual. | |||
| 1 | Were you sent here from Symptoms or another diagnostic table? | Go to Step 2 | Go to Symptoms - HVAC Systems - Manual in HVAC Systems-Manual |
| 2 | Start the engine. Select the DEFROST mode. Select the maximum blower speed. Does sufficient air flow from the defroster outlets? | Go to Step 3 | Go to Step 11 |
| 3 | Measure the engine operating temperature. Does engine reach normal operating temperature? | Go to Step 4 | Go to Step 9 |
| 4 | Select the minimum blower speed. Select the warmest temperature setting. Feel the temperature of the inlet and outlet hoses at the heater core. Does the inlet heater hose feel warmer than the outlet heater hose? | Go to Step 12 | Go to Step 5 |
| 5 | Is the vehicle equipped with A/C? | Go to Step 6 | Go to Step 14 |
| 6 | Test the operation of the A/C compressor clutch. Does the A/C compressor clutch engage? | Go to Step 8 | Go to Step 7 |
| 7 | Repair the A/C compressor clutch. Refer to HVAC Compressor Clutch Does Not Engage in HVAC Systems-Manual. Is the repair complete? | Go to Step 15 | |
| 8 | Perform the A/C system performance test. Refer to Air Conditioning (A/C) System Performance Test (2.2 L61) or Air Conditioning (A/C) System Performance Test (2.0 LSJ ) . Is the A/C system operating within the specifications? | Go to Step 10 | Go to Step 13 |
| 9 | Repair the low engine temperature concern. Refer to Engine Fails To Reach Normal Operating Temperature in Engine Cooling. Is the repair complete? | Go to Step 15 | |
| 10 | Inspect for correct operation of the recirculation door. Is the recirculation door operating correctly? | Go to Step 15 | Go to Step 14 |
| 11 | Repair the air delivery concern. Refer to Air Delivery Improper in HVAC Systems - Manual. Is the repair complete? | Go to Step 15 | |
| 12 | Repair the heating concern. Refer to Heating Performance Diagnostic . Is the repair complete? | Go to Step 15 | |
| 13 | Repair the A/C performance concern. Refer to Air Conditioning (A/C) System Performance Test (2.2 L61) or Air Conditioning (A/C) System Performance Test (2.0 LSJ ) . Is the repair complete? | Go to Step 15 | |
| 14 | Repair the recirculation door concern. Refer to Air Recirculation Malfunction in HVAC Systems - Manual. Is the repair complete? | Go to Step 15 | |
| 15 | Operate the system in order to verify the repair. Did you find and correct the condition? | System OK | Go to Step 2 |
Defrosting Insufficient
High or Low Mode Control Effort
| Step | Action | Yes | No |
|---|---|---|---|
| DEFINITION: The mode control operates with either too much or too little effort. | |||
| 1 | Were you sent here from Symptoms or another diagnostic table? | Go to Step 2 | Go to Symptoms - HVAC Systems - Manual |
| 2 | Is one of the following a concern of the customer: The mode control operates with little or no resistance. The HVAC outlet air is constant, regardless of the mode control setting. While driving the vehicle the mode control setting changes. Does the mode control operate too freely? | Go to Step 3 | Go to Step 7 |
| 3 | With the ignition in the ON position: Select the HIGH blower motor speed. Cycle the mode control through all of the settings. Does the air outlet change through all of the modes? | Go to Step 16 | Go to Step 4 |
| 4 | Inspect the connections of the mode control cable. Is the mode control cable disconnected from the mode cam? | Go to Step 15 | Go to Step 5 |
| 5 | Inspect the mode control cable and cam, while operating the mode controls. Does the mode cam move while operating the mode controls? | Go to Step 21 | Go to Step 6 |
| 6 | Inspect the cable casing while operating the mode controls. Does the cable casing move, instead of the cable, while operating the mode controls? | Go to Step 18 | Go to Step 21 |
| 7 | Inspect the HVAC control assembly for any debris or obstructions that would increase the effort to operate the mode controls. Are there any obstructions? | Go to Step 20 | Go to Step 8 |
| 8 | Disconnect the mode control cable from the mode cam. Operate the HVAC control assembly with the mode control cable disconnected. Does the HVAC control assembly bind now? | Go to Step 10 | Go to Step 9 |
| 9 | With the mode control cable disconnected: Manually operate the mode cam. Inspect for binding. Does the mode cam bind with the cable disconnected? | Go to Step 19 | Go to Step 10 |
| 10 | Disconnect the mode control cable from the HVAC control assembly. Operate the HVAC control assembly with the cable disconnected. Does the HVAC control assembly bind now? | Go to Step 16 | Go to Step 11 |
| 11 | With the mode control cable disconnected at both ends: Extend the cable in both directions. Inspect the cable for binding. Does the mode control cable bind? | Go to Step 17 | Go to Step 12 |
| 12 | Inspect the mode control cable for kinks or bends from incorrect routing. Repair the cable or routing as necessary. Does the mode cable still bind? | Go to Step 17 | Go to Step 13 |
| 13 | Operate the HVAC control assembly with the mode control cable disconnected. Does the HVAC control assembly bind now? | Go to Step 16 | Go to Step 14 |
| 14 | Reassemble the mode control system. Is the action complete? | Go to Step 21 | |
| 15 | Reconnect the mode control cable to the mode cam and install the cable retainers. Is the action complete? | Go to Step 21 | |
| 16 | Replace the HVAC control assembly. Refer to HVAC Control Assembly Replacement in HVAC Systems-Manual. Is the repair complete? | Go to Step 21 | |
| 17 | Replace the mode control cable. Refer to Mode Control Cable Replacement in HVAC Systems-Manual. Is the repair complete? | Go to Step 21 | |
| 18 | Secure the mode control cable casing. Is the action complete? | Go to Step 21 | |
| 19 | Repair the binding door or replace the upper HVAC case assembly. Refer to Air Conditioning (A/C) Evaporator and Blower Module Assembly Replacement or Heater Assembly Replacement . Is the repair complete? | Go to Step 21 | |
| 20 | Remove the debris. Is the action complete? | Go to Step 21 | |
| 21 | Operate the system in order to verify the repair. Did you find and correct the condition? | System OK | Go to Step 2 |
High or Low Mode Control Effort
High or Low Temperature Control Effort
| Step | Action | Yes | No |
|---|---|---|---|
| DEFINITION: The temperature control operates with either too much or too little effort. | |||
| 1 | Were you sent here from Symptoms or another diagnostic table? | Go to Step 2 | Go to Symptoms - HVAC Systems - Manual in HVAC Systems-Manual |
| 2 | Is one of the following a concern of the customer: The temperature control operates with little or no resistance. The HVAC outlet air temperature is constant, regardless of the temperature control setting. While driving the vehicle the temperature control setting changes. Does the temperature control operate too freely? | Go to Step 3 | Go to Step 7 |
| 3 | Idle the engine at normal operating temperature. Cycle the temperature control from the coldest setting to the warmest setting. Does the temperature change from cold to hot? | Go to Step 17 | Go to Step 4 |
| 4 | Inspect the connections of the temperature control cable. Is the temperature control cable disconnected from the temperature door? | Go to Step 15 | Go to Step 5 |
| 5 | Inspect the temperature control cable and linkage at the temperature door, while operating the temperature controls. Does the temperature door move while operating the temperature controls? | Go to Step 22 | Go to Step 6 |
| 6 | Inspect the cable casing while operating the temperature controls. Does the cable casing move, instead of the cable, while operating the temperature controls? | Go to Step 19 | Go to Step 16 |
| 7 | Inspect the HVAC control assembly for any debris or obstructions that would increase the effort to operate the temperature controls. Are there any obstructions? | Go to Step 21 | Go to Step 8 |
| 8 | Disconnect the temperature control cable from the temperature door. Operate the HVAC control assembly with the temperature control cable disconnected. Does the HVAC control assembly bind now? | Go to Step 10 | Go to Step 9 |
| 9 | With the temperature control cable disconnected: Manually operate the temperature door. Inspect the door for binding. Does the temperature door bind with the cable disconnected? | Go to Step 20 | Go to Step 10 |
| 10 | Disconnect the temperature control cable from the HVAC control assembly. Operate the HVAC control assembly with the cable disconnected. Does the HVAC control assembly bind now? | Go to Step 17 | Go to Step 11 |
| 11 | With the temperature control cable disconnected at both ends: Extend the cable in both directions. Inspect the cable for binding. Does the temperature control cable bind? | Go to Step 18 | Go to Step 12 |
| 12 | Inspect the temperature control cable for kinks or bends from incorrect routing. Repair the cable or routing as necessary. Does the temperature cable still bind? | Go to Step 18 | Go to Step 13 |
| 13 | Operate the HVAC control assembly with the temperature control cable disconnected. Does the HVAC control assembly bind now? | Go to Step 17 | Go to Step 14 |
| 14 | Reassemble the temperature control system. Is the action complete? | Go to Step 22 | |
| 15 | Reconnect the temperature control cable to the temperature door linkage install the cable retainers. Is the action complete? | Go to Step 22 | |
| 16 | Repair the lack of heating or lack of cooling condition. Refer to Diagnostic Starting Point - Heating, Ventilation and Air Conditioning . Is the action complete? | Go to Step 22 | |
| 17 | Replace the HVAC control assembly. Refer to HVAC Control Assembly Replacement in HVAC Systems-Manual. Is the repair complete? | Go to Step 22 | |
| 18 | Replace the temperature control cable. Refer to Temperature Control Cable Replacement in HVAC-Systems Manual. Is the repair complete? | Go to Step 22 | |
| 19 | Secure the temperature control cable casing. Is the action complete? | Go to Step 22 | |
| 20 | Repair the binding door. Is the repair complete? | Go to Step 22 | |
| 21 | Remove the debris. Is the action complete? | Go to Step 22 | |
| 22 | Operate the system in order to verify the repair. Did you find and correct the condition? | System OK | Go to Step 2 |
High or Low Temperature Control Effort
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
- Debris is present in the HVAC module.
- 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
- Ensure that the plenum which draws outside air into the HVAC module is clear of debris.
- Disable the A/C compressor clutch operation by disconnecting the clutch coil electrical connector.
- 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.
- Locate an area in the HVAC module case between the blower motor and the evaporator core downstream of the blower motor.
- 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
- 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.
- Shut the engine OFF. Allow the vehicle to sit for 3-5 minutes.
- Seal the 3.175 mm (0.125 in) hole with body sealer or RTV gasket compound.
- Start the engine.
- Operate the blower motor on high for 15-20 minutes to dry.
- Reconnect the A/C compressor clutch coil electrical connector.
- Verify proper clutch operation.
Tools Required
J 43600 ACR 2000 Air Conditioning Service Center. See Special Tools .
| CAUTION | Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. |
| CAUTION | For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. |
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 added to the system by pouring the correct amount into the replaced component or into an open refrigerant line. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities .
J 39400-A Halogen Leak Detector. See Special Tools .
J 39400-A Halogen Leak Detector. See Special Tools .
J 39400-A Halogen Leak Detector. See Special Tools .
J 39400-A Halogen Leak Detector. See Special Tools .
J 39400-A Halogen Leak Detector. See Special Tools .
J 39400-A Halogen Leak Detector. See Special Tools .
J 39400-A Halogen Leak Detector. See Special Tools .
J 39400-A Halogen Leak Detector. See Special Tools .
J 39400-A Halogen Leak Detector. See Special Tools .
J 39400-A Halogen Leak Detector. See Special Tools .
J 39400-A Halogen Leak Detector. See Special Tools .
J 39400-A Halogen Leak Detector. See Special Tools .
J 39400-A Halogen Leak Detector. See Special Tools .
SA9111E Hose Clamp Pliers
| CAUTION | With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. |
SA9111E Hose Clamp Pliers
| CAUTION | With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. |
SA9111E Hose Clamp Pliers
| CAUTION | With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. |
SA9111E Hose Clamp Pliers
SA9111E Hose Clamp Pliers
| CAUTION | With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result. |