Fastener Tightening Specifications
| Application | Specification |
|---|
| Metric | English |
| A/C Refrigerant Valve | 11 N.m | 98 lb in |
| Bolt, A/C Compressor | 22 N.m | 16 lb ft |
| Bolt, A/C Condenser | 9 N.m | 80 lb in |
| Bolt, Distributor Air | 2.5 N.m | 16 lb in |
| Bolt, Hose Assembly, A/C Compressor and Condenser Hose | 22 N.m | 16 lb ft |
| Bolt, Radiator Assembly | 25 N.m | 18 lb ft |
| Bolt, Receiver Dehydrator Assembly | 6 N.m | 53 lb in |
| Bolt, Thermal Expansion Valve | 16 N.m | 12 lb ft |
| Bolt, Thermal Expansion Valve | 1.5 N.m | 13 lb in |
| Nut, A/C Condenser Tube | 9 N.m | 80 lb in |
| Nut, Air Inlet Housing | 9 N.m | 80 lb in |
| Nut, Distributor Air | 2.5 N.m | 16 lb in |
| Nut, Hose Assembly, A/C Compressor and Condenser Hose | 9 N.m | 80 lb in |
| Nut, Hose Assembly, A/C Evaporator | 16 N.m | 12 lb ft |
| Nut, Hose Assembly, A/C Evaporator Clip | 9 N.m | 80 lb in |
| Nut, HVAC Module Assembly | 9 N.m | 80 lb in |
| Nut, Tube Assembly, A/C Compressor | 16 N.m | 12 lb ft |
| Nut, Tube Assembly, A/C Condenser | 9 N.m | 80 lb in |
| Screw, Air Distribution Case | 1.5 N.m | 13 lb in |
| Screw, Air Inlet Housing | 1.5 N.m | 13 lb in |
| Screw, Air Outlet Duct | 1.5 N.m | 13 lb in |
| Screw, Blower Motor | 1.5 N.m | 13 lb in |
| Screw, Blower Motor Resistor | 1.5 N.m | 13 lb in |
| Screw, Evaporator Case Assembly | 1.5 N.m | 13 lb in |
| Screw, Heater Core Cover | 1.5 N.m | 13 lb in |
| Screw, Mode Actuator | 1.5 N.m | 13 lb in |
| Screw, Rear Air Outlet Duct | 1.5 N.m | 13 lb in |
| Screw, Receiver Dehydrator | 1.5 N.m | 13 lb in |
| Sensor, A/C Refrigerant Pressure | 5 N.m | 44 lb in |
Refrigerant System Specifications
| Application | Specification |
|---|
| Metric | English |
| PAG Oil GM P/N 12378526 for United States PAG Oil GM P/N 88900060 for Canada |
| Abrupt Refrigerant Loss | 60 ml 1 | 2.0 oz 1 |
| Compressor Replacement | 74 ml 2 | 2.5 oz 2 |
| The Sanden PXV16 service compressor is used in this model year vehicle is precharged with 74 ml (2.5 oz) of PAG oil. |
| Condenser Replacement | 30 ml 2 | 1.0 oz 2 |
| Evaporator Replacement | 30 ml 2 | 1.0 oz 2 |
| Receiver Dehydrator Replacement | 30 ml 2 | 1.0 oz 2 |
| Total System PAG Oil Capacity | 118 ml | 4.0 oz |
| R-134a |
| Refrigerant Charge | 0.47 kg | 1.03 lbs |
| 1 Abrupt refrigerant loss due to large leak, hose rupture, collision, or pressure relief valve opening. Conditions that allow the refrigerant to seep or bleed off over time do not cause this oil loss. Upon replacement of a component that caused a large refrigerant loss, also add the required amount of oil for the particular component. 2 If more than the specified amount of PAG oil was drained from a component, add the equal amount of oil drained. |
Refrigerant System Capacities
Special Tools
- J 39400-A Halogen Leak Detector
- J 41447 R-134A A/C Tracer Dye-Box of 24. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
- J 42220 Universal 12V Leak Detection Lamp. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
- J 43872 Fluorescent Dye Cleaner. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
- J 46297 A/C Dye Injector Kit. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
- J 46297-12 Replacement Dye Cartridges. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
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 , 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.
- 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»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
- To prevent false diagnosis in the future, thoroughly clean the residual dye from any area where leaks were found. Use a rag and the approved J 43872 . See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
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.
- To prevent false diagnosis, thoroughly clean any residual dye from the service port with a rag and the approved fluorescent dye cleaner J 43872 . See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Halogen Leak Detector
| WARNING | 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 0.45 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 .
Air Conditioning (A/C) System Performance Test (LE5)
This test measures the operating efficiency of the A/C system under the following conditions
- The current ambient air temperature
- The current relative humidity
- The high side pressure of the A/C system
- The low side pressure of the A/C system
- The temperature of the air being discharged into the passenger compartment
Test Description
The numbers below refer to the step numbers on the diagnostic table below.
- 1: This step determines if the A/C system has at least the minimum refrigerant charge required to operate the system without damage.
- 2: This step measures the performance of the A/C system.
- 3: This step is to allow for vehicle variations as well as high ambient temperatures.
| Step | Action | Values | Yes | No |
|---|
| IMPORTANT: The ambient air temperature must be at least 16°C (60°F). Do not induce additional air flow across the front of the vehicle during the test. If you were sent here from a DTC diagnostic table, clear the DTC upon completion of this test. |
| 1 | Park the vehicle inside or in the shade. Open the windows in order to ventilate the interior of the vehicle. If the A/C system was operating, allow the A/C system to equalize for about 2 minutes. Turn OFF the ignition. Install the J 43600 ACR 2000 Air Conditioning Service Center. See Special Tools . Record the ambient air temperature displayed on the J 43600 . See Special Tools . Record the low and high side STATIC pressure readings. Are both the low side and high side pressures within the specified value? | More than 16°C (60°F) - 345 kPa (50 psi) More than 24°C (75°F) - 483 kPa (70 psi) More than 33°C (90°F) - 690 kPa (100 psi) | Go to Step 2 | Go to Leak Testing |
| 2 | IMPORTANT: Record the relative humidity and the ambient air temperature at the time of the test. Close the vehicle doors and windows. Open the drivers door window 12.7-15.2 cm (5-6 in). Select the following HVAC control settings: The A/C is ON. The coldest temperature setting The maximum blower speed Recirculation mode The I/P panel outlet mode All I/P panel outlets are OPEN. Install the temperature probes of the J 43600 in the left and right center panel air outlets. See Special Tools . Apply the parking brake. Place the transaxle/transmission in one of the following positions: PARK (Automatic) NEUTRAL (Manual) Start the engine and warm to operating temperature. Operate the A/C system for 5 minutes. Inspect A/C components for the following conditions: Abnormal frost areas Unusual noises IMPORTANT: Press the RESET button, before using the print function of the J 43600 . See Special Tools . Print the following information: The panel outlet air temperatures The low-side pressure The high-side pressure Compare the low and high side pressures and the panel output temperatures to the A/C Performance Table below. Does all the data recorded fall within the specified ranges of the A/C Performance Table below? | | Go to Step 8 | Go to Step 3 |
| 3 | If the pressures and temperatures recorded do not fall within the specified ranges: Continue to operate the A/C system for an additional 5 minutes. RESET the J 43600 and record the pressures and temperatures again. See Special Tools . Compare the low and high side pressures and the panel output temperature to the table below. Does all the data recorded fall within the specified ranges of the table below? | | Go to Step 8 | Go to Step 4 |
| 4 | Do the high and low side pressures fall within the specified ranges, but the panel outlet temperatures do not? | | Go to Air Conditioning (A/C) Diagnostics - Pressure Zone A | Go to Step 5 |
| 5 | Is the low side pressure greater than the specified range, but the high side pressure within or less than the specified range? | | Go to Air Conditioning (A/C) Diagnostics - Pressure Zone B | Go to Step 6 |
| 6 | Are the low and high side pressures both greater than the specified ranges? | | Go to Air Conditioning (A/C) Diagnostics - Pressure Zone C | Go to Step 7 |
| 7 | Is the high side pressure greater than the specified range, but the low side pressure is within or less than the specified range? | | Go to Air Conditioning (A/C) Diagnostics - Pressure Zone D | Go to Step 8 |
| 8 | Operate the system in order to verify the test results. Did you find the same results? | | System OK | Go to Symptoms - HVAC Systems - Manual |
| IMPORTANT |
|---|
| The ambient air temperature must be at least 16°C (60°F). Do not induce additional air flow across the front of the vehicle during the test. If you were sent here from a DTC diagnostic table, clear the DTC upon completion of this test. |
| IMPORTANT |
|---|
| Record the relative humidity and the ambient air temperature at the time of the test. |
| IMPORTANT |
|---|
| Press the RESET button, before using the print function of the J 43600 . See Special Tools . |
Scheme 1
| Ambient Temperature | Relative Humidity | Low Side Service Port Pressure | High Side Service Port Pressure | Maximum Left Center Discharge Air Temperature |
|---|
| 13-18°C (55-65°F) | 0-100% | 151-220 kPa (22-32 psi) | 578-888 kPa (84-129 psi) | 5°C (41°F) |
| 19-24°C (66-75°F) | Below 40% | 151-241 kPa (22-35 psi) | 799-1157 kPa (116-168 psi) | 8°C (45°F) |
| Above 40% | 165-261 kPa (24-38 psi) | 813-1191 kPa(118-173 psi) | 9°C (48°F) |
| 25-29°C (76-85°F) | Below 35% | 192-275 kPa (28-40 psi) | 1061-1378 kPa (154-200 psi) | 10°C (50°F) |
| 35-50% | 199-282 kPa (29-41 psi) | 1067-1398 kPa (155-203 psi) | 12°C (52°F) |
| Above 50% | 206-296 kPa (30-43 psi) | 1088-1440 kPa (158-209 psi) | 13°C (54°F) |
| 30-35°C (86-95°F) | Below 30% | 227-310 kPa (33-45 psi) | 1267-1632 kPa (184-237 psi) | 13°C (55°F) |
| 30-50% | 234-316 kPa (34-46 psi) | 1288-1667 kPa (187-242 psi) | 14°C (57°F) |
| Above 50% | 241-330 kPa (35-48 psi) | 1322-1729 kPa (192-251 psi) | 15°C (59°F) |
| 36-41°C (96-105°F) | Below 20% | 261-351 kPa (38-51 psi) | 1508-1867 kPa (219-271 psi) | 17°C (61°F) |
| 20-40% | 268-351 kPa (39-51 psi) | 1529-1929 kPa (222-280 psi) | 18°C (63°F) |
| Above 40% | 275-358 kPa (40-52 psi) | 1570-1977 kPa (228-287 psi) | 18°C (64°F) |
| 42-46°C (106-115°F) | Below 20% | 310-385 kPa (45-56 psi) | 1770-2087 kPa (257-303 psi) | 19°C (66°F) |
| Above 20% | 310-385 kPa (45-56 psi) | 1791-2149 kPa (260-312 psi) | 20°C (68°F) |
| 47-49°C (116-120°F) | Below 30% | 344-420 kPa (50-61 psi) | 2011-2342 kPa (292-340 psi) | 23°C (72°F) |
Air Conditioning (A/C) System Performance Test (LNF)
This test measures the operating efficiency of the A/C system under the following conditions
- The current ambient air temperature
- The current relative humidity
- The high side pressure of the A/C system
- The low side pressure of the A/C system
- The temperature of the air being discharged into the passenger compartment
The numbers below refer to the step numbers on the diagnostic table below.
- 1: This step determines if the A/C system has at least the minimum refrigerant charge required to operate the system without damage.
- 2: This step measures the performance of the A/C system.
- 3: This step is to allow for vehicle variations as well as high ambient temperatures.
| Step | Action | Values | Yes | No |
|---|
| IMPORTANT: The ambient air temperature must be at least 16°C (60°F). Do not induce additional air flow across the front of the vehicle during the test. If you were sent here from a DTC diagnostic table, clear the DTC upon completion of this test. |
| 1 | Park the vehicle inside or in the shade. Open the windows in order to ventilate the interior of the vehicle. If the A/C system was operating, allow the A/C system to equalize for about 2 minutes. Turn OFF the ignition. Install the J 43600 ACR 2000 Air Conditioning Service Center. See Special Tools . Record the ambient air temperature displayed on the J 43600 . See Special Tools . Record the low and high side STATIC pressure readings. Are both the low side and high side pressures within the specified value? | More than 16°C (60°F) - 345 kPa (50 psi) More than 24°C (75°F) - 483 kPa (70 psi) More than 33°C (90°F) - 690 kPa (100 psi) | Go to Step 2 | Go to Leak Testing |
| 2 | IMPORTANT: Record the relative humidity and the ambient air temperature at the time of the test. Close the vehicle doors and windows. Open the drivers door window 12.7-15.2 cm (5-6 in). Select the following HVAC control settings: The A/C is ON. The coldest temperature setting The maximum blower speed Recirculation mode The I/P panel outlet mode All I/P panel outlets are OPEN. Install the temperature probes of the J 43600 in the left and right center panel air outlets. See Special Tools . Apply the parking brake. Place the transaxle/transmission in one of the following positions: PARK (Automatic) NEUTRAL (Manual) Start the engine and warm to operating temperature. Operate the A/C system for 5 minutes. Inspect A/C components for the following conditions: Abnormal frost areas Unusual noises IMPORTANT: Press the RESET button, before using the print function of the J 43600 . See Special Tools . Print the following information: The panel outlet air temperatures The low-side pressure The high-side pressure Compare the low and high side pressures and the panel output temperatures to the A/C Performance Table below. Does all the data recorded fall within the specified ranges of the A/C Performance Table below? | | Go to Step 8 | Go to Step 3 |
| 3 | If the pressures and temperatures recorded do not fall within the specified ranges: Continue to operate the A/C system for an additional 5 minutes. RESET the J 43600 and record the pressures and temperatures again. See Special Tools . Compare the low and high side pressures and the panel output temperature to the table below. Does all the data recorded fall within the specified ranges of the table below? | | Go to Step 8 | Go to Step 4 |
| 4 | Do the high and low side pressures fall within the specified ranges, but the panel outlet temperatures do not? | | Go to Air Conditioning (A/C) Diagnostics - Pressure Zone A | Go to Step 5 |
| 5 | Is the low side pressure greater than the specified range, but the high side pressure within or less than the specified range? | | Go to Air Conditioning (A/C) Diagnostics - Pressure Zone B | Go to Step 6 |
| 6 | Are the low and high side pressures both greater than the specified ranges? | | Go to Air Conditioning (A/C) Diagnostics - Pressure Zone C | Go to Step 7 |
| 7 | Is the high side pressure greater than the specified range, but the low side pressure is within or less than the specified range? | | Go to Air Conditioning (A/C) Diagnostics - Pressure Zone D | Go to Step 8 |
| 8 | Operate the system in order to verify the test results. Did you find the same results? | | System OK | Go to Symptoms - HVAC Systems - Manual |
| IMPORTANT |
|---|
| The ambient air temperature must be at least 16°C (60°F). Do not induce additional air flow across the front of the vehicle during the test. If you were sent here from a DTC diagnostic table, clear the DTC upon completion of this test. |
| IMPORTANT |
|---|
| Record the relative humidity and the ambient air temperature at the time of the test. |
| IMPORTANT |
|---|
| Press the RESET button, before using the print function of the J 43600 . See Special Tools . |
Scheme 2
| Ambient Temperature | Relative Humidity | Low Side Service Port Pressure | High Side Service Port Pressure | Maximum Left Center Discharge Air Temperature |
|---|
| 13-18°C (55-65°F) | 0-100% | 151-220 kPa (22-32 psi) | 937-1398 kPa (136-203 psi) | 8°C (46°F) |
| 19-24°C (66-75°F) | Below 40% | 151-227 kPa (22-33 psi) | 1012-1467 kPa (147-213 psi) | 9°C (48°F) |
| Above 40% | 151-254 kPa (22-37 psi) | 1136-1619 kPa (165-235 psi) | 10°C (50°F) |
| 25-29°C (76-85°F) | Below 35% | 165-248 kPa (24-36 psi) | 1288-1660 kPa (187-241 psi) | 12°C (52°F) |
| 35-50% | 179-261 kPa (26-38 psi) | 1371-1708 kPa (199-248 psi) | 13°C (54°F) |
| Above 50% | 192-282 kPa (28-41 psi) | 1433-1798 kPa (208-261 psi) | 13°C (55°F) |
| 30-35°C (86-95°F) | Below 30% | 192-275 kPa (28-40 psi) | 1508-1887 kPa (219-274 psi) | 14°C (57°F) |
| 30-50% | 206-289 kPa (30-42 psi) | 1557-1949 kPa (226-283 psi) | 15°C (59°F) |
| Above 50% | 220-310 kPa (32-45 psi) | 1632-2018 kPa (237-293 psi) | 17°C (61°F) |
| 36-41°C (96-105°F) | Below 20% | 227-303 kPa (33-44 psi) | 1756-2129 kPa (255-309 psi) | 18°C (63°F) |
| 20-40% | 234-316 kPa (34-46 psi) | 1791-2156 kPa (260-313 psi) | 18°C (63°F) |
| Above 40% | 241-323 kPa (35-47 psi) | 1839-2197 kPa (267-319 psi) | 19°C (65°F) |
| 42-46°C (106-115°F) | Below 20% | 261-337 kPa (38-49 psi) | 2032-2342 kPa (295-340 psi) | 20°C (67°F) |
| Above 20% | 268-344 kPa (39-50 psi) | 2053-2370 kPa (298-344 psi) | 21°C (69°F) |
| 47-49°C (116-120°F) | Below 30% | 296-365 kPa (43-53 psi) | 2259-2569 kPa (328-373 psi) | 23°C (73°F) |
Air Conditioning (A/C) Diagnostics - Pressure Zone A
| NOTE |
|---|
| Operate the A/C system on low, in order to enhance oil flow to the high side of the system. |
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
| Step | Action | Yes | No |
|---|
| DEFINITION: Heating system performance. |
| 1 | Were you sent here from Symptoms or another diagnostic table? | Go to Step 2 | Go to Symptoms - HVAC Systems - Manual |
| 2 | Start the engine. Allow the engine to idle. Does the engine reach a normal operating temperature? | Go to Step 3 | Go to Step 9 |
| 3 | WARNING: Refer to Moving Parts and Hot Surfaces Warning . Allow the engine to idle. Select the FLOOR mode. Select the minimum blower speed. Select the warmest temperature setting. Feel the temperature of the inlet and outlet heater hoses at the heater core. Does the inlet heater hose feel warmer than the outlet heater hose? | Go to Step 7 | Go to Step 4 |
| 4 | Install a thermometer into the center IP PANEL air outlet. Secure a thermometer to the heater core outlet hose. Select the PANEL mode. Select the maximum blower speed. Select the warmest temperature setting. Record the temperature at the following locations: The center IP PANEL air outlet The heater core outlet hose Compare the recorded temperatures. Are the two temperature readings about equal? | Go to Step 5 | Go to Step 6 |
| 5 | Inspect and repair the following areas of the vehicle for cold air leaks: The cowl The recirculation door The HVAC module case Perform the necessary repairs. Are the repairs complete? | Go to Step 10 | |
| 6 | Inspect the temperature door operation. Refer to Diagnostic System Check - Vehicle . Perform any necessary repairs. Are the repairs complete? | Go to Step 10 | |
| 7 | Turn OFF the engine. Backflush the heater core. Start the engine. Select the FLOOR mode. Select the minimum blower speed. Select the warmest temperature setting. Feel the temperature of the inlet and outlet heater hoses at the heater core. Does the inlet heater hose feel warmer than the outlet heater hose? | Go to Step 8 | Go to Step 10 |
| 8 | Replace the heater core. Refer to Heater Core Replacement . Is the repair complete? | Go to Step 10 | |
| 9 | Repair the low engine temperature concern. Refer to Engine Fails To Reach Normal Operating Temperature . Is the repair complete? | Go to Step 10 | |
| 10 | Operate the system in order to verify the repair. Did you find and correct the condition? | System OK | Go to Step 2 |
Defrosting Insufficient
Noise Diagnosis - Blower Motor
| Step | Action | Yes | No |
|---|
| DEFINITION: Noise originating from the blower motor. |
| 1 | Were you sent here from Symptoms or another diagnostic table? | Go to Step 2 | Go to Symptoms - HVAC Systems - Manual |
| 2 | Inspect the air inlet grille for debris. Is debris present? | Go to Step 8 | Go to Step 3 |
| 3 | Sit inside the vehicle. Close the vehicle doors and windows. Turn ON the ignition, with the engine OFF. Cycle the blower motor through all of the speeds and modes in order to determine where and when the noise occurs. Is a noise evident during the blower operation? | Go to Step 4 | Go to Step 11 |
| 4 | Inspect for excessive vibration at each blower motor speed by feeling the blower case. Is excess vibration present? | Go to Step 6 | Go to Step 5 |
| 5 | Listen to the blower motor at each speed. Is the blower motor making a squeaking or chirping noise? | Go to Step 9 | Go to Step 11 |
| 6 | Remove the blower motor. Refer to Blower Motor Replacement . Inspect the blower motor impeller for deposits of foreign material. Inspect the blower motor for deposits of foreign material. Did you find any foreign material on the blower motor or blower motor impeller? | Go to Step 8 | Go to Step 7 |
| 7 | Inspect the blower motor for the following conditions: Cracked blades A loose impeller retainer Improper impeller alignment Did you find any of these conditions? | Go to Step 9 | Go to Step 10 |
| 8 | Remove the foreign material. Is the action complete? | Go to Step 10 | |
| 9 | Replace the blower motor. Refer to Blower Motor Replacement . Is the repair complete? | Go to Step 11 | |
| 10 | Install the blower motor. Refer to Blower Motor Replacement . Is the action complete? | Go to Step 11 | |
| 11 | Operate the system in order to verify the repair. Did you find and correct the condition? | System OK | Go to Step 2 |
Air Conditioning Compressor Oil Diagnosis
| Condition | Corrective Action |
|---|
| NOTE: To avoid repeat compressor failure, always inspect the condition of the refrigerant oil and take the appropriate corrective action before installing the replacement compressor. |
| Clean Oil no debris present | No corrective action necessary. |
| Clean Oil with debris present | Inspect the suction port of the replacement compressor for presence of a suction screen. If the replacement compressor does NOT contain a suction screen, install suction screen in the line. Replace desiccant or component containing the desiccant. Replace desiccant filter if applicable. Remove and inspect high pressure side filter (if applicable). Remove, inspect, clean, or replace orifice tube. If the system has a front orifice tube and is equipped with a filter in the rear auxiliary line, remove, inspect, clean, or replace the filter. If the system has a front orifice tube and is not equipped with a filter in the rear auxiliary line, remove the filter in the auxiliary TXV and Install a universal inline A/C Filter P/N 89016656 (AC Delco P/N 15-10413) as close to the rear TXV as possible. |
| Dark brown/black and/or pungent/unusual odor with no debris present | Replace desiccant or component containing the desiccant. Replace desiccant filter if applicable. Flush refrigerant system. |
| Dark brown/black and/or pungent/unusual odor with debris present | Replace desiccant or component containing the desiccant. Replace desiccant filter if applicable. Flush refrigerant system. Inspect the suction port of the replacement compressor for presence of a suction screen. If the replacement compressor does NOT contain a suction screen, install suction screen. Remove and inspect high pressure side filter (if applicable). Remove, inspect, clean, or replace orifice tube. If the system has a front orifice tube and is equipped with a filter in the rear auxiliary line, remove, inspect, clean, or replace the filter. If the system has a front orifice tube and is not equipped with a filter in the rear auxiliary line, remove the filter in the auxiliary TXV and install a universal inline A/C Filter P/N 89016656 (AC Delco P/N 15-10413) as close to the rear TXV as possible. |
| Oil Overcharge | Flush refrigerant system. |
| Refrigerant Contamination | Flush refrigerant system. |
| Hybrid Polyolester Refrigerant Oil (POE) Contamination | Flush refrigerant system. Replace desiccant or component containing the desiccant. Replace desiccant filter if applicable. |
| NOTE |
|---|
| To avoid repeat compressor failure, always inspect the condition of the refrigerant oil and take the appropriate corrective action before installing the replacement compressor. |
Noise Diagnosis - Air Conditioning (A/C) System
| Step | Action | Yes | No |
|---|
| 1 | Were you sent here from Symptoms - HVAC Systems - Manual? | Go to Step 2 | Go to Symptoms - HVAC Systems - Manual |
| 2 | A/C system noises can be generally categorized into three areas: Screeching, squealing, chirping noises Moaning noises Vibration/rattle noises Start the engine. Ensure that the A/C is ON. Do you hear a screeching, squealing noise when you engage the A/C? | Go to Step 3 | Go to Step 9 |
| 3 | With the engine OFF, inspect the drive belt for excessive wear. Refer to Drive Belt Falls Off and Excessive Wear Diagnosis . Is the drive belt excessively worn? | Go to Step 18 | Go to Step 4 |
| 4 | Inspect the drive belt tension. Is the drive belt tension correct? | Go to Step 19 | Go to Step 5 |
| 5 | Inspect the drive belt for excessive oil coverage. Is the drive belt covered with oil? | Go to Step 17 | Go to Step 6 |
| 6 | Start the engine. Ensure that the A/C is ON. Inspect the compressor and the clutch. Is the compressor locked up? | Go to Step 23 | Go to Step 7 |
| 7 | Is the A/C compressor clutch slipping? | Go to Step 23 | Go to Step 8 |
| 8 | Using a stethoscope, listen to the A/C compressor for any abnormal noises. Is the compressor causing an abnormal noise? | Go to Step 15 | Go to Step 10 |
| 9 | Does a moaning noise exist when the A/C clutch is engaged? | Go to Step 10 | Go to Step 12 |
| 10 | Listen to the A/C compressor components and mounting for noise concerns using a stethoscope. Are any of these components loose, damaged or excessively worn? | Go to Step 20 | Go to Step 11 |
| 11 | Start the engine. Engage the A/C compressor clutch. Using a stethoscope, move around the entire refrigerant plumbing system, listening for any abnormal noises caused by component ground-out. Are any of the A/C components grounding out and causing a noise? | Go to Step 22 | Go to Step 13 |
| 12 | Does a vibration or rattle noise exist when the A/C clutch is engaged? | Go to Step 13 | Go to Step 14 |
| 13 | Does the noise stop when the A/C clutch is disengaged? | Go to Step 15 | Go to Step 14 |
| 14 | Idle the engine in PARK with the A/C compressor clutch engaged. Using a stethoscope, move around the entire A/C system listening for any abnormal noises caused by a component. Do any of the A/C components cause an abnormal noise? | Go to Step 21 | Go to Step 24 |
| 15 | Verify that the A/C system is properly charged. Refer to Refrigerant System Specifications . Is the A/C system properly charged? | Go to Step 24 | Go to Step 16 |
| 16 | Recharge the A/C system to specification. Refer to Refrigerant Recovery and Recharging . Is the abnormal compressor noise still present? | Go to Step 24 | Go to Step 25 |
| 17 | Repair the oil leak. Is the repair complete? | Go to Step 25 | |
| 18 | Replace the drive belt. Refer to Drive Belt Replacement (With A/C) or Drive Belt Replacement (Without A/C) . Is the replacement complete? | Go to Step 25 | |
| 19 | Replace the drive belt tensioner. Refer to Drive Belt Tensioner Replacement . Is the replacement complete? | Go to Step 25 | |
| 20 | Repair or replace the A/C compressor mounting component. Is the repair complete? | Go to Step 25 | |
| 21 | Repair or replace the component which is causing the moaning concern as needed. Is the repair complete? | Go to Step 25 | |
| 22 | Correctly route or insulate the A/C component. Is the repair complete? | Go to Step 25 | |
| 23 | Replace the A/C compressor. Refer to Air Conditioning Compressor Replacement (LE5) or Air Conditioning Compressor Replacement (LNF) . Is the replacement complete? | Go to Step 25 | |
| 24 | The concern may be caused by an engine related component. Refer to Vibration Analysis - Engine . Did you find and correct the condition? | Go to Step 25 | |
| 25 | Operate the system in order to verify the repair. Is the system OK? | System OK | Go to Step 2 |
Noise Diagnosis - HVAC Module
| Step | Action | Yes | No |
|---|
| DEFINITION: Noise originating from the HVAC module. |
| 1 | Were you sent here from Symptoms or another diagnostic table? | Go to Step 2 | Go to Symptoms - HVAC Systems - Manual |
| 2 | Start the engine. Cycle through all of the following: Blower motor speeds HVAC modes Temperature control settings Determine the type of noise: Scrape, pop Tick/click, chirp or groaning Air rush/whistle Is a scrape or pop noise evident when selecting modes or temperature settings? | Go to Step 6 | Go to Step 3 |
| 3 | Is a tick/click, chirping, groaning or scraping noise present, but decreases as blower motor speed is decreased? | Go to Step 6 | Go to Step 4 |
| 4 | Is an air rush/whistle noise evident in all modes but not all temperature settings? | Go to Step 6 | Go to Step 5 |
| 5 | Is an air rush/whistle noise evident only in defrost or floor mode? | Go to Step 6 | Go to Step 6 |
| 6 | Remove the instrument panel (I/P) tie bar. Refer to Instrument Panel Tie Bar Replacement (Solstice) or Instrument Panel Tie Bar Replacement (SKY) . Is the action complete? | Go to Step 7 | |
| 7 | Inspect the air flow doors for proper operation. Inspect the ducts for obstructions or foreign materials. Were any of these conditions found? | Go to Step 10 | Go to Step 8 |
| 8 | Inspect the mode and temperature doors and seals for warping or cracking. Are the doors in normal condition? | Go to Step 11 | Go to Step 9 |
| 9 | Replace the appropriate door and/or seals. Is the repair complete? | Go to Step 11 | |
| 10 | Remove any obstructions or foreign material found. Is the action complete? | Go to Step 11 | |
| 11 | Install the I/P tie bar. Refer to Instrument Panel Tie Bar Replacement (Solstice) or Instrument Panel Tie Bar Replacement (SKY) . Is the action complete? | Go to Step 12 | |
| 12 | Operate the system to verify the repair. Did you find and correct the condition? | System OK | Go to Step 2 |
Odor Diagnosis
| Step | Action | Yes | No |
|---|
| DEFINITION: Odor originating or noticed through the HVAC system. |
| 1 | Were you sent here from Symptoms or another diagnostic table? | Go to Step 2 | Go to Symptoms - HVAC Systems - Manual |
| 2 | Sit inside the vehicle. Close all of the doors and windows. Start the engine. Allow the engine to idle at normal operating temperature. Select the maximum blower speed. Select the PANEL air outlet mode. Select the coldest temperature setting. Cycle through all of the blower speeds, modes, and temperatures to define what type of odor is present. Musty smell Coolant smell Oil smell Does the odor have a musty smell? | Go to Step 3 | Go to Step 8 |
| 3 | Inspect the HVAC filter and the air inlet grille for debris. Is debris present? | Go to Step 4 | Go to Step 5 |
| 4 | Remove any debris. Is the action complete? | Go to Step 15 | |
| 5 | Inspect for wet carpeting. Is the carpet wet? | Go to Step 6 | Go to Step 8 |
| 6 | Inspect for the following conditions: Water leaks around the windshield Blockage of the HVAC module drain Leaks around the door seals Is a leak present? | Go to Step 7 | Go to Step 15 |
| 7 | Repair the leak as necessary. Is the repair complete? | Go to Step 15 | |
| 8 | Does the odor have a coolant smell? | Go to Step 9 | Go to Step 12 |
| 9 | Inspect the cooling system for leaks. Refer to Loss of Coolant . Is a leak present? | Go to Step 10 | Go to Step 12 |
| 10 | Inspect for coolant leaking inside the vehicle or for a film build-up on the windshield. Is the condition present? | Go to Step 11 | Go to Step 15 |
| 11 | Replace the heater core. Refer to Heater Core Replacement . Is the repair complete? | Go to Step 15 | |
| 12 | Does the odor have an oily smell? | Go to Step 13 | Go to Step 15 |
| 13 | Inspect the engine compartment for any leaks. Refer to the following procedures: Oil Leak Diagnosis Fluid Leak Diagnosis Repair any oil leaks. Is the repair complete? | Go to Step 15 | |
| 14 | A musty odor can be caused by mold or mildew build-up on the evaporator or the heater core or inside of the HVAC module. Refer to Odor Correction . Is the action 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 |
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 air conditioning duct 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 the of 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.
- J 43600 ACR 2000 Air Conditioning Service Center. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
- J 45037 A/C Oil Injector. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
| WARNING | To prevent personal injury, avoid breathing A/C Refrigerant and lubricant vapor or mist. Work in a well ventilated area. To remove refrigerant from the A/C System, use service equipment designed for recovery that is certified to meet the requirements of the appropriate SAE Standards. If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant, refrigerant recovery, and lubricant manufacturers. |
| WARNING | For personal protection, goggles and lint-free gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If refrigerant 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. |
| CAUTION | You must replace the desiccant if the A/C refrigerant system has been open to atmosphere for more than four hours, or if the A/C refrigerant oil has been contaminated. Failure to replace the desiccant will result in damage to the A/C refrigerant system. |
| CAUTION | 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. |
| CAUTION | To avoid system damage use only R-134a dedicated tools when servicing the A/C system. |
| CAUTION | 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. |
| CAUTION | 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.
A/C Refrigerant System Oil Charge Replenishing
If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 . See Special Tools . For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Specifications .
- J 43600 ACR 2000 Air Conditioning Service Center. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
- J 45268 Flush Adapter Kit. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
- J 41447 R134A A/C Tracer Dye - Box of 24. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
- J 42220 Universal 12V Leak Detection Lamp. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Note. Flushing with the ACR 2000 is not intended to remove metal from the A/C system.
Flushing is intended to remove the following
fLUSHING pROCEDURE
- Contaminated polyalkylene glycol (PAG) oil
- Desiccant, following a desiccant bag failure
- Overcharge of PAG oil
- Refrigerant contamination
Scheme 3
- Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
- Remove the thermal expansion valve (TXV). Refer to «Air Conditioning Evaporator Thermal Expansion Valve Replacement»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
- Install the stud for the J 45268 kit onto the J 45268-115. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
- Install the J 45268-115 in place of the TXV.
- Install the TXV mounting bolts and tighten to 7 N.m (62 lb in).
- Connect the evaporator line to the J 45268-115.
- Install the TXV block fitting nut. Tighten the bolts to 27 N.m (20 lb ft).
- Remove the A/C compressor. Refer to «Air Conditioning Compressor Replacement (LE5)»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Air Conditioning Compressor Replacement (LNF)»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__air-conditioning-compressor-replacement-lnf) .
- Install J 45268-10 to the A/C compressor hose assembly.
- Install the nut and bolt from the J 45268 kit to the J 45268-10 and compressor hose assembly. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . Tighten the bolts to 27 N.m (20 lb ft).
- 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 to the J 45268-1 flush filter adapter. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . Connect the red hose from the J 43600 to the J 45268-8 flush adapter. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
- Reverse flow refrigerant flush is recommended for desiccant bag failure. Replace the receiver dehydrator 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 to the J 45268-1 flush filter adapter. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . Connect the red hose from J 43600 to the J 45268-8 flush adapter. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
- Flush the A/C system. Follow the instructions supplied with the J 43600 . See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
- Disconnect the red hose on the J 43600 from the J 45268-10. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
- Disconnect the blue hose on the J 43600 from the J 45268-1. See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
- Remove J 45268-1 from the J 45268-10.
- Remove the J 45268-10 from the A/C compressor hose assembly.
- 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) . NOTE: Flushing will remove the fluorescent leak detection dye from the A/C system. Add one bottle of J 41447 . See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . Add the total system capacity of PAG oil to the A/C compressor. Refer to «Refrigerant System Specifications»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-specifications) .
- 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»(/saturn/sky/i-final-2010-2010/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»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-specifications) . Add the calculated amount to the compressor, as needed. NOTE: Flushing will remove the fluorescent leak detection dye from the A/C system. Add one bottle of J 41447 . See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
- Install the A/C compressor. Refer to «Air Conditioning Compressor Replacement (LE5)»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Air Conditioning Compressor Replacement (LNF)»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__air-conditioning-compressor-replacement-lnf) .
- Remove J 45268-115.
- Inspect the TXV for debris. Clean or replace as needed.
- Install the TXV. Refer to «Air Conditioning Evaporator Thermal Expansion Valve Replacement»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
- Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
- Leak test the fittings using J 42220 . See «Special Tools»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Draining Procedure
- Remove the compressor crankcase oil drain plug and drain the crankcase into a clean, graduated container.
- 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.
- Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor.
- Inspect oil drained from removed compressor. Refer to «Air Conditioning Compressor Oil Diagnosis»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__air-conditioning-compressor-oil-diagnosis) .
- Properly discard the used refrigerant oil.
Balancing Procedure
- The replacement compressor is shipped with 74 ml (2.5 oz) of refrigerant oil.
- Compare the amount of refrigerant oil recorded during compressor removal to the amount of refrigerant oil shipped in the replacement compressor. If the amount of refrigerant oil drained and recorded from the removed compressor is: Less than 74 ml (2.5 oz) Leave the 74 ml (2.5 oz) in the replacement compressor. More than 74 ml (2.5 oz) Add to the compressor the difference between the 74 ml (2.5 oz) and the amount drained.
Scheme 4
Scheme 4: Air Conditioning Compressor Replacement (LE5)
Air Conditioning Compressor Replacement (LNF)
Removal Procedure
- Remove the seal washer from the A/C refrigerant component.
- Inspect the seal washer for signs of damage to help determine the root cause of the failure.
- Inspect the A/C refrigerant components for damage or burrs. Repair if necessary.
- Discard the sealing washer.
Installation Procedure
- Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer.
- Remove the cap or tape from the A/C refrigerant components.
- Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components.
- Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting.
- Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure.
Scheme 5
Scheme 5: Air Conditioning Compressor Hose Replacement (LNF)
Air Conditioning Compressor Hose Replacement (LE5)
Scheme 6
Scheme 6: Condenser Tube Replacement (LNF)
Scheme 7
Scheme 7: Condenser Tube Replacement (LE5)
Scheme 8
Scheme 8: Air Conditioning Evaporator Tube Replacement
J 39400-A Halogen Leak Detector
- Recover the refrigerant from the air conditioning (A/C) system. Refer to «Refrigerant Recovery and Recharging»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
- Remove the A/C refrigerant valve (2).
- Remove and discard the O-ring seal (3).
- Lightly coat the NEW O-ring seal with mineral base 525 viscosity refrigerant oil.
- Install the O-ring seal (3) onto the valve if necessary.
- Install the A/C refrigerant valve (2). Tighten: Tighten the valve to 11 N.m (98 lb in).
- Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/saturn/sky/i-final-2010-2010/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
- Leak test the fitting valve area using the J 39400-A .
- Install the service port cap (1).
Scheme 9
Scheme 9: Receiver and Dehydrator Replacement
Scheme 10
Scheme 10: Air Conditioning Evaporator Thermal Expansion Valve Replacement
Scheme 11
Scheme 11: Air Conditioning (A/C) Refrigerant Pressure Sensor Replacement
| Callout | Component Name |
|---|
| Preliminary Procedure: Disconnect the electrical connector from the A/C pressure sensor. |
| 1 | A/C Refrigerant Pressure Sensor CAUTION: Refer to Fastener Caution . Tighten: 5 N.m (44 lb in) |
| 2 | Seal O-Ring Tip: Remove and discard O-ring. |
Scheme 12
Scheme 12: Evaporator Air Temperature Sensor Replacement
| Callout | Component Name |
|---|
| Preliminary Procedure: Remove the HVAC module assembly. Refer to Air Conditioning and Heater Module Assembly Removal and Installation . |
| 1 | Heater Core Cover Screw CAUTION: Refer to Fastener Caution . Tighten: 1.5 N.m (13 lb in) |
| 2 | Heater Core Cover |
| 3 | Air Conditioning Refrigerant Temperature Sensor Procedure Disconnect the air conditioning refrigerant temperature sensor electrical connector. Twist the air conditioning refrigerant temperature sensor to the left to release and pull upward. |
Scheme 13
Scheme 13: Air Conditioning Condenser Replacement
Scheme 14
Scheme 14: Air Conditioning (A/C) Evaporator Case Assembly Replacement
| Callout | Component Name |
|---|
| Preliminary Procedure Remove the HVAC module assembly. Refer to Air Conditioning and Heater Module Assembly Removal and Installation . Remove the heater core cover. Refer to Heater Core Cover Replacement . Remove the air inlet assembly. Refer to Air Inlet Assembly Replacement . Note routing of electrical wiring to ensure proper installation. Disconnect the 5 electrical connectors. |
| 1 | Rear Air Outlet Duct Screw (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten: 1.5 N.m (13 lb in) |
| 2 | Rear Air Outlet Duct |
| 3 | Drain Tube, Evaporator Case Seal |
| 4 | Evaporator Case Assembly Screw (Qty: 10) Tighten: 1.5 N.m (13 lb in) |
| 5 | Air Distributor |
| 6 | Evaporator Case - Lower |
| 7 | Evaporator Case - Upper |
| 8 | Air Conditioning Evaporator |
| 9 | Blower Motor Resistor Screw (Qty: 2) Tighten: 1.5 N.m (13 lb in) |
| 10 | Blower Motor Screw (Qty: 2) Tighten: 1.5 N.m (13 lb in) |
| 11 | Blower Motor Assembly |
| 12 | Air Inlet Housing Baffle |
Scheme 15
Scheme 15: Air Conditioning and Heater Module Assembly Removal and Installation
Scheme 16
Scheme 16: Air Conditioning Evaporator Core Replacement
| Callout | Component Name |
|---|
| Preliminary Procedure: Remove the HVAC module assembly. Refer to Air Conditioning and Heater Module Assembly Removal and Installation . |
| 1 | Evaporator Case Seal |
| 2 | Thermal Expansion Valve Bolts (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten: 1.5 N.m (13 lb in) |
| 3 | Thermal Expansion Valve |
| 4 | Sealing Washer Tip: Remove and discard seals. Refer to Air Conditioning System Seal Replacement . |
| 5 | Rear Air Outlet Duct Screw (Qty: 2) Tighten: 1.5 N.m (13 lb in) |
| 6 | Rear Air Outlet Duct |
| 7 | Lower Evaporator Case Assembly Screw (Qty: 9) Tighten: 1.5 N.m (13 lb in) |
| 8 | Evaporator Case - Lower |
| 9 | Air Conditioning Evaporator |
Scheme 17
Scheme 17: Heater Inlet Hose Replacement (LE5)
Scheme 18
Scheme 18: Heater Inlet Hose Replacement (LNF)
Scheme 19
Scheme 19: Heater Outlet Hose Replacement (LNF)
Scheme 20
Scheme 20: Heater Outlet Hose Replacement (LE5)
Scheme 21
Scheme 21: Air Inlet Assembly Replacement
Scheme 22
Scheme 22: Air Inlet Housing Front Panel Replacement
Scheme 23
Scheme 23: Blower Motor Resistor Replacement
Scheme 24
Scheme 24: Blower Motor Replacement
Scheme 25
Scheme 25: Side Window Air Outlet Replacement
| Callout | Component Name |
|---|
| Preliminary Procedures: Remove the instrument panel (I/P) upper trim panel. Refer to Instrument Panel Upper Trim Panel Replacement . |
| 1 | Side Window Defogger Outlet Grille - RH Procedure: Squeeze the tabs on the back of the outlet grille to release it from the trim panel. |
| 2 | Side Window Defogger Outlet Grille - LH Procedure: Squeeze the tabs on the back of the outlet grille to release it from the trim panel. |
Scheme 26
Scheme 26: Instrument Panel Outer Air Outlet Replacement - Left Side
Scheme 27
Scheme 27: Instrument Panel Center Air Outlet Replacement
Scheme 28
Scheme 28: Instrument Panel Outer Air Outlet Replacement - Right Side
Scheme 29
Scheme 29: Instrument Panel Outer Air Outlet Deflector Replacement - Left Side
| Callout | Component Name |
|---|
| Preliminary Procedure: Remove the instrument panel (I/P) trim pad. Refer to Instrument Panel Trim Pad Replacement . |
| 1 | Instrument Panel Outer Air Outlet Grille Assembly - Left |
Scheme 30
Scheme 30: Instrument Panel Center Air Outlet Deflector Replacement
| Callout | Component Name |
|---|
| Fastener Tightening Specifications: Refer to Fastener Tightening Specifications . Preliminary Procedure: Remove the instrument panel (I/P) cluster trim plate. Refer to Instrument Cluster Trim Panel Replacement (Solstice) . |
| 1 | Outlet, Air Center Grille Tip: Remove the foam from the rear of the center air outlet. Depress the tabs and pull the air outlet grille from the center instrument panel cluster trim plate. |
Scheme 31
Scheme 31: Instrument Panel Outer Air Outlet Deflector Replacement - Right Side
| Callout | Component Name |
|---|
| Preliminary Procedure: Remove the Instrument Panel Trim Pad. Refer to Instrument Panel Trim Pad Replacement . |
| 1 | Grille Assembly, Instrument Panel (I/P) Outer Air Outlet - Right |
Scheme 32
Scheme 32: Air Distributor Duct Replacement
Scheme 33
Scheme 33: Heater Core Cover Replacement
Scheme 34
Scheme 34: Heater Core Replacement
| Callout | Component Name |
|---|
| Preliminary Procedure Remove the HVAC module assembly. Refer to Air Conditioning and Heater Module Assembly Removal and Installation . Disconnect the actuator electrical connectors from the air distribution case. |
| 1 | Air Outlet Duct Screw CAUTION: Refer to Fastener Caution . Tighten: 1.5 N.m (14 lb in) |
| 2 | Air Outlet Duct |
| 3 | Heater Core Cover Screw Tighten: 1.5 N.m (14 lb in) |
| 4 | Heater Core Cover |
| 5 | Heater Core Pass Through Seal |
| 6 | Air Distribution Case Screw Tighten: 1.5 N.m (14 lb in) |
| 7 | Air Distribution Case |
| 8 | Heater Core Bracket Screw (Qty: 2) Tighten: 1.5 N.m (14 lb in) |
| 9 | Heater Core Bracket |
| 10 | Heater Core |
Engine Coolant
Engine coolant is the key element of the heating system. The thermostat controls 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 heat of the coolant flowing through the heater core is absorbed by the ambient air drawn through the HVAC module. Heated air is distributed to the passenger compartment, through the HVAC module, for passenger comfort.
The amount of heat delivered to the passenger compartment is controlled by opening or closing the HVAC module air temperature door. The coolant exits the heater core through the return heater hose and 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 38185 Hose Clamp Pliers J 39400-A Halogen Leak Detector J 41447 R-134a Tracer Dye-Box of 24 J 42220 Universal 12V Leak Detection Lamp J 43181 Heater Line Quick Connect Release Tool J 43244 Relay Puller Pliers J 43600 ACR 2000 Air Conditioning Service Center J 43872 Fluorescent Dye Cleaner J 45037 A/C Oil Injector J 45268 Flush Adaptor Kit J 46297 A/C Dye Injector Kit J 46297-12 Replacement Dye Cartridges
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