Text preview for : en_4j2_7b.pdf part of Daewoo Nubira/Lacetti Also known as: Chevrolet Nubira / Lacetti, Chevrolet Optra Optra5, Suzuki Forenza Reno Covers the 1.4L, 1.6L and 1.8L engine. Year 2004



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SECTION : 7B

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

TABLE OF CONTENTS
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 7B­2 General Specifications . . . . . . . . . . . . . . . . . . . . . 7B­2 Fastener Tightening Specifications . . . . . . . . . . . 7B­2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B­3 Special Tools Table . . . . . . . . . . . . . . . . . . . . . . . . 7B­3 SCHEMATIC AND ROUTING DIAGRAMS . . . . . 7B­6 A/C System ­ Typical . . . . . . . . . . . . . . . . . . . . . . 7B­6 Manual Control A/C Diagram . . . . . . . . . . . . . . . . 7B­7 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B­8 GENERAL DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 7B­8 Testing the Refrigerant System . . . . . . . . . . . . . . 7B­8 Insufficient Cooling "Quick Check" Procedure . . 7B­8 A/C Performance Test . . . . . . . . . . . . . . . . . . . . . . 7B­9 Pressure­Temperature Relationship of R­134A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B­10 Leak Testing Refrigerant System . . . . . . . . . . . . 7B­11 V5 SYSTEM AIR CONDITIONING DIAGNOSIS 7B­12 Insufficient Cooling Diagnosis . . . . . . . . . . . . . . 7B­12 SYMPTOM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 7B­16 Pressure Test Chart (R­134A System) . . . . . . 7B­16 Low and High Side Pressure Relationship Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B­18 MAINTENANCE AND REPAIR . . . . . . . . . . . . . . 7B­19 ON­VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . 7B­19 GENERAL A/C SYSTEM SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . 7B­19 O­Ring Replacement . . . . . . . . . . . . . . . . . . . . . 7B­19 Handling Refrigerant . . . . . . . . . . . . . . . . . . . . . . 7B­19 Handling of Refrigerant Lines and Fittings . . . . 7B­19 Maintaining Chemical Stability in the Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B­20 Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System . . . . . . . . . . . . . . 7B­20 SERVICEABLE COMPONENTS . . . . . . . . . . . . . 7B­23 Components Used In Non­A/C Systems . . . . . A/C Pressure Transducer . . . . . . . . . . . . . . . . . . A/C Compressor Relay . . . . . . . . . . . . . . . . . . . . Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A/C Expansion Valve . . . . . . . . . . . . . . . . . . . . . . A/C High­Pressure Pipe Line . . . . . . . . . . . . . . . Evaporator Core . . . . . . . . . . . . . . . . . . . . . . . . . . A/C Suction Hose Assembly . . . . . . . . . . . . . . . A/C Discharge Hose Compressor to Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Receiver­Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNIT REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . 7B­23 7B­24 7B­24 7B­25 7B­25 7B­26 7B­29 7B­30 7B­31 7B­32 7B­33 7B­35 7B­37 7B­37

V5 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B­37 V5 AIR CONDITIONING COMPRESSOR OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B­38 Clutch Plate and Hub Assembly . . . . . . . . . . . . Clutch Rotor and Bearing . . . . . . . . . . . . . . . . . . Clutch Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . Control Valve Assembly . . . . . . . . . . . . . . . . . . . Rear Head, Gasket, Valve Plate, Reed Plate, and O­ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cylinder to Front Head O­ring . . . . . . . . . . . . . . Leak Testing (External) . . . . . . . . . . . . . . . . . . . . GENERAL DESCRIPTION AND SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . . . . . . . . . . The V5 A/C System . . . . . . . . . . . . . . . . . . . . . . . System Components ­ Functional . . . . . . . . . . System Components ­ Control . . . . . . . . . . . . . V5 Compressor ­ General Description . . . . . . . 7B­38 7B­40 7B­42 7B­44 7B­46 7B­47 7B­48 7B­50 7B­51 7B­51 7B­51 7B­51 7B­52 7B­52

V5 Compressor ­ Description of Operation . . . 7B­52

7B ­ 2IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

SPECIFICATIONS
GENERAL SPECIFICATIONS
Application Compressor Receiver­Dryer Refrigerant Refrigerant Oil in A/C System Type Capacity Type Capacity Evaporator Capacity (Airflow rate 8.7 kg/min) Unit ­ ­ ­ g ­ cc (ml) Kcal/h Description V5 AL R/DRIER R­134a System 640±20 (RHD : 680±20) Union Carbide 488 PAG OIL 220 6000±10%

FASTENER TIGHTENING SPECIFICATIONS
Application Pressure Transducer Expansion Valve Stud Bolts Liquid Pipe Support Clamp Bolts Liquid Pipe Block­to­Receiver Dryer Retaining Nut Liquid Pipe Block­to­Expansion Valve Retaining Nut Refrigerant Discharge Hose Block­to­Condenser Retaining Nut Refrigerant Discharge Hose Block­to­Compressor Retaining Nut Evaporator Core Cover Screws Heater Core Housing­to­Evaporator Housing Retaining Screws Suction Hose Block­to­Compressor Retaining Nut Suction Hose Support Clamp­to­Longitudinal Member Bolt Suction Hose Support Clamp­to­Engine Bracket Bolt (1.4D, 1.6D only) Suction Hose Support Clamp­to­Engine Bracket Bolt (1.8D, 2.0D only) Suction Hose Block­to­Expansion Valve Retaining Nut (Receiver Dryer) Band Clamp Bolt Receiver Dryer­to­Condenser Pipe Block Bolt Upper Compressor­to­Bracket Mounting Bolts (1.4D, 1.6D only) Lower Compressor­to­Bracket Mounting Bolts (1.4D, 1.6D only) Front Compressor­to­Bracket Mounting Bolts (1.8D, 2.0D only) Rear Compressor­to­Bracket Mounting Bolts (1.8D, 2.0D only) Condenser Mount Bolts (Compressor) Clutch Plate and Hub Assembly Retaining Nut (Compressor) Through Bolts NSm 7 8 4 14 14 16 33 1.2 1.2 33 8 4 14 14 5 5 25 45 35 20 4 17 10 Lb­Ft ­ ­ ­ 10 10 12 24 ­ ­ 24 ­ ­ 10 10 ­ ­ 18 33 26 15 ­ 13 ­ Lb­In 62 71 35 ­ ­ ­ ­ 11 11 ­ 71 35 ­ ­ 44 44 ­ ­ ­ ­ 35 ­ 89

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MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B ­ 3

SPECIAL TOOLS
SPECIAL TOOLS TABLE

J­5403 Snap Ring Pliers

J­8433­3 Forcing Screw

J­6083 Snap Ring Pliers

J­9398­A Bearing Remover

J­8092 Driver Handle

J­9481 Bearing Installer

J­8433­1 Puller Crossbar

J­9553­1 O­Ring Remover

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7B ­ 4IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

J­9625­A Pressure Testing Connector

J­34993 Cylinder Alignment Rods

J­23128­A Seal Seat Remover and Installer

J­33017 Pulley Rotor and Bearing Installer

J­35372 Support Block

J­33019 Bearing Staking Tool Set Includes: J­33019­1 Bearing Staking Guide J­33019­2 Bearing Staking Pin

J­33011 O­Ring Installer

J­33020 Pulley Puller

J­33013­B Hub and Drive Plate Remover and Installer

J­34614 Shaft Seal Protector

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MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B ­ 5

J­33022 Shaft Nut Socket

J­33025 Clutch Coil Puller Legs

J­33023­A Puller Pilot

J­34992 Compressor Holding Fixture

J­33024 Clutch Coil Installer Adapter

J­33027 Clutch Hub Holding Tool

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7B ­ 6IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

SCHEMATIC AND ROUTING DIAGRAMS
A/C SYSTEM ­ TYPICAL

1. 2. 3.

Compressor Pressure Relief Valve Condenser

4. 5. 6.

Receiver­Dryer Evaporator Expansion Valve

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MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B ­ 7

MANUAL CONTROL A/C DIAGRAM

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7B ­ 8IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

DIAGNOSIS
GENERAL DIAGNOSIS INSUFFICIENT COOLING "QUICK TESTING THE REFRIGERANT CHECK" PROCEDURE SYSTEM
If you suspect a problem in the refrigerant system, check for the following conditions: 1. Check the outer surfaces of the radiator and the condenser cores to be sure that the airflow is not blocked by dirt, leaves, or other foreign material. Check between the condenser and the radiator, as well as all outer surfaces. Check for restrictions or kinks in the condenser core, the hoses, and the tubes. Check the operation of the blower fan. Check all the air ducts for leaks or restrictions. Low airflow rate may indicate a restricted evaporator core. Check for slippage of the compressor clutch. Check the drive belt tension. Perform the following "hand­feel" procedure to get a quick idea of whether the A/C system has the proper charge of Refrigerant­134a. The air temperature must be above 21°C (70°F) for most models. 1. Warm up engine. Run the engine at idle. 2. Open the hood and all the doors. 3. Turn the A/C switch ON. 4. Set the temperature control to the full cold position. 5. Set the blower speed switch on the maximum speed setting. 6. "Hand­feel" the temperature of the evaporator outlet pipe. The pipe should be cold. 7. Check for other problems. Refer to "Testing the Refrigerant System" in this section. 8. Leak check the system. Refer to "Leak Testing the Refrigerant System" in this section. If you find a leak, discharge the system and repair the leak as required. After completing the repair, evacuate the system and charge it. 9. If there is no leak, refer to "Insufficient Cooling Diagnosis" in this section.

2. 3. 4.

5. 6.

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MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B ­ 9

A/C PERFORMANCE TEST
RELATIVE HUMIDITY (%) AMBIENT AIR TEMPERATURE °C 21 20 27 32 38 21 30 27 32 38 21 40 27 32 38 21 50 27 32 38 21 60 27 32 38 21 70 27 32 38 21 80 27 32 21 90 27 32 °F 70 81 90 100 70 81 90 100 70 81 90 100 70 81 90 100 70 81 90 100 70 81 90 100 70 81 90 70 81 90 LOW SIDE PRESSURE Psi 26 24 26 33 26 24 27 34 26 26 29 37 26 26 32 71 27 26 34 44 27 28 36 47 27 30 37 27 30 38 Kpa 179 165 179 228 179 165 186 234 179 179 200 255 179 179 221 490 186 179 234 303 186 193 248 324 186 207 255 186 207 262 2000 2000 2000 2000 2000 2000 2000 2000 ENGINE SPEED (RPM) CENTER DUCT AIR TEMPERATURE °C 7 8 9 14 7 8 10 15 8 9 11 17 8 9 13 19 8 9 15 22 9 10 16 24 9 12 17 9 12 18 °F 45 46 48 57 45 46 50 59 46 48 52 63 46 48 55 66 46 48 59 72 48 50 61 75 48 54 63 48 54 64 HIGH SIDE PRESSURE Psi 160 212 277 333 160 220 283 349 162 227 295 364 162 235 304 380 165 246 324 393 171 260 330 401 178 266 339 178 272 340 Kpa 1103 1462 1910 2296 1103 1517 1951 2406 1117 1565 2034 2510 1117 1620 2096 2620 1138 1696 2234 2710 1179 1793 2275 2765 1227 1834 2337 1227 1875 2344

* Test Conditions : Doors & hood opened, A/C ON, Recirculation mode, Full Cool with maximum Blower speed, No Sunlight, Wind velocity at 8km/h (5 mph).

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7B ­ 10IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

PRESSURE­TEMPERATURE RELATIONSHIP OF R­134A
Temperature °C (°F)* ­8 (17.6) ­7 (19.4) ­6 (21.2) ­5 (23.0) ­4 (24.8) ­3 (26.6) ­2 (28.4) ­1 (30.2) 0 (32.0) 1 (33.8) 2 (35.6) 3 (37.4) 4 (39.2) 5 (41.0) 6 (42.8) 7 (44.6) 8 (46.4) Pressure kPa (psi)* 113.1 (16.4) 121.5 (17.6) 130.2 (18.9) 139.1 (20.2) 148.4 (21.5) 157.9 (22.9) 167.6 (24.3) 177.8 (25.8) 188.2 (27.3) 198.8 (28.8) 209.9 (30.4) 221.2 (32.1) 232.9 (33.8) 245.0 (35.5) 257.4 (37.3) 269.8 (39.1) 282.9 (41.0) Temperature °C (°F)* 9 (48.2) 10 (50.0) 15 (59.0) 20 (68.0) 25 (77.0) 30 (86.0) 35 (95.0) 40 (104.0) 45 (113.0) 50 (122.0) 55 (131.0) 60 (140.0) 65 (149.0) 70 (158.0) 75 (167.0) 80 (176.0) ­ Pressure kPa (psi)* 296.2 (43.0) 309.6 (44.9) 383.7 (55.7) 467.7 (67.8) 567.5 (82.3) 667.8 (96.9) 785.6 (113.9) 916.4 (133.0) 1 062.2 (154.0) 1 222.1 (177.2) 1 398.2 (202.8) 1 589.6 (230.5) 1 799.0 (260.9) 2 026.6 (293.9) 2 272.2 (329.5) 2 544.0 (369.0) ­

* All calculated values are rounded to one decimal place. Evaporator Range: From ­7 to 7°C (19.4 to 44.6°F), the temperatures represent the gas temperatures inside the coil and not on the coil surfaces. Add 2 to 6°C (4 to 11°F) to the coil and air­off temperatures. Condenser Range: From 45 to 70°C (113°to 158°F), the temperatures are not ambient. Add 19 to 22°C (34 to 40°C) to the ambient temperatures for proper heat transfer. Then refer to the pressure chart. Example: 32°C (90°F) Ambient temperature + 22°C (40°F) = 54°C (130°F) Condenser temperature, which yields 1 379 kPa (200 psi), based on 50 km/h (31 mph) airflow.

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MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B ­ 11

LEAK TESTING REFRIGERANT SYSTEM
Test for leaks whenever you suspect a refrigerant leak in the system. You should also test for leaks whenever you perform a service operation which results in disturbing the lines or the connections. Leaks are commonly found at the refrigerant fittings or at the connections. Leaks are commonly caused by the following problems: S S S Improper torque. Damaged O­ring seals. Dirt or lint on the O­ring seals.

4. 5.

6. S S S S S S S S

Do not block the air intake. The audible tone changes from 1 to 2 clicks per second into a solid alarm if there is a leak. Adjust the balance control to maintain 1 to 2 clicks per second. Test all of the following areas, even after one leak has been confirmed: Evaporator inlet and outlet. Receiver­drier inlet and outlet. Condenser inlet and outlet. Brazed and welded areas. Damaged areas. Hose couplings. Compressor rear head. All fittings and joints.

Liquid Leak Detectors
Use a liquid leak detector solution on locations such as fittings. Apply the solution to the area in question with the swab that is supplied with the solution. Look for bubbles to appear. This will indicate the existence and the location of any leak. For areas where this is not practical, such as sections of the evaporator and the condenser, an electronic leak detector is more useful.

Testing Service Ports/Access Valves
The sealing caps provide protection for the service ports. Make sure that these caps are not missing or loose. Always use the correct cap for each port.

Testing the Evaporator Core
Leaks in the evaporator core are difficult to find. Test the evaporator core using the following procedure: 1. 2. 3. 4. 5. Run the blower fan at the maximum speed setting for at least 15 minutes. Turn the blower OFF. Wait for 10 minutes. Remove the blower motor resistor. Refer to Section 7A, Heating and Ventilation System. Insert the leak detector probe as close as possible to the evaporator core. The detector will indicate a leak with a solid alarm. Use a flashlight to search for refrigerant oil on the core surface.

Electronic Leak Detectors
Follow the manufacturer's instructions for calibration, operation, and maintenance of an electronic leak detector. Battery condition is especially important to the accuracy of a portable model. Set the detector to R­134a before beginning the test. Notice : Electronic leak detectors are sensitive to windshield washing solutions, solvents and cleaners, and certain vehicle adhesives. Surfaces must be clean to prevent false readings. Make sure that all surfaces are dry to prevent damage to the detector.

6.

General Testing Instructions
1. 2. 3. Follow the entire path of the refrigerant system. Completely circle each joint at 25 to 50 mm (1 to 2 inches) per second. Hold the probe tip within 6 mm (1/4 inch) of the surface.

Testing the Compressor Shaft Seal
1. 2. 3. Blow shop air behind and in front of the compressor clutch/pulley for at least 15 seconds. Wait 1 to 2 minutes. Probe the area in front of the pulley. If the detector emits a solid alarm, there is a leak.

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7B ­ 12IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

V5 SYSTEM AIR CONDITIONING DIAGNOSIS INSUFFICIENT COOLING DIAGNOSIS
Test Description The numbers below refer to steps on the diagnostic table. 13. See the Important below. 32. See the Important below. Step 1 2 Action Record the customer's complaint. Can you verify the customer's complaint? Check the A/C fuse. Check the blower fan operation. Check the engine cooling fan operation. Check the A/C compressor belt. Check the A/C condenser for restricted airflow. Check the clutch coil connection. Repair or replace any components as needed. Check the discharge air temperature with the A/C turned ON. Is the discharge air temperature normal? 1. Turn the ignition switch to LOCK. 2. Connect the high­ and the low­pressure gauges. Are both pressures within the value specified? 1. Check the A/C system for leaks. 2. Repair any refrigerant leaks as needed. 3. Recover, evacuate, and recharge the A/C system. 4. Observe the two pressure gauges. Are both pressures above the value specified? Observe the two pressure gauges. Are both pressures below the value specified? Add 0.45 kg (1 pound) of refrigerant R­134a. Check the A/C system for leaks. Repair any refrigerant leaks, as needed. Recover, evacuate, and recharge the A/C system. 5. Observe the two pressure gauges. Are both pressures above the value specified? 1. Start the engine and allow it to run at idle. 2. Set the A/C controls to the following positions: The A/C switch to the ON. The fresh air control switch to fresh air (indicator lamp OFF). S The blower motor to 4. S The temperature to full cold. Does the A/C compressor clutch engage? S S 1. 2. 3. 4. 1. 2. 3. 4. 5. 6. 7. 8. Important : Perform this test under garage conditions with the air temperature at 21­32°C (70­90°F), and no sun load. Follow this test carefully for accurate results. Important : Perform this test exactly as described to obtain accurate results. Value(s) ­ At least 7°C (12°F) below ambient air temperature Yes Go to Step 2 System OK No System OK Go to Step 3

3

69­345 kPa (10­50 psi)

Go to Step 4

Go to Step 5

4

345 kPa (50 psi)

Go to Step 7

­

5 6

69 kPa (10 psi) 345 kPa (50 psi)

Go to Step 6 Go to Step 7

Go to Step 7 ­

7

­

Go to Step 8

Go to Step 10

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MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B ­ 13
Step 8 Action 1. Check for a knocking noise from the A/C compressor. 2. Cycle the A/C compressor ON and OFF in order to verify the source of the noise. Do you hear a loud knocking noise? 1. Recover the A/C system refrigerant. 2. Replace the A/C compressor. 3. Evacuate and recharge the A/C system. 4. Check the A/C system for leaks. Is the compressor running normally? 1. Turn the ignition switch to LOCK. 2. Disconnect the A/C compressor clutch coil connector. 3. Connect a jumper wire from ground to one A/C compressor clutch coil terminal. 4. Connect a fused jumper wire from the positive battery terminal to the other A/C compressor clutch coil terminal. Does the A/C clutch engage? Repair the electrical circuit to the A/C compressor clutch coil. Does the A/C clutch engage? Replace the A/C compressor clutch coil. Does the A/C clutch engage? 1. Close all of the vehicle's windows and doors. 2. Set the A/C controls to the following positions: S The A/C switch to the ON position. S The fresh air control switch to fresh air. S The blower motor to 4. S The temperature to full cold. 3. Start the engine and allow it to run at idle for 5 minutes. 4. Feel the evaporator inlet and outlet pipes. Is there a noticeable difference in the temperature of the evaporator inlet and outlet pipes? 14 1. Turn the ignition switch to LOCK. 2. Recover the A/C system refrigerant. 3. Examine the high­pressure pipe for an obstruction. 4. Examine the expansion valve for an obstruction or a malfunction. 5. Repair the obstruction or replace the expansion valve as needed. 6. Evacuate and recharge the A/C system. 7. Check the A/C system for leaks. 8. Note the discharge air temperature with the A/C ON. Is the discharge temperature normal? At least 7°C (12°F) below ambient air temperature Go to Step 15 Go to Step 13 Value(s) ­ Yes Go to Step 9 No Go to Step 13

9

­

Go to Step 13

­

10

­

Go to Step 11

Go to Step 12

11

­

Go to Step 8

­

12 13

­ ­

Go to Step 8 Go to Step 15

­ Go to Step 14

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7B ­ 14IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
Step 15 Action 1. Record the low­ and the high­side pressures after the A/C system has been operating for 5 minutes or more with the engine cooling fan ON. 2. Locate the intersection of the low­ and the high side pressures. Refer to "Low­ and High­Side Pressure Relationship Chart" in this section. Do the low­ and the high­side pressures intersect in the white area of the chart? Check the high­ and the low­side pressures. Do the low­ and the high­side pressures intersect in the grey area of the chart? Feel the liquid pipe between the condenser and the expansion valve. Is the pipe cold? 1. Examine the condenser for any restriction of the airflow. 2. Check the cooling fans for proper operation. 3. Remove the restriction or repair the fans, as required. Is the pipe temperature normal now? 1. Recover, evacuate, and recharge the A/C system. 2. Check the A/C system for leaks. Is the system free from leaks? Observe the readings on the pressure gauges. Are the A/C compressor high­ and the low­side pressures within the specified value of each other? 1. Run the engine at 3,000 rpm. 2. Set the A/C controls to the following positions: S The A/C switch to the ON. S The fresh air control switch to fresh air. S The blower motor to 4. S The temperature to full cold. 3. Close all of the vehicle's windows and doors. 4. Turn the A/C switch ON and OFF every 20 seconds for 3 minutes. Are the A/C compressor high­ and the low­side pressures within the specified value of each other? 22 Observe the pressure rise on both gauges and the temperatures of both the compressor suction pipe and the discharge pipe. Is the pressure rise on both gauges slow and the suction pipe warm with the discharge pipe very hot? 1. Turn the ignition switch to LOCK. 2. Make sure the compressor clutch is disengaged. 3. Attempt to turn the clutch driver (not the pulley). Can you turn the clutch driver freely by hand? ­ Go to Step 25 Go to Step 23 Value(s) ­ Yes System OK No Go to Step 16

16

­

Go to Step 17

Go to Step 20

17

­

Go to Step 18

Go to Step 19

18

At least 7°C (12°F) below ambient air temperature

Go to Step 13

­

19

­

Go to Step 13

­

20

207 kPa (30 psi) 207 kPa (30 psi)

Go to Step 21

Go to Step 26

21

Go to Step 22

Go to Step 13

23

­

Go to Step 25

Go to Step 24

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MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B ­ 15
Step 24 Action 1. Start the engine. 2. Observe the low­side pressure gauge while running the engine between 3,000 and 3,800 rpm. Does the low­side pressure rise rapidly? 1. Recover the A/C system refrigerant. 2. Replace the A/C compressor. 3. Evacuate and recharge the A/C system. Is the compressor functioning normally? Check the low­side pressure. Is the low­side pressure within the specified value? Feel the high­side pipe leading up to the expansion valve connecting block. Is the pipe cold before the connecting block? 1. Check for a restriction in the high­side pipe before the expansion valve. 2. Repair or replace the high­side pipe. Is the pipe performing normally? Add the specified amount of refrigerant to the A/C system. Does the cooling performance improve? 1. Check the A/C system for leaks. 2. Repair any refrigerant leaks, as needed. 3. Evacuate and recharge the A/C system. 4. Check the A/C system for leaks. Is the system free from leaks? 1. Recover the refrigerant. 2. Check the expansion valve for obstructions. 3. Repair or replace the expansion valve, as required. 4. Evacuate and recharge the system. 5. Check the A/C system for leaks. Is the system free from leaks? 1. Run the engine for 5 minutes at 2,000 rpm. 2. Set the A/C controls to the following positions: S The A/C switch to the ON position. S The fresh air control switch to recirculate (indicator lamp ON). S The blower motor to 1. S The temperature to full cold. 3. Close all of the vehicle's windows and doors. 4. Open the vehicle hood. Is the low­side pressure within the specified value? 33 1. Recover the A/C system refrigerant. 2. Replace the A/C compressor control valve. 3. Evacuate and recharge the A/C system. 4. Check the A/C system for leaks. Is the system free from leaks? ­ Go to Step 13 ­ Value(s) ­ Yes Go to Step 32 No Go to Step 25

25

­

Go to Step 13

­

26 27

172­241 kPa (25­35 psi) ­

Go to Step 27 Go to Step 28

Go to Step 32 Go to Step 29

28

­

Go to Step 13

­

29

0.40 kg (14 ounces) ­

Go to Step 30

Go to Step 31

30

Go to Step 13

­

31

­

Go to Step 13

­

32

172­241 kPa (25­35 psi)

Go to Step 13

Go to Step 33

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7B ­ 16IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

SYMPTOM DIAGNOSIS PRESSURE TEST CHART (R­134A SYSTEM)
Test Results Discharge (high) pressure abnormally high Related Symptioms After stopping the compressor, the pressure drops about 299 kPa (28 psig) quickly, then falls gradually. The condenser is excessively hot. Probable Cause Air in the system. Remedy Recover, evacuate and recharge the system with the specified amount of refrigerant. Recover, evacuate and recharge the system with the specified amount of refrigerant. Clean the condenser or the radiator fins. Check the voltage and the fan rpm. Check the fan direction. Locate and repair the restriction. Check the system for a leak. Charge the system. Repair or replace the compressor.

Excessive refrigerant in the system.

Reduced or no airflow through the condenser.

Condenser or the radiator fins are clogged. Condenser or the radiator fan is not working properly.

Line to the condenser is excessively hot. Discharge pressure abnormally low The condenser is not hot.

Restricted flow of refrigerant in the system. Insufficient refrigerant in the system. Faulty compressor pressure relief valve. Faulty compressor seal. Faulty expansion valve. Moisture in the system. Insufficient refrigerant in the system. Faulty expansion valve.

High and low pressures are balanced soon after stopping the compressor. Low­side pressure is higher than normal. The outlet of the expansion valve is not frosted. Low pressure gauge indicates vacuum. Suction (low) pressure abnormally low Condenser is not hot.

Replace valve.

the

expansion

Recover, evacuate, and recharge the system. Repair the leaks. Recover, evacuate, and recharge the system. Replace valve. the expansion

The expansion valve is not frosted and the lowpressure line is not cold. Low­Pressure gauge indicates a vacuum. Discharge temperature is low and the airflow from the vents is restricted. The expansion valve is frosted. The receiver­dryer outlet is cool and the inlet is warm. Suction pressure abnormally high Low­pressure hose and check joint are cooler than the temperature around the evaporator.

Frozen expansion valve. Evaporator is frozen. Clear the restricted evaporator case drain. Clean or replace the expansion valve. Replace the receiver­dryer. Replace valve. the expansion

Expansion valve is clogged. Receiver­dryer is clogged. Expansion valve is opened for too long.

Capillary tube is loose.
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MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B ­ 17
Test Results Suction pressure abnormally high Related Symptioms Suction pressure is lowered when the condenser is cooled by water. High and low pressure are equalized as soon as the compressor is stopped and both gauges fluctuate while the compressor is running. Probable Cause Excessive refrigerant in the system. Faulty gasket. Remedy Recover, evacuate, and recharge the system. Repair or replace the compressor.

Faulty high­pressure valve. (V5 compressor only) Foreign particles stuck in the high­pressure valve. (V5 compressor only) Suction and discharge pressure abg normally high ll hi h Reduced airflow through the condenser. Clogged condenser or radiator fins. Radiator cooling fans working improperly. Condenser is excessively hot. Suction and discharge pressure abnormally low Low­pressure hose and metal end areas are cooler than the evaporator. Temperature around the expansion valve is low compared to that around the receiver­dryer. Refrigerant leaks The compressor clutch is dirty. The compressor bolts are dirty. The compressor gasket is wet with oil. Excessive refrigerant in the system. Clogged or kinked low­pressure hose. Clogged high­pressure line. Clean the condenser and the radiator. Check the voltage and the radiator cooling fan rpm. Check the fan direction. Recover, evacuate, and recharge the system. Repair or replace the low­ pressure hose. Repair or replace the high­ pressure line.

Leaking compressor shaft seal. Leaking around a compressor housing bolt. Leaking compressor gasket.

Repair or replace the compressor. Tighten the bolt(s) or replace the compressor. Repair or replace the compressor.

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7B ­ 18IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

LOW AND HIGH SIDE PRESSURE RELATIONSHIP CHART

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MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B ­ 19

MAINTENANCE AND REPAIR
ON­VEHICLE SERVICE GENERAL A/C SYSTEM SERVICE PROCEDURES O­RING REPLACEMENT
Important : Even though O­rings may look identical, it is extremely important that only recommended service replacement air conditioning O­rings be used or excessive leakage of refrigerant may occur. Important : Always slip the O­ring onto the flange tube to ensure proper locating and sealing. Install new Daewoo­approved service replacement air conditioning (A/C) O­rings whenever a joint or a fitting is disassembled, except when the O­rings are provided on new components. When replacing O­rings on an A/C component or a joint connection, the fitting design should be identified to ensure installation of the correct air conditioning service replacement O­ring. Some joint connections and components will implement a "captured" O­ring design fitting that uses a groove to retain the O­ring. Others do not have a groove and use a "non­captured" or "standard" O­ring. Assembly and tightening procedures are the same for both designs, but the O­rings are different. Notice : Before installation, verify that both O­rings and fittings have not been nicked or deformed. Deformed or nicked parts must be replaced. Failure to use the proper service replacement parts and procedures may result in excessive refrigerant leakage. If it is necessary to transport or carry any container of refrigerant in a vehicle, do not carry it in the passenger compartment.

HANDLING OF REFRIGERANT LINES AND FITTINGS
Notice : Using too low or too high torque when tightening a fitting can result in loose joints or deformed joint parts. Both conditions can result in refrigerant leakage. S Keep all metal tubing lines free of dents or kinks. Any line restrictions will cause the loss of system capacity. S Never bend a flexible hose line to a radius of less than four times the diameter of the hose. S Never allow a flexible hose line to come within 65 mm (2­1/2 inches) of the exhaust manifold. S Inspect flexible hose lines regularly for leaks or brittleness. S Replace flexible hose lines with new lines if you find signs of deterioration or leaking. S Discharge all refrigerant of the refrigeration system before disconnecting any fitting in the refrigeration system. S Proceed very cautiously regardless of the gauge readings. CAUTION : Keep your face and your hands away from the fitting so that you will not be injured if there happens to be liquid refrigerant in the line. S Open the fittings very slowly. S If you notice pressure when you loosen a fitting, allow the pressure to bleed off as described under "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section. S Cap or tape any refrigerant line immediately after it is opened. This will prevent the entrance of moisture and dirt, which can cause internal compressor wear or plugged lines in the condenser, the evaporator core, the expansion valve, or the compressor inlet screens. Important : Use two proper wrenches to connect the O­ ring fittings. S Back up the opposing fitting to prevent distortion of the connecting lines or the components. S Back up both the swagged fitting on the flexible hose connections and the coupling to which it is attached with two wrenches to prevent turning the fitting and damaging the ground seat. S Keep the O­rings and the seats in perfect condition. A burr or a piece of dirt may cause a refrigerant leak.

HANDLING REFRIGERANT
CAUTION : Always work in a well­ventilated area and avoid breathing any refrigerant fumes. If you have difficulty with breathing, seek medical attention immediately. If refrigerant comes in contact with any part of your body, flush the exposed area with water. If a rash or pain develops, seek medical attention. Air conditioning systems contain refrigerant. This is a chemical mixture which requires special handling procedures to avoid personal injury. Always wear goggles and wrap a clean cloth around the fittings, the valves and the connections when performing work that involves opening the refrigerant system. Do not weld or steam clean on or near any vehicle­installed air conditioning lines or components. All refrigerant drums are shipped with a heavy metal screw cap. The purpose of the cap is to protect the valve and the safety plug from damage. It is good practice to replace the cap after each use of the drum.
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7B ­ 20IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
S Dip new O­rings in clean polyalkaline glycol refrigerant oil before installation. CAUTION : To avoid personal injury, always wear goggles and gloves when performing work that involves opening the refrigeration system. A charging station discharges, evacuates, and recharges an air­conditioning (A/C) system with one hookup. Filtering the refrigerant during the recovery cycle together with filtering during the evacuation cycle ensures a supply of clean, dry refrigerant for A/C system charging. S Never use the R­134a charging station on a system charged with R­12. The refrigerants and the oils from each system are not compatible with those from the other system and must never be mixed, even in the smallest amount. Mixing refrigerant residue will damage the equipment. S Never use adapters which convert from one size fitting to another. Such use allows contamination, which may cause system failure.

MAINTAINING CHEMICAL STABILITY IN THE REFRIGERATION SYSTEM
The efficient operation and the life of the air conditioning (A/C) system is dependent upon the chemical stability of the refrigeration system. When foreign materials, such as dirt, air, or moisture, contaminate the refrigeration system, they will change the stability of the refrigerant and the polyalkaline glycol (PAG) compressor oil. They will also affect the pressure­temperature relationship, reduce efficient operation, and can possibly cause interior corrosion and abnormal wear of moving parts. Observe the following practices to ensure chemical stability in the system: S Wipe away dirt or oil at and near any connection before opening that connection. This will reduce the chance of dirt entering the system. Cap, plug, or tape both sides of a connection as soon as possible after opening the connection. This will prevent the entry of dirt, foreign material, and moisture. Keep all tools clean and dry, including the manifold gauge set and all replacement parts. Use a clean and dry transfer device and container to add polyalkaline glycol refrigerant oil. This will ensure that the oil remains as moisture­free as possible. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section. Have everything you need ready to allow you to perform all operations quickly when opening an A/C system. Do not leave the A/C system open any longer than necessary. Evacuate and recharge any A/C system that has been opened. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section for the instructions to perform this procedure properly.

Charging Station Setup and Maintenance
There are many charging stations available. All perform the various tasks required to discharge the system and recover refrigerant, evacuate the system, add a measured amount of oil, and recharge an A/C system with a measured amount of refrigerant. Refer to the manufacturer's instructions for all initial setup procedures and all maintenance procedures.

S

S S

Control Panel Functions
A charging station will have controls and indicators to allow the operator to control and monitor the operation in progress. Refer to the manufacturer's instructions for details. These can be expected to include the following: 1. Main Power Switch S 2. S S S 3. 4. 5. 6. Supplies electrical power to the control panel. Shows the time programmed for vacuum. Shows the weight of the refrigerant programmed for recharging. Refer to the manufacturer's instructions for detailed programming information. Shows the system's low­side pressure. Shows the system's high­side pressure. Controls the various operating functions. Connects the low side of the A/C system to the unit. Shows whether the refrigerant is wet or dry. Connects the high side of the A/C system to the unit.
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S

Display

S

All service parts are dehydrated and sealed before shipping. They should remain sealed until just before making connections. All the parts should be at room temperature before uncapping. This prevents condensation of moisture from the air from entering the system. Reseal all parts as soon as possible.

Low­Side Manifold Gauge S S S High­Side Manifold Gauge Controls Panel Low­Side Valve S

DISCHARGING, ADDING OIL, EVACUATING, AND CHARGING PROCEDURES FOR A/C SYSTEM
CAUTION : Use only refillable refrigerant tanks that are authorized for the charging station being used. The use of other tanks may cause personal injury or void the warranty. Refer to the manufacturer's instructions for the charging station.

7. 8.

Moisture Indicator S S High­Side Valve

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B ­ 21 Refrigerant Recovery
Important : Use only a refrigerant tank that is designed for the charging station in use. The unit's overfill limitation mechanism is calibrated specifically for use with this tank. The tank's valves are also manufactured specifically for this unit. 1. Attach the high­side hose with the quick disconnect coupler to the high­side fitting of the vehicle's A/C system. Open the coupler valve. Attach the low­side hose with the quick disconnect coupler to the low­side fitting of the vehicle's A/C system. Open the coupler valve. Check the high­side and the low­side gauges on the unit's control panel in order to ensure that the A/C system has pressure. If there is no pressure, there is no refrigerant in the system to recover. The unit tank must contain a sufficient amount of R­134a refrigerant for charging. Check the amount of refrigerant in the tank. If there is less than 3.6 kg (8 pounds) of refrigerant, add new refrigerant to the tank. Refer to the manufacturer's instructions for adding refrigerant. 1. Verify that the high­side and the low­side hoses are connected to the A/C system. Open both the high­side and the low­side valves on the unit's control panel. 2. Open both the gas and the liquid valves on the tank. Important : Refer to the manufacturer's instructions for the charging station in use. It is necessary to evacuate the system before recharging it with new or recycled refrigerant. 3. Start the vacuum pump and begin the evacuation process. Non­condensable gases (mostly air) are vented from the tank automatically during the recycling process. You may hear the pressure being released. 4. Check for leaks in the system. Refer to the manufacturer's instructions for the charging station in use. Important : Change the vacuum pump oil frequently. Refer to the manufacturer's instructions for the charging station in use.

2. 3.

4. 5.

Important : If there is no refrigerant in the system, do not continue with the recovery operation which would, under this condition, draw air into the recovery tank. 6. 7. 8. 9. 10. 11. Open both the high­side and the low­side valves. Open the gas and the liquid valves on the tank. Drain any oil that may be in the oil separator. Close the oil drain valve. Plug the unit into the proper voltage outlet. Turn on the main power switch.

A/C System Oil Charge Replenishing
Any oil removed from the A/C system during the recovery process must be replenished at this time. 1. Use the correct graduated bottle of PAG oil for the R­134a system. Important: S Keep the oil bottles tightly capped at all times to protect the oil from moisture and contamination. S You must have an A/C system vacuum for this operation. Never open the oil injection valve while there is positive pressure in the A/C system. This will result in oil blowback through the bottle vent. S Never let the oil level drop below the pickup tube while charging or replenishing the system, as this will allow air into the A/C system. 2. Refer to the manufacturer's instructions for the charging station in use. Add the proper amount of PAG oil to the system. 3. Close the valve when the required oil charge has been pulled into the system.

Notice : Never reuse refrigerant oil. Damage to the A/C system may result from such reuse. Dispose of the refrigerant oil properly. 12. Begin the recovery process. Refer to the manufacturer's instructions for the charging station in use. Important : Some A/C system polyalkaline glycol (PAG) lubricating oil may be removed with the refrigerant during recovery. The amount of oil removed varies. A charging station separates the oil from the refrigerant and provides a means of determining how much oil was removed. Replace the same amount of oil when recharging the system. Refer to the manufacturer's instructions for the charging station in use. 13. Wait 5 minutes, then check the control panel low­ side gauge. If the A/C has maintained vacuum, the recovery is complete. 14. If the low­side gauge pressure rises above zero, there is more refrigerant in the system. Recover the additional refrigerant. Repeat this step until the system maintains vacuum for 2 minutes. Important : If the control indicator shows that the refrigerant tank is full during the recovery process and the unit shuts off, install an empty unit tank to store the refrigerant needed for steps later in the procedure. Do not use any other type of tank.

Charging
Important : Evacuate the A/C system before charging. 1. Close the low­side valve on the control panel. 2. Open the high­side valve on the control panel. 3. Refer to the manufacturer's instructions for the charging station in use. 4. Enter the amount of refrigerant needed to charge the A/C, making sure to use the correct system of measurement, i.e. kilogram (kg) or pound (lb). 5. Begin the charging process.

Evacuation
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7B ­ 22IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM Successful Transfer Complete
1. Close the high­side valve on the unit's control panel. Both valves should be closed. 2. Start the vehicle and the A/C system. 3. Let the engine run until the readings on the high­ side gauge and the low­side gauge stabilize. 4. Compare the readings to the system specifications. 5. Check the evaporator outlet temperature to ensure that the A/C system is operating within the system specifications. 6. Keep the A/C running. 7. Close the high­side coupler valve. 8. Disconnect the high­side hose from the vehicle. 9. Open the high­side and low­side valves on the control panel. The system will quickly draw in refrigerant from both hoses through the low­side hose. 10. Close the low­side coupler valve. 11. Disconnect the low­side hose from the vehicle.

Unsuccessful Transfer
Sometimes the total charge does not transfer into the A/C system. There are two reasons why this may occur: 1. The pressure in the unit's tank and the pressure in the A/C system are roughly equal. S S 2. This will cause the transfer to proceed too slowly. Refer to the manufacturer's instructions for the charging station in use.

There was not enough refrigerant in the unit's tank to transfer the full charge. S It is necessary to recover the partial charge of refrigerant from the vehicle and then evacuate the A/C system and charge it again. Refer to the manufacturer's instructions for the charging station in use.

S

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MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B ­ 23

SERVICEABLE COMPONENTS COMPONENTS USED IN NON­A/C SYSTEMS
Refer to Section 7A, Heating and Ventilation System for on­vehicle service procedures for the following sections: S Blower Motor. S Blower Resistor. S Control Assembly Knob Lighting. S Control Assembly. S Heater Hoses. S High­Blower Relay. S A/C Control Vacuum Tank. S Temperature Control Cable. S Heater/Air Distributor Case Assembly (A/C Module). S Heater Core

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7B ­ 24IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

A/C PRESSURE TRANSDUCER
Removal Procedure
1. 2. 3. 4. Disconnect the negative battery cable. Release the connector lock and pull the transducer wire connector out. Remove the transducer with a wrench. Discard the O­ring seal.

Installation Procedure
1. 2. Install the new O­ring seal on the transducer. Install the pressure transducer.

Tighten
3. 4. Tighten the pressure transducer to 7 NSm (62 lb­in). Connect the wire connector. Connect the negative battery cable.

A/C COMPRESSOR RELAY
Removal Procedure
1. 2. Disconnect the negative battery cable. Pull the relay straight up and out from its location in the engine fuse block at the left front corner.

Installation Procedure
1. 2. 3. Align the relay terminal contacts with the base receptacle. Push the relay into the base until it is seated. Connect the negative battery cable.

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MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B ­ 25

AIR FILTER
(Left­Hand Drive Shown, Right­Hand Drive Similar) Removal Procedure
1. 2. 3. Remove the glove box. Refer to Section 9E, Instrumentation/Driver Information. Remove the screws and the air filter. Remove the air filter.

Installation Procedure
1. 2. 3. Install the air filter. Install the air filter cover and the screws. Install the glove box. Refer to Section 9E, Instrumentation/Driver Information.

A/C EXPANSION VALVE
(Left­Hand Drive Shown, Right­Hand Drive Similar) Removal Procedure
1. 2. Disconnect the negative battery cable. Recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section. Remove the suction hose/liquid pipe block retaining nuts at the fire wall. Remove the expansion valve connector block retaining stud bolts. Remove the expansion valve. Discard the O­rings.

3.

4. 5. 6.

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7B ­ 26IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM Installation Procedure
1. 2. 3. 4. Clean the grooves that fit the O­rings of any dirt or contamination. Install new O­rings on the evaporator tubes. Install a expansion valve onto the evaporator tubes. Insert the expansion valve connector block retaining stud bolts.

Tighten
Tighten the expansion valve retaining stud bolts to 8 NSm (71 lb­in).

5.

Install the suction hose/liquid pipe block retaining nuts.

Tighten
6. 7. Tighten the suction hose/liquid pipe block­to­expansion valve retaining nuts to 14 NSm (10 lb­ft). Connect the negative battery cable. Evacuate and recharge the A/C system. Refer to"Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.

A/C HIGH­PRESSURE PIPE LINE
(Left­Hand Drive Shown, Right­Hand Drive Similar) Removal Procedure
1. 2. Disconnect the negative battery cable. Recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section. Remove the nut at the discharge hose block connected to compressor. Remove the handlamp housing at the left­hand side. Refer to Section 9B, Lighting Systems. Remove the nut at the condenser connecting block. Remove the refrigerant discharge hose.

3.

4. 5. 6.

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MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B ­ 27
7. 8. 9. Remove the air cleaner housing bolts and the air filter housing assembly. Disconnect the electrical connector at the pressure transducer. Remove the liquid pipe block­to­expansion valve retaining nut at the fire wall.

10. Remove the handlamp housing at the left­hand side. Refer to Section 9B, Lighting Systems. 11. Remove the liquid pipe block­to­receiver dryer retaining nut.

12. Remove the bolts which secure the support clamps that hold the liquid pipe to the vehicle. 13. Remove the liquid pipe from the vehicle. 14. Cap the opening at the receiver­dryer to prevent contamination.

Installation Procedure
1. 2. Position the liquid pipe into the vehicle. Install the liquid pipe support clamp bolts.

Tighten
Tighten the liquid pipe support clamp bolts to 4 NSm (35 lb­in).

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7B ­ 28IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
3. 4. Install a new O­ring on the pipe at the receiver dryer. Install the liquid pipe block­to­receiver­dryer retaining nut.

Tighten
5. Tighten the liquid pipe block­to­receiver­dryer retaining nut to 14 NSm (10 lb­ft). Install the handlamp housing at the right­hand side. Refer to Section 9B, Lighting Systems.

6.

Install the liquid evaporator pipe block retaining nut to the fire wall.

Tighten
7. 8. Tighten the liquid pipe block­to­expansion valve retaining nut to 14 NSm (10 lb­ft). Connect the electrical connector at the pressure transducer. Install the air cleaner housing bolts and the air filter housing assembly.

Position the refrigerant discharge hose into the vehicle. 10. Install the nut at the condenser connecting block.

9.

Tighten
Tighten the refrigerant discharge hose block­to­condenser retaining nut to 16 NSm (12 lb­ft). 11. Install the handlamp housing at the left­hand side. Refer to Section 9B, Lighting Systems.

12. Install the nut at the discharge hose block connected to compressor.

Tighten
Tighten the refrigerant discharge hose block­to­ compressor retaining nut to 33 NSm (24 lb­ft). 13. Connect the negative battery cable. 14. Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.

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MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B ­ 29

EVAPORATOR CORE
(Left­Hand Drive Shown, Right­Hand Drive Similar) Removal Procedure
1. 2. Disconnect the negative battery cable. Recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section. Remove the heater/air distributor case assembly. Refer to Section 7A, Heating and Ventilation System. Remove the wiring harness and electrical connectors from the heater/air distributor case assembly. Remove the screws that connect the heater core housing and the evaporator housing. Remove evaporator core cover screws from the evaporator core housing. Remove the evaporator core.

3.

4. 5. 6. 7.

Installation Procedure
1. 2. Install the evaporator core into the case. Install the screws on the evaporator core housing.

Tighten
Tighten the evaporator core cover screws to 1.2 NSm (11 lb­in).

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7B ­ 30IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
3. Install the screws that connect the heater core housing and the evaporator housing.

Tighten
4. 5. 6. Tighten the screws to 1.2 NSm (11 lb­in). Connect the wiring harness and electrical connectors to the heater/air distributor case assembly. Install the heater/air distributor case assembly. Refer to Section 7A, Heating and Ventilation System. Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section. Connect the negative battery cable.

7.

A/C SUCTION HOSE ASSEMBLY
Removal Procedure
1. 2. Disconnect the negative battery cable. Discharge and recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section. Remove the air cleaner housing bolts and the air filter housing aseembly. Disconnect the elsctrical connector at the pressure transducer. Remove the suction hose block retaining nut at the fire wall. Cap the openings to the expansion valve to prevent contamination. Remove the suction hose support clamp bolts.

3. 4. 5. 6. 7.

8.

Remove the retaining nut from the hose connecting block and disconnect the air conditioning hose assembly connector block from the compressor. 9. Remove the A/C suction hose assembly. 10. Cap the openings to the compressor to prevent contamination.

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MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B ­ 31 Installation Procedure
1. 2. Position the A/C suction hose into the vehicle. Insert the suction hose block­to­compressor to the compressor.

Tighten
Tighten the retaining nut at the suction hose block to 33 NSm (24 lb­ft).

3.

Install the suction hose support clamp­to­longitudinal member.

Tighten
Tighten the suction hose support clamp­to­longitudinal member bolt to 8 NSm (71 lb­in).

4.

Install the suction hose support clamp­to­engine bracket.

Tighten
(1.4 DOHC, 1.6DOHC only) Tighten the suction hose support clamp­to­engine bracket bolt to 4 NSm (35 lb­in).

Tighten
(1.8 DOHC, 2.0 DOHC only) Tighten the suction hose support clamp­to­engine bracket bolt to 14 NSm (10 lb­ft).

5.

Install the suction hose block­to­expansion valve retaining nut at the fire wall.

Tighten
Tighten the suction hose block­to­expansion valve retaining nut to 14 NSm (10 lb­ft). 6. 7. 8. 9. Connect the electrical connector at the pressure transducer. Install the air cleaner housing bolts and the air filter housing assembly. Connect the negative battery cable. Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.

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7B ­ 32IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

A/C DISCHARGE HOSE­COMPRESSOR TO CONDENSER
Removal Procedure
1. 2. Disconnect the negative battery cable. Recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section. Remove the nut at the discharge hose block connected to compressor. Remove the headlamp housing at the left­hand side. Refer to Section 9B, Lighting Systems. Remove the nut at the condenser connecting block. Remove the refrigerant discharge hose.

3.

4. 5. 6.

Installation Procedure
1. Install new sealing washers at the compressor connecting block end and a new O­ring at the condenser connecting block end. Position the hose into the vehicle, and install the nut at the condenser connecting block.

2.

Tighten
Tighten the refrigerant discharge hose block­to­condenser retaining nut to 16 NSm (12 lb­ft).

3.

Make the hose connecting the connecting block to the compressor, and install the retaining nut.

Tighten
4. 5. Tighten the refrigerant discharge hose block­to­ compressor retaining nut to 33 NSm (24 lb­ft). Connect the negative battery cable. Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.

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MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B ­ 33

RECEIVER­DRYER
Removal Procedure
1. 2. Disconnect the negative battery cable. Discharge and recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section. Remove the condenser. Refer to "Condenser" in this section. Remove the receiver­dryer­to­condenser pipe block bolt.

3. 4. 5.

Loosen the bolt that secures the receiver­dryer band clamp. Notice : Hold the receiver­dryer­to­condenser pipe to support it so that the pipe is not damaged while being removed from the receiver­dryer. 6. Remove the receiver­dryer by sliding it up and out of the band clamp. 7. Cap all open connections to prevent contamination. 8. Drain the oil from the receiver­dryer into a graduated container. Record the amount of oil drained. 9. Discard the used oil.

Installation Procedure
Important : Do not uncap the new receiver­dryer until just prior to installation. 1. Add the new oil to the new receiver­dryer. Use the exact amount of oil that you drained from the old receiver­dryer. 2. Install new O­rings onto the two pipes that connect to the receiver­dryer. 3. Install the receiver­dryer into the band clamp. Support the receiver­dryer­to­condenser pipe while pushing the receiver­dryer downward until the pipe is fully installed. 4. Tighten the bolt on the band clamp.

Tighten
Tighten the band clamp bolt to 5 NSm (44 lb­in). 5. Install the receiver dryer­to­condenser pipe block bolt.

Tighten
6. 7. Tighten the receiver­dryer­to­condenser pipe block bolt to 5 NSm (44 lb­in). Install the condenser. Refer to "Condenser" in this section. Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.

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7B ­ 34IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

COMPRESSOR
Removal Procedure
1. 2. Disconnect the negative battery cable. Discharge and recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section. Remove the discharge hose mounting nut. Lift the discharge hose mounting block and the suction hose from the compressor.

3. 4.

5. 6. 7.

Raise and suitably support the vehicle. Remove the engine under cover. Refer to Section 9N, Frame and Underbody. Remove the accessory drive belt.

8.

Disconnect the electrical connector at the compressor. 9. Remove the compressor­to­bracket bolts. (1.4 DOHC shown, others similar) 10. Remove the compressor. 11. Drain the oil from the compressor into a container. Measure the amount of the oil that is drained. Then discard the used oil.

Installation Procedure
1. Add oil to the new compressor. Use the exact amount of oil that you drained from the old compressor. Install the compressor. Install the compressor­to­bracket mounting bolts.

2. 3.

Tighten
(1.4 DOHC, 1.6 DOHC only) Tighten the upper compressor­to­bracket mounting bolts(M8) to 25 NSm (18 lb­ft). Tighten the lower compressor­to­bracket mounting bolts(M10) to 45 NSm (33 lb­ft).

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MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B ­ 35 Tighten
(1.8 DOHC, 2.0 DOHC only) Tighten the front compressor­to­bracket mounting bolts to 35 NSm (26 lb­ft). Tighten the rear compressor­to­bracket mounting bolts to 20 NSm (15 lb­ft).

4. 5. 6. 7. 8.

Install new sealing washers to the suction hose and the discharge hose mounting. Connect the electrical connector at the compressor. Install the accessory drive belt. Install the engine under cover. Refer to Section 9N, Frame and Underbody. Lower the vehicle.

9.

Place the suction hose into its cavity in the compressor and install the discharge hose mounting block to clamp it into place. Hold this all together while tightening the retaining nut.

Tighten
Tighten the refrigerant discharge hose block­to­ compressor retaining nut to 33 NSm (24 lb­ft). 10. Connect the negative battery cable. 11. Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section.

CONDENSER
Removal Procedure
1. 2. Disconnect the negative battery cable. Discharge and recover the refrigerant. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System"in this section. Remove the front bumper. Refer to Section 9O, Bumpers and Fascias. Remove the discharge hose block­to­condenser retaining nut. Remove the discharge hose from the condenser. Remove the liquid pipe block­to­receiver­dryer cretaining nut. Remove the liquid pipe from the receiver­dryer.

3. 4. 5. 6. 7.
DAEWOO V­121 BL4

7B ­ 36IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
8. Remove the condenser mount bolts. 9. Remove the condenser. 10. Cap all the open lines and the fittings to prevent contamination.

Installation Procedure
1. 2. Position the condenser into the vehicle. Install the condenser mount bolts.

Tighten
Tighten the condenser mount bolts to 4 NSm (35 lb­ in).

3. 4. 5.

Install a new O­ring onto the high­pressure pipe mounting block fitting on the receiver­dryer. Install the liquid pipe into the receiver­dryer. Install the liquid pipe block­to­receiver­dryer retaining nut.

Tighten
6. 7. 8. Tighten the liquid pipe block­to­receiver­dryer retaining nut to 14 NSm (10 lb­ft). Install a new O­ring onto the discharge hose connecting block fitting. Install the discharge hose fitting into the condenser. Install the discharge hose connecting block­to­condenser retaining nut at the condenser connecting block.

Tighten
Tighten the refrigerant discharge hose block­to­condenser retaining nut to 16 NSm (12 lb­ft). 9. Install the front bumper. Refer to Section 9O, Bumpers and Fascias. 10. Connect the negative battery cable. 11. Evacuate and recharge the A/C system. Refer to "Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System" in this section. 12. Operate the HVAC control to verify the proper function of the heating and cooling systems.

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MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B ­ 37

UNIT REPAIR COMPONENT LOCATOR V5 COMPRESSOR

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Rear Head Compressor Control Valve O­Ring Rear Head Gasket Valve Plate Suction Reed Clutch Coil Retaining Ring Drive Plate Clutch Pulley Bearing Clutch Hub Key Shaft Nut Seal Retaining Ring Shaft Lip Seal Shaft Seal O­Ring Compressor Housing

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

Compressor Control Valve Pulley Bearing­to­Head Retaining Ring Rotor Pulley Through­Bolt Through­Gasket Compressor Housing­to­Cylinder O­Ring Shaft and Guide Pin Assembly Cylinder Rear Head O­Ring Thrust Washer Race Bearing Oil Drain Plug Clutch and Hub Keyway Compressor Shaft

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7B ­ 38IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM

V5 AIR CONDITIONING COMPRESSOR OVERHAUL CLUTCH PLATE AND HUB ASSEMBLY
Tools Required J­33013­B Hub and Drive Plate Remover/Installer J­33022 Shaft Nut Socket J­33027 Clutch Hub Holding Tool J­34992 Compressor Holding Fixture

Disassembly Procedure
1. 2. Remove the compressor. Refer to "Compressor" in this section. Install the compressor holding fixture J­34992 to the compressor and hold the compressor holding fixture using a bench vise. Use the clutch hub holding tool J­33027 to keep the clutch drive plate and the hub assembly from turning. Remove the shaft nut using the shaft nut socket J­33022. Thread the hub and drive plate remover J­33013­B into the hub. Hold the body of the remover with a wrench and turn the center screw into the remover body to remove the clutch drive plate and the hub assembly. Remove the clutch hub key. Retain the key for assembly.

3.

4. 5.

6.

Assembly Procedure
1. Install the clutch hub key into the hub keyway. Allow the key to project approximately 3.2 mm (1/8 inch) out of the keyway. The hub key is curved slightly to provide an interference fit in the hub key groove. Be sure the frictional surface of the clutch plate and the pulley rotor are clean before installing the clutch drive plate and the hub assembly.

2.

Notice : Do not drive or pound on the clutch hub or the shaft. Internal damage to the compressor may result.
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MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B ­ 39
3. Align the clutch hub key with the shaft keyway. Place the clutch drive plate and the hub assembly onto the compressor shaft.

Remove the hub and drive plate remover/installer J­33013­B center bolt and reverse the body direction on the center bolt. The body of the hub and drive plate remover/installer J­33013­B should be backed off sufficiently to allow the center bolt to be threaded onto the end of the compressor shaft. Notice : If the center bolt is threaded fully onto the end of the compressor shaft, or if the body of the hub and drive plate remover/installer J­33013­B is held and the center bolt is rotated, the key will wedge and could break the clutch drive plate and the hub assembly. 5. Install the hub and drive plate remover/installer J­33013­B and the bearing onto the clutch drive plate. Thread the center bolt onto the compressor shaft. 6. Hold the center bolt with a wrench. Tighten the hex portion of the hub and drive plate remover/installer J­33013­B body to press the hub onto the shaft. Tighten the body several turns. 7. Remove the hub and drive plate remover/installer J­33013­B and check to see that the clutch hub key is still in place in the keyway before installing the clutch drive plate and the hub assembly to its final position. The ai