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Heating, Ventilation, and Air Conditioning - Volt

SPECIFICATIONS

FASTENER SPECIFICATIONS

Single Use Non-Threaded Fasteners/Components

Reusable Threaded Fastener Tightening Specifications

APPROXIMATE FLUID CAPACITIES

ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS

DIAGNOSTIC INFORMATION AND PROCEDURES

HANDLING OF REFRIGERANT LINES AND FITTINGS

CAUTION: To avoid system damage use only R-134a dedicated tools when servicing the A/C system.

Keep all metal tubing lines free of dents or kinks. Any line restrictions will cause the loss of system capacity. Never bend a flexible hose line to a radius of less than four times the diameter of the hose.

Never allow a flexible hose line to come within 65 mm (2 - 1/2 in) of the exhaust manifold. Inspect flexible hose lines regularly for leaks or brittleness.

Replace flexible hose lines with new lines if you find signs of deterioration or leaking.

Discharge the refrigeration system of all refrigerant before disconnecting any fitting in the refrigeration system.

Proceed very cautiously regardless of the gauge readings.

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.

Open the fittings very slowly.

If you notice pressure when you loosen a fitting, allow the pressure to bleed off as described Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System.

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.

NOTE: Use two proper wrenches to connect the fittings.

Back up the opposing fitting to prevent distortion of the connecting lines or the components.

Keep the sealing surfaces in perfect condition. A burr or a piece of dirt may cause a refrigerant leak. When seal washers are used, always install the seal washer without lubrication.

CAUTION: Use only the lubricant specified for this vehicles refrigerant system. Do not mix refrigerant oils which may result in system contamination and unknown reaction by-products which may cause HVAC System failure.

When O-rings are used, always lightly coat the new O-ring seal with the proper refrigerant oil prior to installation.

LEAK TESTING

Special Tools

GE-50078 Infrared Refrigerant Leak Detector

GE-42220 Universal 12V Leak Detection Lamp

GE-43872 Fluorescent Dye Cleaner

For equivalent regional tools, refer to Special Tools.

Refrigerant Leak Testing

NOTE: All A/C system repairs must be verified using electronic leak detection. Dye detection may take up 2 or 3 days to be reliable.

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 refrigerant oil throughout the refrigerant system.

Verifying some passive leaks may require using the GE-50078 detector, even though the A/C system contains fluorescent dye.

Visual Inspection

Visually trace the entire refrigerant system and look for signs of lubricant leakage, damage, and corrosion on all lines hoses and components (Oil can be an indication of a leak). Each questionable area should be checked for leaks using an electronic leak detector.

Fluorescent Leak Detector

NOTE: Always use UV protective eyewear when working with UV light.

Fluorescent dye will assist in locating any leaks in the A/C system.

NOTE: POE oil is water soluble.

Condensation on the evaporator core or the refrigerant lines may wash the POE 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 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 GE-42220 lamp.

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 GE-43872 cleaner.

Replacing System Dye After Flushing

NOTE: Do not add dye to the refrigerant system equipped with high voltage electric compressors. The only means of replenishing dye after flushing is by replacing component containing the dye. Currently a compatible dye wafer is contained in the

O.E. desiccant package. Adding dye that is not compatible with the high voltage

electric compressor may cause compressor damage and high voltage isolation faults.

To prevent false diagnosis, thoroughly clean any residual dye from the service port with a rag and the approved fluorescent dye cleaner GE-43872 cleaner.

Electronic Leak Detection

Infrared detectors operate differently than heated sensor type detectors. They detect changes in concentration of refrigerant rather than absolute concentration. If the tip is held at a detected leak for more than 5 seconds the detector will saturate and zero to that concentration and will no longer detect leaks at that concentration or less. Move tip away from the leak saturation area for 30 seconds to reset the sensitivity of the detector.

Adequate system pressure is required for effective leak detection.

If system is empty install 10% of system charge. Temperature must be above 60 F.

Do not use:

Soap solutions (not effective for leak detection)

Shop air (will introduce contamination to the refrigerant system) High pressure gasses i.e nitrogen (May cause system damage

Air movement from the engine cooling fan can affect the detectors ability to detect leaks. Always leak test with engine off and if possible after engine has reached normal operating temperature.

All fittings and components should be checked.

Take care not to contaminate the probe tip if the part being tested is contaminated.

No cleaners containing solvents should be used prior to using electronic leak detector.

Always follow the refrigerant system around in a continuous path so that no areas of potential leaks are missed. Move the tip along the refrigerant system at a rate of no more than 75 mm per second and a distance of 10 mm from the surface being tested. If a leak is found, always continue to test the remainder of the system.

Follow the instructions supplied with the GE-50078 detector.

AIR CONDITIONING (A/C) SYSTEM PERFORMANCE TEST

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.

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.

A/C Performance Table

A/C DIAGNOSTICS CHART

HEATING PERFORMANCE DIAGNOSTIC

DEFROSTING INSUFFICIENT

NOISE DIAGNOSIS - BLOWER MOTOR

ODOR DIAGNOSIS

REPAIR INSTRUCTIONS

ODOR CORRECTION

Eliminating Air Conditioning (A/C) 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:

1. Ensure that the plenum which draws outside air into the HVAC module is clear of debris.

2. Disable the air conditioning (A/C) compressor clutch operation by disconnecting the clutch coil electrical connector.

3. Dry the evaporator core by performing the following steps:

1. Start the engine.

2. Select the warmest temperature setting.

3. Select the recirculation mode.

4. Run the blower motor on high for 10 minutes.

4. Locate an area in the air conditioning duct between the blower motor and the evaporator core downstream of the blower motor.

5. 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

6. Wear safety goggles and latex gloves in order to perform the following actions:

1. Select the maximum blower speed.

2. Insert the deodorizer extension tube into the hole to the mark on the extension tube.

3. Use short spray bursts and vary the direction of spray for a 2 - 3 minute period of time.

7. Shut the engine OFF. Allow the vehicle to sit for 3 - 5 minutes.

8. Seal the 3.175 mm (0.125 in) hole with body sealer or RTV gasket compound.

9. Start the engine.

10. Operate the blower motor on high for 15 - 20 minutes to dry.

11. Reconnect the A/C compressor clutch coil electrical connector.

12. Verify proper A/C clutch operation.

REFRIGERANT RECOVERY AND RECHARGING

Special Tools

GE 48997 Hybrid A/C Oil Injector Adapter Hose GE 43600 Hybrid A/C Oil Injector Adapter Hose GE-48800 CoolTech A/C Recharge Machine

GE-45037-A A/C Oil Injector

For equivalent regional tools, refer to Special Tools.

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 with side protection and lint-free gloves (insulated against heat loss and impermeable to refrigerant) must 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 may result. The exposed area should be flushed immediately with cold water and prompt medical attention should be obtained.

CAUTION: This A/C refrigerant system is equipped with a High Voltage electric A/C compressor and you must replace the desiccant if the A/C refrigerant system has been open to atmosphere for more than thirty minutes, 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 and potentially void the vehicle warranty for the refrigerant system.

CAUTION: This A/C system's high voltage A/C Compressor uses Polyolester (POE) refrigerant oil instead of Polyalkylene Glycol (PAG) refrigerant oil. Use only approved GM POE oil no more than two hours after removal from its sealed moisture proof packaging (reference GM POE label for proper usage) in refrigerant systems equipped with a High Voltage A/C compressor. GM POE oil is intended to be used with the

GE-45037-A A/C oil injector and the GE-48997 A/C POE oil injector hose. Use of any refrigerant oil other than the approved GM POE, handled and installed per GM's requirements may result in compressor failure and/or loss of HV isolation with associated DTC's set.

CAUTION: Do not lubricate A/C line seal washers as mineral oil will damage the seal and cause leaks. Use only 525 viscosity mineral oil to lubricate o-rings as well as fitting threads for the prevention of fitting seizure.

CAUTION: Failure to flush the refrigerant recovery recharge equipment hoses before adding refrigerant to a hybrid vehicle with an electric compressor may result in an unacceptable amount of Polyalkylene Glycol (PAG) oil entering the refrigerant system. This could result in reduced electrical resistance of the Polyolester (POE) oil and reduce its ability to provide the required level of high voltage isolation.

Both the GE 43600 Hybrid A/C Oil Injector Adapter Hose and GE-48800 CoolTech A/C Recharge Machine are a complete air conditioning service center for R-134a. 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. Both units 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.

GE-48800 CoolTech A/C Recharge Machine is released as a required replacement for the previously essential GE 43600 Hybrid A/C Oil Injector Adapter Hose. The GE-48800 CoolTech A/C Recharge Machine is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil.

Refer to the GE 43600 Hybrid A/C Oil Injector Adapter Hose and GE-48800 CoolTech A/C Recharge Machine ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Approximate Fluid Capacities for the correct amount.

A/C Refrigerant System Oil Charge Replenishing

If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. If no oil was removed from the A/C system during recovery, do not charge any POE oil into the A/C system. POE refrigerant oil can be injected into a charged A/C system using GE-45037-A injector along with GE 48997 adapter. For the proper quantities of oil to add to the A/C refrigerant system, refer to Approximate Fluid Capacities.

FLUSHING

Special Tools

GE-42220 Universal 12V Leak Detection Lamp

GE-43600-50 Flush Loop Hose

GE-45268 Flush Adapter Kit

GE-48800 CoolTech A/C Recharge Machine

For equivalent regional tools. Refer to Special Tools.

ACR2000 (GE-48800) Hose Flush Procedure

NOTE: The following hose flushing procedure must be performed every time the ACR2000 (GE-48800) is used on the hybrid vehicles. It must be completed before the ACR2000 (GE-48800) is connected to the vehicle to begin a diagnostic or service procedure.

The high voltage (HV) electric air conditioning (A/C) compressor uses a polyolester (POE) refrigerant oil instead of a polyalkylene glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation.

The following hose flush procedure is required to prevent oil cross- contamination. Laboratory testing has shown that flushing the ACR2000 (GE-48800) using the following procedure will minimize oil cross- contamination to a negligible amount (<500 ppm).

Failure to flush the ACR2000 (GE-48800) hoses before adding refrigerant to a hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may also cause a battery energy control module hybrid battery voltage system isolation lost diagnostic trouble code (DTC P1AE7) to be set. Additionally the A/C system warranty will be voided.

The ACR2000 (GE-48800) will need to be retrofitted with a GE-43600-50 (Hose- ACR2000 Oil Flush Loop) to be able to perform the following procedure. All hybrid dealers will receive a GE-43600-50, with installation instructions, which is a component of the hybrid essential tool package. Dealers not included in the hybrid marketing plan and needing to service a hybrid vehicle can obtain the GE-43600-50 from SPX Kent Moore, 1-800-GM-TOOLS (1-800-468-6657).

The GE-43600-50 Retrofit Kit replaces the existing hose mount fittings on the ACR2000. Installation instructions are included to properly update the ACR2000 for hybrid vehicle A/C service.

New hybrid compliant A/C refrigerant recharging equipment (GE-48800) will replace current ACR2000 equipment. GE-48800 meets new SAE

refrigerant recovery standard J-2788 and is specially designed for GM hybrid vehicle A/C service.

Before Beginning the Hose Flushing Procedure

1. Always allow the ACR2000 to complete the hose flush cycle to assure that all oil and refrigerant is removed from the hoses and the ACR2000 flow control circuit.

2. Assure the ACR2000 has at least 4.08 kg (9 lb) of chargeable refrigerant before proceeding.

3. A Low Filter Flow message displayed during the hose flushing process indicates that the hose couplers are not connected or open.

Hose Flushing Procedure

1. Connect the ACR2000 service hose couplers to the GE-43600-50 hose flush adapter fittings and open the service hose coupler valves.

2. Power on the ACR2000.

3. If there is positive pressure in the ACR2000 service hoses, press START to recover the service hoses. If there is 88 - 98 kPa (26 - 29 Hg) of vacuum showing on the display screen, skip to step 7.

4. Press Vacuum.

5. Press Start. Allow the vacuum program to run until the display screen shows between 88 - 98 kPa (26 - 29 Hg).

6. Press Pause.

7. Press Main Menu.

8. Press Scroll Menu.

9. Press Oil Flush.

10. Press Next.

11. Enter 03:00 (for a three minute flush) and press Start.

12. The ACR2000 will now flush the service hoses for three minutes and then recover the refrigerant

13. Close the ACR2000 service hose couplers and remove the GE-43600-50 hose flush adapter.

14. The ACR2000 can now be connected to the hybrid vehicle to perform the A/C system diagnostic or service procedures.

ACR2000 (GE-48800) A/C System Procedure

NOTE: Flushing with the ACR 2000 is not intended to remove metal from the A/C system.

Flushing is intended to remove the following contaminants: Contaminated polyolester (POE) oil

Desiccant, following a desiccant bag failure Overcharge of POE oil

Refrigerant contamination

NOTE: Warmer engine or ambient temperature decreases the refrigerant recovery time during the A/C flush procedure.

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.

2. Remove the air conditioning refrigerant desiccant. Refer to Air Conditioning Refrigerant Desiccant Replacement.

3. Remove the air conditioning refrigerant desiccant plug from the desiccant cartridge.

4. Install the air conditioning refrigerant desiccant plug without the desiccant cartridge.

5. Remove the evaporator thermal expansion valve. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement

6. Install GE-45268-115 to the evaporator.

7. Remove the drive motor battery cooler thermal expansion valve. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement

8. Install another GE-45268-115 to the drive motor battery cooler.

9. Install A/C evaporator tube to both GE-45268-115.

10. Install A/C evaporator TXV tube to both GE-45268-115 using an oversized seal washer.

11. Remove the A/C and drive motor battery cooling compressor. Refer to Air Conditioning and Drive Motor Battery Cooling Compressor Replacement

12. Inspect the end of the suction hose for a suction screen.

13. Remove the suction screen, if installed.

14. Install GE-45268-4 to the A/C compressor suction hose.

15. Install GE-452688-5 to the A/C compressor discharge hose.

Fig. 1: A/C Filter And Check Valve

Courtesy of GENERAL MOTORS COMPANY

16. Forward flow refrigerant flushing is recommended for contaminated refrigerant or POE oil.

17. Perform the following procedure:

NOTE: The filter inside the GE-45268-1 is serviceable. Remove and discard the check valve from the filter.

1. Service the filter with ACDelco P/N GF 470, before each flush.

Connect the GE-45268-1 flush filter to the suction port of the GE-45268-4 flush adapter.

2. Connect the blue hose from the GE-48800 ACR 2000 Air Conditioning Service Center to the J 45268-1 flush filter adapter.

3. Connect the red hose from the GE-48800 ACR 2000 Air Conditioning Service Center to the GE-45268-5 flush adapter.

18. Reverse flow refrigerant flushing is recommended for desiccant cartridge failure.

NOTE: The filter inside the J 45268-1 is serviceable. Remove and discard the check valve from the filter.

1. Service the filter with AC P/N GF 470, before each flush. Connect the J 45268-1 flush filter to the discharge port of the GE-45268-5 flush adapter.

2. Connect the blue hose from the GE-48800 ACR 2000 Air Conditioning Service Center to the J 45268-1 flush filter adapter.

3. Connect the red hose from the GE-48800 ACR 2000 Air Conditioning Service Center to the suction port of the GE-45268-4 flush adapter.

NOTE: Close the valve on the external refrigerant tank, before starting the flush process.

19. Flush the front A/C system. Follow the instructions supplied with the GE-48800 ACR 2000 Air Conditioning Service Center.

NOTE: Close the valve on the external refrigerant tank, before starting the flush process.

20. Flush the A/C system. Follow the instructions supplied with the GE-48800 ACR 2000 Air Conditioning Service Center

21. Remove the GE-45268-4 from the A/C compressor suction hose.

22. Remove the GE-45268-5 from the A/C compressor discharge hose.

NOTE: Flushing will remove all the POE oil from the A/C system.

The A/C system must be replenished with the correct amount of POE oil.

23. If the removed A/C compressor is being reinstalled, perform the following procedure: Drain the POE oil from the A/C compressor.

Add the total system capacity of POE oil to the A/C compressor. Refer to Approximate Fluid Capacities .

24. If you will replace the A/C compressor after flushing the system, perform the following procedure:

1. Refer to the Approximate Fluid Capacities.

2. DO NOT drain the new POE oil from the compressor.

3. Deduct the amount of POE oil shipped with the service compressor from the amount of POE oil listed in the capacities table. Refer to Approximate Fluid Capacities.

4. Add the calculated amount to the compressor, as needed.

25. Install the air conditioning and drive motor battery cooling compressor. Refer to Air Conditioning and Drive Motor Battery Cooling Compressor Replacement

NOTE: Flushing will remove the fluorescent leak detection dye from the A/C system.

NOTE: The air conditioning refrigerant desiccant is manufactured with POE fluorescent leak detection dye wafer inside.

26. Replace the air conditioning refrigerant desiccant. Refer to Air Conditioning Refrigerant Desiccant Replacement.

27. Remove A/C evaporator TXV tube from both GE-45268-115.

28. Remove A/C evaporator tube from both GE-45268-115.

29. Remove both GE-45268-115.

30. Install the drive motor battery cooler thermal expansion valve. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement

31. Install the evaporator thermal expansion valve. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement

32. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging

33. Leak test the fittings using GE-42220 Universal 12V Leak Detection Lamp

AIR CONDITIONING AND DRIVE MOTOR BATTERY COOLING COMPRESSOR REPLACEMENT

Fig. 2: Air Conditioning and Drive Motor Battery Cooling Compressor Courtesy of GENERAL MOTORS COMPANY

COMPRESSOR PRESSURE RELIEF VALVE REPLACEMENT

Fig. 3: Compressor Pressure Relief Valve

Courtesy of GENERAL MOTORS COMPANY

AIR CONDITIONING COMPRESSOR HOSE REPLACEMENT

Removal Procedure

1. Disconnect Battery Negative Cable. Refer to Battery Negative Cable Disconnection and Connection

2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging

3. Remove Dash Upper Extension Panel Opening Cover. Refer to Dash Upper Extension Panel Opening Cover Replacement

4. Remove Air Cleaner Outlet Duct. Refer to Air Cleaner Outlet Duct Replacement

Fig. 4: Air Conditioning Compressor Hose And Nut Courtesy of GENERAL MOTORS COMPANY

5. Remove the air conditioning compressor hose nut (1) from the air conditioning evaporator hose (3).

6. Raise the vehicle. Refer to Lifting and Jacking the Vehicle

Fig. 5: A/C Cycling Switch Electrical Connector Courtesy of GENERAL MOTORS COMPANY

7. Disconnect the A/C cycling switch electrical connector (1).

Fig. 6: Air Conditioning Compressor Hose Bolt And Air Conditioning Evaporator Hose Courtesy of GENERAL MOTORS COMPANY

8. Remove the air conditioning compressor hose bolt (1) from the air conditioning evaporator hose (2).

9. Remove Air Conditioning Compressor Hose

Installation Procedure

1. Replace Air Conditioning Refrigerant Pressure Sensor O-Ring Seal. Refer to Air Conditioning Refrigerant Pressure Sensor O-Ring Seal Replacement

Fig. 7: Air Conditioning Compressor Hose Bolt And Air Conditioning Evaporator Hose Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Fastener Caution

2. Install the air conditioning evaporator hose (2) and the air conditioning compressor hose bolt (1) to the air conditioning compressor and tighten to 22 N.m (16 lb ft)

Fig. 8: A/C Cycling Switch Electrical Connector Courtesy of GENERAL MOTORS COMPANY

3. Connect the A/C cycling switch electrical connector (1).

4. Lower the vehicle.

Fig. 9: Air Conditioning Compressor Hose And Nut Courtesy of GENERAL MOTORS COMPANY

5. Install the air conditioning compressor hose (2) and the air conditioning compressor hose nut (1) to the air conditioning evaporator hose (3) and tighten to 22 N.m (16 lb ft)

6. Install Air Cleaner Outlet Duct. Refer to Air Cleaner Outlet Duct Replacement

7. Install Dash Upper Extension Panel Opening Cover. Refer to Dash Upper Extension Panel Opening Cover Replacement

8. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging

9. Connect Battery Negative Cable. Refer to Battery Negative Cable Disconnection and Connection

AIR CONDITIONING COMPRESSOR AND CONDENSER HOSE REPLACEMENT

Removal Procedure

1. Disconnect Battery Negative Cable. Refer to Battery Negative Cable Disconnection and Connection

2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging

3. Remove Dash Upper Extension Panel Opening Cover. Refer to Dash Upper Extension Panel Opening Cover Replacement

4. Remove Front Bumper Fascia. Refer to Front Bumper Fascia Removal and Installation

5. Remove Air Cleaner Assembly. Refer to Air Cleaner Assembly Replacement

6. Remove Air Conditioning Compressor Hose. Refer to Air Conditioning Compressor Hose Replacement

7. Remove Radiator Outlet Hose. Refer to Radiator Outlet Hose Replacement

Fig. 10: Air Conditioning Evaporator Tube, Condenser Tube And Nut Courtesy of GENERAL MOTORS COMPANY

8. Remove the air conditioning evaporator tube nut (3).

9. Remove the air conditioning evaporator tube (1) along with the condenser tube (2) from the condenser.

Fig. 11: Air Conditioning Compressor, Condenser Hose And Bolt Courtesy of GENERAL MOTORS COMPANY

10. Remove the air conditioning compressor and condenser hose bolt (1).

11. Remove the air conditioning compressor and condenser hose (2) from the air conditioning compressor (3).

Fig. 12: A/C Compressor And Condenser Hose Tube, Retainer, Wiring Harness And Cycling Switch Electrical Connector

Courtesy of GENERAL MOTORS COMPANY

12. Remove the air conditioning compressor and condenser hose tube (4).

13. Unclip the retainer (1) holding the air conditioning compressor and condenser hose tube to the engine bracket.

14. Unclip the wiring harness (2) from the air conditioning compressor and condenser hose tube.

15. Disconnect the air conditioning cycling switch electrical connector (3).

16. Remove Air Conditioning Compressor High Pressure Cut Off Switch. Refer to Air Conditioning Compressor High Pressure Cut Off Switch Replacement

Installation Procedure

1. Change the air conditioning O-ring seal. Refer to Air Conditioning Refrigerant Pressure Sensor O-Ring Seal Replacement.

2. Install Air Conditioning Compressor High Pressure Cut Off Switch. Refer to Air Conditioning Compressor High Pressure Cut Off Switch Replacement

Fig. 13: A/C Compressor And Condenser Hose Tube, Retainer, Wiring Harness And Cycling Switch Electrical Connector

Courtesy of GENERAL MOTORS COMPANY

3. Install the air conditioning compressor and condenser hose tube (1).

Fig. 14: Air Conditioning Compressor, Condenser Hose And Bolt Courtesy of GENERAL MOTORS COMPANY

4. Install the air conditioning compressor and condenser hose (2) to the air conditioning compressor (3).

CAUTION: Refer to Fastener Caution

5. Install the air conditioning compressor and condenser hose bolt (1) to the compressor and tighten to 22 N.m (16 lb ft).

Fig. 15: Air Conditioning Evaporator Tube, Condenser Tube And Nut Courtesy of GENERAL MOTORS COMPANY

6. Install the air conditioning evaporator tube (1) along with the condenser tube (2) to the condenser

7. Install the air conditioning evaporator tube nut (3) and tighten to 22 N.m (16 lb ft).

8. Install Radiator Outlet Hose. Refer to Radiator Outlet Hose Replacement

9. Install Air Conditioning Compressor Hose. Refer to Air Conditioning Compressor Hose Replacement

10. Install Air Cleaner Assembly. Refer to Air Cleaner Assembly Replacement

11. Install Front Bumper Fascia. Refer to Front Bumper Fascia Removal and Installation

12. Install Dash Upper Extension Panel Opening Cover. Refer to Dash Upper Extension Panel Opening Cover Replacement

13. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging

14. Connect Battery Negative Cable. Refer to Battery Negative Cable Disconnection and Connection

CONDENSER TUBE REPLACEMENT

Removal Procedure

1. Disconnect Battery Negative Cable. Refer to Battery Negative Cable Disconnection and Connection

2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging

3. Remove Front Bumper Fascia. Refer to Front Bumper Fascia Removal and Installation

4. Remove Dash Upper Extension Panel Opening Cover. Refer to Dash Upper Extension Panel Opening Cover Replacement

5. Remove Air Conditioning Evaporator Hose Assembly. Refer to Air Conditioning Evaporator Hose Assembly Replacement

6. Remove Air Cleaner Assembly. Refer to Air Cleaner Assembly Replacement

Fig. 16: Air Conditioning Evaporator Tube, Condenser Tube And Nut Courtesy of GENERAL MOTORS COMPANY

7. Remove the condenser tube nut (3) and remove the air conditioning evaporator tube (1) together with the condenser tube (2) from condenser.

Fig. 17: Condenser Tube, Retainers And Nuts Courtesy of GENERAL MOTORS COMPANY

8. Remove the 2 condenser tube nuts (3).

9. Remove the 2 condenser tube retainers (1) and remove the condenser tube (2).

Installation Procedure

1. Replace Air Conditioning Refrigerant Pressure Sensor O-Ring Seal. Refer to Air Conditioning Refrigerant Pressure Sensor O-Ring Seal Replacement

Fig. 18: Condenser Tube, Retainers And Nuts Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Fastener Caution

2. Install the condenser tube (2) the 2 condenser tube nuts (3).

3. Install the 2 condenser tube retainer (1) and the 2 condenser tube nuts (3) and tighten to 9 N.m (80 lb in).

Fig. 19: Air Conditioning Evaporator Tube, Condenser Tube And Nut Courtesy of GENERAL MOTORS COMPANY

4. Install the air conditioning evaporator tube (1) together with the condenser tube (2) to the condenser and tighten to 22 N.m (16 lb ft)

5. Install Air Cleaner Assembly. Refer to Air Cleaner Assembly Replacement

6. Install Air Conditioning Evaporator Hose Assembly. Refer to Air Conditioning Evaporator Hose Assembly Replacement

7. Install Dash Upper Extension Panel Opening Cover. Refer to Dash Upper Extension Panel Opening Cover Replacement

8. Install Front Bumper Fascia. Refer to Front Bumper Fascia Removal and Installation

9. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging

10. Connect Battery Negative Cable. Refer to Battery Negative Cable Disconnection and Connection

AIR CONDITIONING EVAPORATOR HOSE ASSEMBLY REPLACEMENT

Removal Procedure

1. Disconnect Battery Negative Cable. Refer to Battery Negative Cable Disconnection and Connection

2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging -

3. Remove Dash Upper Extension Panel Opening Cover. Refer to Dash Upper Extension Panel Opening Cover Replacement

4. Remove Air Cleaner Outlet Duct. Refer to Air Cleaner Outlet Duct Replacement

Fig. 20: Air Conditioning Compressor Hose And Nut Courtesy of GENERAL MOTORS COMPANY

5. Remove the air conditioning compressor hose nut (1) from the air conditioning evaporator hose (3).

Fig. 21: Air Conditioning Evaporator Hose And Nut Courtesy of GENERAL MOTORS COMPANY

6. Remove the air conditioning evaporator hose nut (1) and remove the air conditioning evaporator hose (2) from TXV stud.

7. Disconnect the evaporative emission pipe at the canister purge solenoid valve, unclip and reposition the pipe. Refer to Plastic Collar Quick Connect Fitting Service .

Fig. 22: Air Conditioning Evaporator Hose And Nut Courtesy of GENERAL MOTORS COMPANY

8. Remove the air conditioning evaporator hose nut (2) and remove the air conditioning evaporator hose (1) from TXV stud.

9. Unclip and remove the evaporator hose assembly from the vehicle.

Installation Procedure

1. Replace Air Conditioning Refrigerant Pressure Sensor O-Ring Seal. Refer to Air Conditioning Refrigerant Pressure Sensor O-Ring Seal Replacement

2. Position the evaporator hose assembly to the vehicle.

Fig. 23: Air Conditioning Evaporator Hose And Nut Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Fastener Caution

3. Install the air conditioning evaporator hose (1) and the air conditioning evaporator hose nut (2) and tighten to 22 N.m (16 lb ft).

4. Connect the evaporative emission pipe to the canister purge solenoid valve. Refer to Plastic Collar Quick Connect Fitting Service .

Fig. 24: Air Conditioning Evaporator Hose And Nut Courtesy of GENERAL MOTORS COMPANY

5. Install the air conditioning evaporator hose (2) and the air conditioning evaporator hose nut (1) and tighten to 22 N.m (16 lb ft).

Fig. 25: Air Conditioning Compressor Hose And Nut Courtesy of GENERAL MOTORS COMPANY

6. Install the air conditioning compressor hose (2) and the air conditioning compressor hose nut (1) to the air conditioning evaporator hose (3) and tighten to 22 N.m (16 lb ft)

7. Install Air Cleaner Outlet Duct. Refer to Air Cleaner Outlet Duct Replacement

8. Install Dash Upper Extension Panel Opening Cover. Refer to Dash Upper Extension Panel Opening Cover Replacement

9. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging

10. Connect Battery Negative Cable. Refer to Battery Negative Cable Disconnection and Connection

AIR CONDITIONING COMPRESSOR HIGH PRESSURE CUT OFF SWITCH REPLACEMENT

Fig. 26: Air Conditioning Compressor High Pressure Cut Off Switch Courtesy of GENERAL MOTORS COMPANY

AIR CONDITIONING REFRIGERANT DESICCANT REPLACEMENT

Fig. 27: Air Conditioning Refrigerant Desiccant Courtesy of GENERAL MOTORS COMPANY

AIR CONDITIONING EVAPORATOR THERMAL EXPANSION VALVE REPLACEMENT

Fig. 28: Air Conditioning Evaporator Thermal Expansion Valve Courtesy of GENERAL MOTORS COMPANY

AIR CONDITIONING REFRIGERANT PRESSURE SENSOR O-RING SEAL REPLACEMENT

Removal Procedure

1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure

2. Remove the O-ring seal from the A/C refrigerant component.

3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure.

4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary.

NOTE: Cap or tape the open A/C refrigerant components immediately to prevent system contamination.

5. Cap or tape the A/C refrigerant components.

Fig. 29: Proper Seating Of A/C Refrigerant O-Ring Courtesy of GENERAL MOTORS COMPANY

6. Discard the O-ring seal.

Installation Procedure

1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary.

2. Remove the cap or tape from the A/C refrigerant components.

3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components.

CAUTION: Use only the lubricant specified for this vehicles refrigerant system. Do not

mix refrigerant oils which may result in system contamination and unknown reaction by-products which may cause HVAC System failure.

4. Lightly coat the new O-ring seal with the proper refrigerant oil prior to installation.

NOTE: DO NOT reuse O-ring seals.

5. Carefully slide the new O-ring seal onto the A/C refrigerant component.

Fig. 30: Proper Seating Of A/C Refrigerant O-Ring Courtesy of GENERAL MOTORS COMPANY

6. The O-ring seal must be fully seated.

7. Assemble the A/C components.

Refer to the appropriate repair procedure.

AIR CONDITIONING REFRIGERANT LOW PRESSURE SERVICE VALVE REPLACEMENT

Fig. 31: Air Conditioning Refrigerant Low Pressure Service Valve Courtesy of GENERAL MOTORS COMPANY

AIR CONDITIONING REFRIGERANT HIGH PRESSURE SERVICE VALVE REPLACEMENT

Fig. 32: Air Conditioning Refrigerant High Pressure Service Valve Courtesy of GENERAL MOTORS COMPANY

AIR CONDITIONING CYCLING SWITCH REPLACEMENT

Fig. 33: Air Conditioning Cycling Switch Courtesy of GENERAL MOTORS COMPANY

AIR CONDITIONING CONDENSER REPLACEMENT

Special Tools

BO-38185 Hose Clamp Pliers Equivalent regional tools: Special Tools Removal Procedure

1. Disconnect Battery Negative Cable. Refer to Battery Negative Cable Disconnection and Connection

2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging

3. Remove Radiator Air Lower Baffle and Deflector. Refer to Radiator Air Lower Baffle and Deflector Replacement

4. Remove Radiator Air Upper Baffle and Deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement

5. Remove the drive motor control module radiator inlet hose from air conditioning condenser. Refer to Drive Motor Control Module Radiator Inlet Hose Replacement .

6. Remove the drive motor generator control module cooling outlet hose from air conditioning condenser. Refer to Drive Motor Generator Control Module Cooling Outlet Hose Replacement (Underbody Line) Drive Motor Generator Control Module Cooling Outlet Hose Replacement (Underbody Line to Traction Power Inverter Module Inlet)

7. Remove the condenser tube from air conditioning condenser. Refer to Condenser Tube Replacement.

Fig. 34: Air Conditioning Condenser Bracket Spring And Radiator Assembly Courtesy of GENERAL MOTORS COMPANY

8. Remove the 2 air conditioning condenser bracket spring (3) from radiator assembly (2).

Fig. 35: Air Conditioning Condenser, Bracket And Retaining Tabs Courtesy of GENERAL MOTORS COMPANY

9. Remove the air conditioning condenser (2) with air conditioning condenser bracket (1).

10. Unlock the 3 retaining tabs (3).

Fig. 36: Air Conditioning Condenser And Bracket Courtesy of GENERAL MOTORS COMPANY

11. Remove the air conditioning condenser (2) from air conditioning condenser bracket (1).

12. Remove the air conditioning refrigerant desiccant from the air conditioning condenser. Refer to Air Conditioning Refrigerant Desiccant Replacement.

13. Remove the engine coolant temperature sensor from the air conditioning condenser. Refer to Engine Coolant Temperature Sensor Replacement - Radiator .

Installation Procedure

1. Install the engine coolant temperature sensor to the air conditioning condenser. Refer to Engine Coolant Temperature Sensor Replacement - Radiator .

2. Install the air conditioning refrigerant desiccant to the air conditioning condenser. Refer to Air Conditioning Refrigerant Desiccant Replacement.

Fig. 37: Air Conditioning Condenser And Bracket Courtesy of GENERAL MOTORS COMPANY

3. Install the air conditioning condenser (2) to air conditioning condenser bracket (1).

Fig. 38: Air Conditioning Condenser, Bracket And Retaining Tabs Courtesy of GENERAL MOTORS COMPANY

4. Install the air conditioning condenser (2) with air conditioning condenser bracket (1).

5. Lock the 3 retaining tabs (3).

Fig. 39: Air Conditioning Condenser Bracket Spring And Radiator Assembly Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Fastener Caution

6. Install the 2 air conditioning condenser bracket spring (3) to radiator assembly (2).

7. Install the condenser tube to the air conditioning condenser. Refer to Condenser Tube Replacement.

8. Install the drive motor generator control module cooling outlet hose to air conditioning condenser. Refer to Drive Motor Generator Control Module Cooling Outlet Hose Replacement (Underbody Line) Drive Motor Generator Control Module Cooling Outlet Hose Replacement (Underbody Line to Traction Power Inverter Module Inlet)

9. Install the drive motor control module radiator inlet hose from air conditioning condenser. Refer to Drive Motor Control Module Radiator Inlet Hose Replacement .

10. Install Radiator Air Upper Baffle and Deflector. Refer to Radiator Air Upper Baffle and Deflector Replacement

11. Install Radiator Air Lower Baffle and Deflector. Refer to Radiator Air Lower Baffle and Deflector Replacement

12. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging

13. Connect Battery Negative Cable. Refer to Battery Negative Cable Disconnection and Connection

AIR CONDITIONING EVAPORATOR LOWER CASE REPLACEMENT

Removal Procedure

1. Disconnect Battery Negative Cable. Refer to Battery Negative Cable Disconnection and Connection

2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging

3. Remove Air Conditioning Evaporator Upper Case. Refer to Air Conditioning Evaporator Upper Case Replacement

4. Remove Blower Motor. Refer to Blower Motor Replacement

5. Remove Air Conditioning Evaporator. Refer to Air Conditioning Evaporator Replacement

6. Remove the evaporator seals.

Installation Procedure

1. Install the evaporator seals.

2. Install Air Conditioning Evaporator. Refer to Air Conditioning Evaporator Replacement

3. Install Blower Motor. Refer to Blower Motor Replacement

4. Install Air Conditioning Evaporator Upper Case. Refer to Air Conditioning Evaporator Upper Case Replacement

5. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging

6. Connect Battery Negative Cable. Refer to Battery Negative Cable Disconnection and Connection

AIR CONDITIONING EVAPORATOR UPPER CASE REPLACEMENT

Fig. 40: Air Conditioning Evaporator Upper Case Courtesy of GENERAL MOTORS COMPANY

AIR CONDITIONING AND HEATER MODULE ASSEMBLY REMOVAL AND INSTALLATION

Removal Procedure

1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection

2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging

3. Drain the cooling system. Refer to Cooling System Draining and Filling

4. Remove Dash Upper Extension Panel Opening Cover. Refer to Dash Upper Extension Panel Opening Cover Replacement

Fig. 41: Intake Manifold Cover

Courtesy of GENERAL MOTORS COMPANY

5. Remove Intake Manifold Cover (3). Refer to Intake Manifold Cover Replacement

Fig. 42: Air Cleaner Outlet Duct, Air Cleaner Assembly And Throttle Body Courtesy of GENERAL MOTORS COMPANY

6. Remove Air Cleaner Outlet Duct (2). Refer to Air Cleaner Outlet Duct Replacement

Fig. 43: Air Conditioning Evaporator Hose And Nut Courtesy of GENERAL MOTORS COMPANY

7. Remove Air Conditioning Evaporator Hose Assembly (1) @ Air Conditioning Evaporator Thermal Expansion Valve. Refer to Air Conditioning Evaporator Hose Assembly Replacement

Fig. 44: Heater Inlet Hose And Quick Connect Courtesy of GENERAL MOTORS COMPANY

8. Remove Heater Inlet Hose (2) @ Heater Core Inlet Tube. Refer to Heater Inlet Hose Replacement

Fig. 45: Heater Water Shutoff Valve Inlet Hose Courtesy of GENERAL MOTORS COMPANY

9. Remove Heater Water Shutoff Valve Inlet Hose (2) @ Heater Core Outlet Tube. Refer to Heater Water Shutoff Valve Inlet Hose Replacement

Fig. 46: Heater And Air Conditioning Evaporator And Blower Module Nut Courtesy of GENERAL MOTORS COMPANY

10. Remove Heater and Air Conditioning Evaporator and Blower Module Nut (1) @ Cowl Panel.

Fig. 47: Windshield Wiper System Module Courtesy of GENERAL MOTORS COMPANY

11. Remove Windshield Wiper System Module (2). Refer to Windshield Wiper System Module Replacement

12. Remove the left and right front side door (4). Refer to Front Side Door Replacement

13. Remove Drivers Seat and Passengers Seat. Refer to Driver or Passenger Seat Removal and Installation

14. Remove Front Floor Console. Refer to Front Floor Console Replacement

Fig. 48: Steering Column

Courtesy of GENERAL MOTORS COMPANY

15. Remove Steering Column (1). Refer to Steering Column Replacement

Fig. 49: Instrument Panel Carrier Assembly Courtesy of GENERAL MOTORS COMPANY

16. Remove Instrument Panel (1). Refer to Instrument Panel Assembly Replacement

17. Disconnect the instrument panel wiring connectors.

Fig. 50: Instrument Panel Tie Bar And Reinforcement Bolts Courtesy of GENERAL MOTORS COMPANY

18. Remove Instrument Panel Tie Bar (2). Refer to Instrument Panel Tie Bar Replacement

Fig. 51: Air Conditioning Evaporator And Blower Module Drain Hose

Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to HVAC Module Drain Tube Caution .

19. Prior to removing the air conditioning evaporator and blower module drain tube/hose, use clean and absorbent shop clothes/towels to cover the electrical components protecting the electrical components from water damage.

20. Remove Air Conditioning Evaporator and Blower Module Drain Hose (1) @ Heater and Air Conditioning Evaporator and Blower Module.

21. Support the heater and air conditioning evaporator and blower (HVAC) module assembly.

Fig. 52: Heater And Air Conditioning Evaporator And Blower Module Courtesy of GENERAL MOTORS COMPANY

22. Remove Heater and Air Conditioning Evaporator and Blower Module (1) from the vehicle.

23. Transfer all necessary components.

Installation Procedure

Fig. 53: Heater And Air Conditioning Evaporator And Blower Module Courtesy of GENERAL MOTORS COMPANY

1. Install Heater and Air Conditioning Evaporator and Blower Module (1) onto the vehicle.

2. Temporarily support HVAC module assembly.

Fig. 54: Air Conditioning Evaporator And Blower Module Drain Hose

Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to HVAC Module Drain Tube Caution .

3. Install Air Conditioning Evaporator and Blower Module Drain Hose (1) @ Heater and Air Conditioning Evaporator and Blower Module.

4. Remove the absorbent shop clothes/towels covering the electrical components.

Fig. 55: Instrument Panel Tie Bar And Reinforcement Bolts Courtesy of GENERAL MOTORS COMPANY

5. Install Instrument Panel Tie Bar (2). Refer to Instrument Panel Tie Bar Replacement

6. Connect the instrument panel wiring connectors.

Fig. 56: Instrument Panel Carrier Assembly Courtesy of GENERAL MOTORS COMPANY

7. Install Instrument Panel (1). Refer to Instrument Panel Assembly Replacement

Fig. 57: Steering Column

Courtesy of GENERAL MOTORS COMPANY

8. Install Steering Column (1). Refer to Steering Column Replacement

9. Install Front Floor Console. Refer to Front Floor Console Replacement

10. Install Drivers Seat and Passengers Seat. Refer to Driver or Passenger Seat Removal and Installation

11. Install the left and right front side doors (4). Refer to Front Side Door Replacement

Fig. 58: Windshield Wiper System Module Courtesy of GENERAL MOTORS COMPANY

12. Install Windshield Wiper System Module (2). Refer to Windshield Wiper System Module Replacement

Fig. 59: Heater And Air Conditioning Evaporator And Blower Module Nut Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Fastener Caution .

13. Install and tighten Heater and Air Conditioning Evaporator and Blower Module Nut (1) @ Cowl Panel to 9.0

N.m (80 lb in)

Fig. 60: Heater Water Shutoff Valve Inlet Hose Courtesy of GENERAL MOTORS COMPANY

14. Install Heater Water Shutoff Valve Inlet Hose (2) @ Heater Core Outlet Tube. Refer to Heater Water Shutoff Valve Inlet Hose Replacement

Fig. 61: Heater Inlet Hose And Quick Connect Courtesy of GENERAL MOTORS COMPANY

15. Install Heater Inlet Hose (2) @ Heater Core Inlet Tube. Refer to Heater Inlet Hose Replacement

Fig. 62: Air Conditioning Evaporator Hose And Nut Courtesy of GENERAL MOTORS COMPANY

16. Install Air Conditioning Evaporator Hose Assembly (1) @ Air Conditioning Evaporator Thermal Expansion Valve. Refer to Air Conditioning Evaporator Hose Assembly Replacement

Fig. 63: Air Cleaner Outlet Duct, Air Cleaner Assembly And Throttle Body Courtesy of GENERAL MOTORS COMPANY

17. Install Air Cleaner Outlet Duct (2). Refer to Air Cleaner Outlet Duct Replacement

Fig. 64: Intake Manifold Cover

Courtesy of GENERAL MOTORS COMPANY

18. Install Intake Manifold Cover (3). Refer to Intake Manifold Cover Replacement

19. Install Dash Upper Extension Panel Opening Cover. Refer to Dash Upper Extension Panel Opening Cover Replacement

20. Fill the cooling system to the proper level. Refer to Cooling System Draining and Filling .

21. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging

22. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection

23. Inspect for coolant leaks.

24. Visually inspect for air conditioning system refrigerant leaks.

AIR CONDITIONING EVAPORATOR REPLACEMENT

Fig. 65: Air Conditioning Evaporator

Courtesy of GENERAL MOTORS COMPANY

AIR CONDITIONING EVAPORATOR AND BLOWER CASE REPLACEMENT

Removal Procedure

1. Disconnect Battery Negative Cable. Refer to Battery Negative Cable Disconnection and Connection

2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging

3. Remove Air Conditioning and Heater Module Assembly. Refer to Air Conditioning and Heater Module Assembly Removal and Installation

4. Remove Heater Core. Refer to Heater Core Replacement

Fig. 66: Air Conditioning Lower Case Bolt Courtesy of GENERAL MOTORS COMPANY

5. Remove the air conditioning lower case bolt (1).

Fig. 67: Air Conditioning Evaporator Lower Case And Bolt Courtesy of GENERAL MOTORS COMPANY

6. Remove the air conditioning evaporator lower case bolt (1).

7. Remove the air conditioning evaporator lower case (2).

8. Remove the air conditioning evaporator and blower case from the air conditioning evaporator upper and lower case bolts.

9. Remove Mode Valve Gear. Refer to Mode Valve Gear Replacement

10. Remove Vent Valve Lever. Refer to Vent Valve Lever Replacement

11. Remove Air Conditioning Evaporator. Refer to Air Conditioning Evaporator Replacement

Fig. 68: Air Conditioning Evaporator/Blower Case And Wiring Harness Courtesy of GENERAL MOTORS COMPANY

12. Remove the air conditioning evaporator and blower case wiring harness (1).

13. Remove the air conditioning evaporator and blower case (2).

Installation Procedure

Fig. 69: Air Conditioning Evaporator/Blower Case And Wiring Harness Courtesy of GENERAL MOTORS COMPANY

1. Install the air conditioning evaporator and blower case wiring harness (1) to the air conditioning evaporator and blower case (2).

2. Install Air Conditioning Evaporator. Refer to Air Conditioning Evaporator Replacement

3. Install Vent Valve Lever. Refer to Vent Valve Lever Replacement

4. Install Mode Valve Gear. Refer to Mode Valve Gear Replacement

Fig. 70: Air Conditioning Evaporator Lower Case And Bolt Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Fastener Caution

5. Install the air conditioning evaporator lower case (2).

6. Install the air conditioning evaporator lower case bolt (1) and tighten to 2.5 N.m (22 lb in).

Fig. 71: Air Conditioning Lower Case Bolt Courtesy of GENERAL MOTORS COMPANY

7. Install the air conditioning evaporator lower case bolt (1) and tighten to 2.5 N.m (22 lb in).

8. Install Heater Core. Refer to Heater Core Replacement

9. Install Air Conditioning and Heater Module Assembly. Refer to Air Conditioning and Heater Module Assembly Removal and Installation

10. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging

11. Connect Battery Negative Cable. Refer to Battery Negative Cable Disconnection and Connection

HEATER INLET HOSE REPLACEMENT

Special Tools

BO-38185 Hose Clamp Pliers Equivalent regional tools: Special Tools Removal Procedure

1. Drain the cooling system. Refer to Cooling System Draining and Filling

2. Remove Front Wheelhouse Liner (Left Side). Refer to Front Wheelhouse Liner Replacement (Left Side) .

3. Remove Dash Upper Extension Panel Opening Cover. Refer to Dash Upper Extension Panel Opening Cover Replacement

4. Remove Air Cleaner Outlet Duct. Refer to Air Cleaner Outlet Duct Replacement

Fig. 72: Heater Inlet Hose And Quick Connect Courtesy of GENERAL MOTORS COMPANY

5. Disconnect Heater Inlet Hose Quick Connect (1) @ Heater Inlet Hose (2)

6. Remove Heater Inlet Hose (2) @ Heater Core Inlet Tube

Fig. 73: Heater Inlet Hose And Retainers

Courtesy of GENERAL MOTORS COMPANY

7. Remove Heater Inlet Hose (2) @ Heater Inlet Hose Retainers (1) (Qty: 2)

Fig. 74: Heater Coolant Heater, Heater Inlet Hose And Quick Connect Courtesy of GENERAL MOTORS COMPANY

8. Disconnect Heater Inlet Hose Quick Connect (2) @ Heater Inlet Hose (3)

9. Disconnect Heater Inlet Hose (3) @ Heater Coolant Heater (1)

10. Remove Heater Inlet Hose (3)

Installation Procedure

Fig. 75: Heater Coolant Heater, Heater Inlet Hose And Quick Connect Courtesy of GENERAL MOTORS COMPANY

1. Install Heater Inlet Hose (3) @ Heater Coolant Heater (1)

CAUTION: Refer to Fastener Caution

2. Connect Heater Inlet Hose Quick Connect (2) @ Heater Inlet Hose (3)

Fig. 76: Heater Inlet Hose And Retainers Courtesy of GENERAL MOTORS COMPANY

3. Install Heater Inlet Hose (2) @ Heater Inlet Hose Retainers (1) (Qty: 2)

Fig. 77: Heater Inlet Hose And Quick Connect Courtesy of GENERAL MOTORS COMPANY

4. Install Heater Inlet Hose (2) @ Heater Core Inlet Tube

5. Connect Heater Inlet Hose Quick Connect (1) @ Heater Inlet Hose (2)

6. Install Air Cleaner Outlet Duct. Refer to Air Cleaner Outlet Duct Replacement

7. Install Dash Upper Extension Panel Opening Cover. Refer to Dash Upper Extension Panel Opening Cover Replacement

8. Install Front Wheelhouse Liner (Left Side). Refer to Front Wheelhouse Liner Replacement (Left Side)

9. Fill the cooling system. Refer to Cooling System Draining and Filling

HEATER INLET AND OUTLET PIPE REPLACEMENT

Fig. 78: Heater Inlet And Outlet Pipe

Courtesy of GENERAL MOTORS COMPANY

HEATER COOLANT PUMP REPLACEMENT

Fig. 79: Heater Coolant Pump

Courtesy of GENERAL MOTORS COMPANY

PASSENGER COMPARTMENT AIR FILTER REPLACEMENT

Removal Procedure

1. Remove Instrument Panel Compartment. Refer to Instrument Panel Compartment Replacement

Fig. 80: Passenger Compartment Air Filter Courtesy of GENERAL MOTORS COMPANY

2. Unclip Passenger Compartment Air Filter (2)

Installation Procedure

Fig. 81: Passenger Compartment Air Filter Courtesy of GENERAL MOTORS COMPANY

1. Install Passenger Compartment Air Filter (2)

2. Install Instrument Panel Compartment. Refer to Instrument Panel Compartment Replacement

AIR INLET DUCT REPLACEMENT

Fig. 82: Air Inlet Duct

Courtesy of GENERAL MOTORS COMPANY

AIR INLET HOUSING REPLACEMENT

Removal Procedure

1. Remove Air Conditioning and Heater Module Assembly. Refer to Air Conditioning and Heater Module Assembly Removal and Installation

Fig. 83: Air Inlet Housing Bolts

Courtesy of GENERAL MOTORS COMPANY

2. Remove Air Inlet Housing Bolts (1) (Qty: 2)

Fig. 84: Air Inlet Housing And Retainers Courtesy of GENERAL MOTORS COMPANY

3. Remove Air Inlet Housing (2) @ Heater and Air Conditioning Evaporator Case

1. Disconnect all electrical connectors.

2. Disengage the air inlet housing (2) from the retainers (1).

Installation Procedure

Fig. 85: Air Inlet Housing And Retainers Courtesy of GENERAL MOTORS COMPANY

1. Install Air Inlet Housing (2) @ Heater and Air Conditioning Evaporator Case

1. Guide the air inlet housing (2) into the retainers (1).

2. Connect the electrical connectors.

Fig. 86: Air Inlet Housing Bolts

Courtesy of GENERAL MOTORS COMPANY

CAUTION: Remove Fastener Caution

2. Install and tighten Air Inlet Housing Bolts (1) (Qty: 2) to 2.5 N.m (22 lb in)

3. Install Air Conditioning and Heater Module Assembly. Refer to Air Conditioning and Heater Module Assembly Removal and Installation

HEATER AND AIR CONDITIONING CONTROL MODE LEVER REPLACEMENT

Fig. 87: Heater And Air Conditioning Control Mode Lever Courtesy of GENERAL MOTORS COMPANY

BLOWER MOTOR REPLACEMENT

Fig. 88: Blower Motor

Courtesy of GENERAL MOTORS COMPANY

INSTRUMENT PANEL OUTER AIR OUTLET REPLACEMENT - LEFT SIDE

Removal Procedure

Fig. 89: Instrument Panel Knee Bolster Courtesy of GENERAL MOTORS COMPANY

1. Remove Instrument Panel Knee Bolster (2). Refer to Instrument Panel Knee Bolster Replacement

Fig. 90: Instrument Panel Switch Trim Plate Courtesy of GENERAL MOTORS COMPANY

2. Remove Instrument Panel Switch Trim Plate (2). Refer to Instrument Panel Switch Trim Plate Replacement

Fig. 91: Instrument Panel Outer Air Outlet Courtesy of GENERAL MOTORS COMPANY

3. Depress the three tabs on the instrument panel outer air outlet (1) from behind the instrument panel to properly release the outlet.

Fig. 92: Instrument Panel Outer Air Outlet - Left Side And Bolts Courtesy of GENERAL MOTORS COMPANY

4. Remove Instrument Panel Bolts (1) (Qty: 2)

5. Remove Instrument Panel Outer Air Outlet - Left Side (2)

6. Use a flat bladed plastic tool to remove.

Fig. 93: Instrument Panel Outer Air Outlet And Trim Plate Applique Courtesy of GENERAL MOTORS COMPANY

7. Release the plastic retaining tabs to separate the instrument panel trim plate applique (1) from the instrument panel outer air outlet (2).

8. Transfer components as necessary.

Installation Procedure

Fig. 94: Instrument Panel Outer Air Outlet And Trim Plate Applique Courtesy of GENERAL MOTORS COMPANY

1. Install the instrument panel trim plate applique (1) to the instrument panel outer air outlet (2).

Fig. 95: Instrument Panel Outer Air Outlet - Left Side And Bolts Courtesy of GENERAL MOTORS COMPANY

2. Install Instrument Panel Outer Air Outlet - Left Side (2)

CAUTION: Refer to Fastener Caution .

3. Install and tighten Instrument Panel Bolts (1) (Qty: 2) to 2.5 N.m (22 lb in)

Fig. 96: Instrument Panel Switch Trim Plate Courtesy of GENERAL MOTORS COMPANY

4. Install Instrument Panel Switch Trim Plate (2). Refer to Instrument Panel Switch Trim Plate Replacement

Fig. 97: Instrument Panel Knee Bolster Courtesy of GENERAL MOTORS COMPANY

5. Install Instrument Panel Knee Bolster (2). Refer to Instrument Panel Knee Bolster Replacement

INSTRUMENT PANEL CENTER AIR OUTLET REPLACEMENT

Fig. 98: Instrument Panel Center Air Outlet

Courtesy of GENERAL MOTORS COMPANY

INSTRUMENT PANEL OUTER AIR OUTLET REPLACEMENT - RIGHT SIDE

Removal Procedure

Fig. 99: Instrument Panel Compartment Courtesy of GENERAL MOTORS COMPANY

1. Remove Instrument Panel Compartment (1). Refer to Instrument Panel Compartment Replacement

Fig. 100: Instrument Panel Outer Air Outlet Courtesy of GENERAL MOTORS COMPANY

2. Depress the three tabs on the instrument panel outer air outlet (1) from behind the instrument panel to properly release the outlet.

Fig. 101: Instrument Panel Trim Plate Applique - Right Side And Bolts Courtesy of GENERAL MOTORS COMPANY

3. Remove Instrument Panel Bolts (1) (Qty: 4)

4. Remove Instrument Panel Trim Plate Applique - Right Side (2)

5. Use a flat bladed plastic tool to remove.

Fig. 102: Instrument Panel Outer Air Outlet And Trim Plate Applique Courtesy of GENERAL MOTORS COMPANY

6. Release the plastic retaining tabs to separate the instrument panel trim plate applique (1) from the instrument panel outer air outlet (2).

7. Transfer components as necessary.

Installation Procedure

Fig. 103: Instrument Panel Outer Air Outlet And Trim Plate Applique Courtesy of GENERAL MOTORS COMPANY

1. Install the instrument panel trim plate applique (1) to the instrument panel outer air outlet (2).

Fig. 104: Instrument Panel Trim Plate Applique - Right Side And Bolts Courtesy of GENERAL MOTORS COMPANY

2. Install Instrument Panel Trim Plate Applique - Right Side (2)

CAUTION: Refer to Fastener Caution .

3. Install and tighten Instrument Panel Bolts (1) (Qty: 4) to 2.5 N.m (22 lb in)

Fig. 105: Instrument Panel Compartment Courtesy of GENERAL MOTORS COMPANY

4. Install Instrument Panel Compartment (2). Refer to Instrument Panel Compartment Replacement

FLOOR FRONT AIR OUTLET DUCT REPLACEMENT - RIGHT SIDE

Fig. 106: Floor Front Air Outlet Duct - Right Side

Courtesy of GENERAL MOTORS COMPANY

FLOOR FRONT AIR OUTLET DUCT REPLACEMENT - LEFT SIDE

Fig. 107: Floor Front Air Outlet Duct - Left Side Courtesy of GENERAL MOTORS COMPANY

FLOOR REAR AIR OUTLET DUCT REPLACEMENT

Fig. 108: Floor Rear Air Outlet Duct

Courtesy of GENERAL MOTORS COMPANY

HEATER AND AIR CONDITIONING CONTROL TEMPERATURE LEVER REPLACEMENT

Fig. 109: Heater and Air Conditioning Control Temperature Lever Courtesy of GENERAL MOTORS COMPANY

HEATER CORE REPLACEMENT

Removal Procedure

1. Drain the cooling system. Refer to Cooling System Draining and Filling

2. Remove Front Floor Console Extension Panel - Left Side. Refer to Front Floor Console Extension Panel Replacement - Left Side

3. Place protective coverings and suitable drain pans below heater core to protect the carpeting.

Fig. 110: Heater Core Cover And Screws Courtesy of GENERAL MOTORS COMPANY

4. Remove Heater Core Cover Screws (2) (Qty: 2)

5. Remove Heater Core Cover (1)

Fig. 111: Heater Core, Clamps, Tubes And Sealing Rings Courtesy of GENERAL MOTORS COMPANY

6. Remove Heater Core Clamps (3) (Qty: 2)

7. Remove Heater Core Tubes (Qty: 2) @ Heater Core (1)

8. Remove Heater Core (1)

9. Remove and DISCARD Heater Core Tube Sealing Rings (4) (Qty: 2)

Installation Procedure

Fig. 112: Heater Core, Clamps, Tubes And Sealing Rings Courtesy of GENERAL MOTORS COMPANY

1. Install Heater Core (1)

NOTE: Install NEW seal rings.

2. Install NEW Heater Core Tube Sealing Rings (4) (Qty: 2)

3. Install Heater Core Tubes (Qty: 2) @ Heater Core (1)

4. Tighten Heater Core Clamps (3) (Qty: 2)

Fig. 113: Heater Core Cover And Screws Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Fastener Caution

5. Install Heater Core Cover (1)

6. Install and tighten Heater Core Cover Screws (2) (Qty: 2) to 2.5 N.m (22 lb in)

7. Install Front Floor Console Extension Panel - Left Side. Refer to Front Floor Console Extension Panel Replacement - Left Side

8. Fill the cooling system. Refer to Cooling System Draining and Filling

HEATER COOLANT HEATER REPLACEMENT

Special Tools

BO-38185 Hose Clamp Pliers Equivalent regional tools: Special Tools Removal Procedure

WARNING: Always perform the High Voltage Disabling procedure prior to servicing any High Voltage component or connection. Personal Protection Equipment (PPE) and proper procedures must be followed.

The High Voltage Disabling procedure includes the following steps: Identify how to disable high voltage.

Identify how to test for the presence of high voltage.

Identify condition under which high voltage is always present and personal protection equipment (PPE) and proper procedures must be followed.

Before working on any high voltage system, be sure to wear the following Personal Protection Equipment:

Safety glasses with appropriate side shields when within 15 meters (50 feet) of the vehicle, either indoors or outdoors.

Certified and up-to-date Class "0" Insulation gloves rated at 1000V with leather protectors.

Visually and functionally inspect the gloves before use.

Wear the Insulation gloves with leather protectors at all times when working with the high voltage battery assembly, whether the system is energized or not.

Failure to follow the procedures may result in serious injury or death.

1. Disable the high voltage system. Refer to High Voltage Disabling

2. Drain the cooling system. Refer to Cooling System Draining and Filling

3. Remove Front Wheelhouse Liner (Right Side). Refer to Front Wheelhouse Liner Replacement (Right Side)

4. Disconnect Heater Inlet Hose @ Heater Coolant Heater. Refer to Heater Inlet Hose Replacement

5. Disconnect Heater Inlet and Outlet Pipe @ Heater Coolant Heater. Refer to Heater Inlet And Outlet Pipe Replacement

Fig. 114: Heater Coolant Heater Bracket Assembly And Bolts Courtesy of GENERAL MOTORS COMPANY

6. Remove the 2 heater coolant heater bracket assembly bolts (3) with heater coolant heater bracket assembly (2) from the drive train (1).

Fig. 115: Heater Coolant Heater Bracket Assembly, Bolts And Wiring Harness Courtesy of GENERAL MOTORS COMPANY

7. Remove the 2 wiring harness bolts (4) and the wiring harness (1) from the heater coolant heater assembly (2).

8. Unclip the wiring harness retainers and disconnect the electrical connectors.

9. Remove the 2 heater coolant heater bracket bolts (3) and remove the heater coolant heater bracket assembly (2).

Fig. 116: Heater Coolant Heater, Bracket And Bolts Courtesy of GENERAL MOTORS COMPANY

10. Remove the 4 heater coolant heater bracket bolts (2) from the heater coolant heater bracket (3) and heater coolant heater (1).

Fig. 117: Heater Coolant Heater, Bracket And Bolts Courtesy of GENERAL MOTORS COMPANY

11. Remove the 3 heater coolant heater bracket bolts (3) from the heater coolant heater bracket (1) and remove the heater coolant heater (2).

Installation Procedure

Fig. 118: Heater Coolant Heater, Bracket And Bolts Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Fastener Caution

1. Install the heater coolant heater (2) to the heater coolant heater bracket (1).

2. Install and tighten the 3 heater coolant heater bracket bolts (3) to the heater coolant heater bracket 9 N.m (80 lb in).

Fig. 119: Heater Coolant Heater, Bracket And Bolts Courtesy of GENERAL MOTORS COMPANY

3. Install and tighten the 4 heater coolant heater bracket bolts (2) to the heater coolant heater bracket (3) and the heater coolant heater (1) 9 N.m (80 lb in).

4. Clip in the wiring harness retainers and connect the electrical connectors.

Fig. 120: Heater Coolant Heater Bracket Assembly, Bolts And Wiring Harness Courtesy of GENERAL MOTORS COMPANY

5. Install the heater coolant heater bracket assembly (2) and the 2 heater coolant heater bracket bolts (3) and tighten to 9 N.m (80 lb in)

6. Install the 2 wiring harness bolts (4) along with the wiring harness (1) and tighten to 9 N.m (80 lb in).

Fig. 121: Heater Coolant Heater Bracket Assembly And Bolts Courtesy of GENERAL MOTORS COMPANY

7. Install the 2 heater coolant heater bracket assembly bolts (3) along with the heater coolant heater bracket assembly (2) to the drive train (1) and tighten to 9 N.m (80 lb in).

8. Connect Heater Inlet and Outlet Pipe @ Heater Coolant Heater. Refer to Heater Inlet And Outlet Pipe Replacement

9. Connect Heater Inlet Hose @ Heater Coolant Heater. Refer to Heater Inlet Hose Replacement

10. Install Front Wheelhouse Liner (Right Side). Refer to Front Wheelhouse Liner Replacement (Right Side)

11. Fill the cooling system. Refer to Cooling System Draining and Filling

12. Enable the high voltage system. Refer to High Voltage Enabling

HEATER WATER SHUTOFF VALVE REPLACEMENT

Fig. 122: Heater Water Shutoff Valve

Courtesy of GENERAL MOTORS COMPANY

HEATER WATER SHUTOFF VALVE INLET HOSE REPLACEMENT

Fig. 123: Heater Water Shutoff Valve Inlet Hose Courtesy of GENERAL MOTORS COMPANY

HEATER WATER AUXILIARY PUMP INLET HOSE REPLACEMENT

Special Tools

BO-38185 Hose Clamp Pliers Equivalent regional tools: Special Tools Removal Procedure

1. Drain the cooling system. Refer to Cooling System Draining and Filling

2. Disconnect Battery Negative Cable. Refer to Battery Negative Cable Disconnection and Connection

3. Remove Front Compartment Splash Shield. Refer to Front Compartment Splash Shield Replacement

Fig. 124: Heater Water Auxiliary Pump Inlet Hose And Clamp Courtesy of GENERAL MOTORS COMPANY

4. Loosen Heater Water Auxiliary Pump Inlet Hose Clamp (1)

5. Remove Heater Water Auxiliary Pump Inlet Hose (2) @ Surge Tank

Fig. 125: Heater Water Auxiliary Pump Inlet Hoses And Clamps Courtesy of GENERAL MOTORS COMPANY

6. Loosen Heater Water Auxiliary Pump Inlet Hose Clamps (1) (Qty: 2)

7. Remove Heater Water Auxiliary Pump Inlet Hoses (2) (Qty: 2) @ Engine

Fig. 126: Heater Water Auxiliary Pump Inlet Hose And Clamp Courtesy of GENERAL MOTORS COMPANY

8. Loosen Heater Water Auxiliary Pump Inlet Hose Clamp (1)

9. Remove Heater Water Auxiliary Pump Inlet Hose (2) @ Water Pump Inlet Adapter

Fig. 127: Heater Water Auxiliary Pump Inlet Hose And Clamps Courtesy of GENERAL MOTORS COMPANY

10. Disconnect Heater Water Auxiliary Pump Inlet Hose Clamps (2) (Qty: 3)

11. Remove Heater Water Auxiliary Pump Inlet Hose (1) @ Vehicle

Installation Procedure

Fig. 128: Heater Water Auxiliary Pump Inlet Hose And Clamps Courtesy of GENERAL MOTORS COMPANY

1. Install Heater Water Auxiliary Pump Inlet Hose (1) @ Vehicle

2. Install Heater Water Auxiliary Pump Inlet Hose Clamps (2) (Qty: 3)

Fig. 129: Heater Water Auxiliary Pump Inlet Hose And Clamp Courtesy of GENERAL MOTORS COMPANY

CAUTION: Refer to Fastener Caution

3. Install Heater Water Auxiliary Pump Inlet Hose (2) @ Water Pump Inlet Adapter

4. Tighten Heater Water Auxiliary Pump Inlet Hose Clamp (1)

Fig. 130: Heater Water Auxiliary Pump Inlet Hoses And Clamps Courtesy of GENERAL MOTORS COMPANY

5. Install Heater Water Auxiliary Pump Inlet Hoses (2) (Qty: 2) @ Engine

6. Tighten Heater Water Auxiliary Pump Inlet Hose Clamps (1) (Qty: 2)

Fig. 131: Heater Water Auxiliary Pump Inlet Hose And Clamp Courtesy of GENERAL MOTORS COMPANY

7. Install Heater Water Auxiliary Pump Inlet Hose (2) @ Surge Tank

8. Tighten Heater Water Auxiliary Pump Inlet Hose Clamp (1)

9. Install Front Compartment Splash Shield. Refer to Front Compartment Splash Shield Replacement

10. Connect Battery Negative Cable. Refer to Battery Negative Cable Disconnection and Connection

11. Fill the cooling system. Refer to Cooling System Draining and Filling

HEATER OUTLET HOSE VAPOR VENT HOSE REPLACEMENT

Fig. 132: Heater Outlet Hose Vapor Vent Hose Courtesy of GENERAL MOTORS COMPANY

DESCRIPTION AND OPERATION

HEATING AND AIR CONDITIONING SYSTEM DESCRIPTION AND OPERATION

Heating

The heating system uses the engine and a high voltage heater to provide heat to the passenger compartment. The high voltage heater is used when the engine is not running and passenger compartment heat is requested. The high voltage heater provides different levels of heat depending on the amount of heat needed and outside temperature.

The HVAC Control Module turns on the coolant pump and monitors the temperature sensors in the passenger compartment, outside air, engine radiator, high voltage heater and the engine to determine the position of the coolant flow control valve and if the high voltage heater is needed. Passenger compartment heat is provided by air flowing through the heater core. The heater core is heated by coolant from either the engine or the high voltage heater.

The engine cooling system circulates a 50/50 mixture of Dex-cool and deionized water.

Air Conditioning

The A/C system uses the refrigerant R-134a which is a gas at very low temperatures and can transfer heat from the passenger compartment and high voltage battery to the outside air. The A/C system is mechanically protected with the use of a high pressure relief valve on the A/C compressor. If the refrigerant pressure sensor were to fail or if the A/C system becomes restricted and the refrigerant pressure continued to rise, the high pressure relief will open and release refrigerant from the system.

The high voltage electric A/C compressor is a self contained high voltage inverter, electric motor, and direct coupled compressor. The electric A/C compressor has the ability to run and provide cooling performance while the vehicle engine is not running. This feature enables the electric A/C compressor to run at a speed independent of the engine. The electronic climate control module and the Vehicle Integration Control Module (VICM) will command the electric A/C compressor to a speed necessary to maintain a desired cooling level rather than cycle the electric A/C compressor on and off.

The electric A/C compressor builds pressure and adds heat to the refrigerant gas. The refrigerant gas flows from the electric A/C compressor to the condenser where heat is transferred to the outside air when the refrigerant condenses from a gas to a liquid. The liquid refrigerant then flows to a thermal expansion valve (TXV) on the battery chiller. The TXV lowers the pressure of the liquid refrigerant which makes the refrigerant expand from a liquid to a vapor. The low pressure refrigerant vapor flows into the battery chiller and begins to boil and change into a gas as the refrigerant absorbs heat from the battery coolant also flowing inside the battery chiller. The battery coolant and refrigerant are separated by several plates inside the battery chiller. The liquid refrigerant also flows to a second TXV on the evaporator. The low pressure refrigerant vapor flows from the TXV into the evaporator and begins to boil and change into a gas as the refrigerant absorbs heat from the passenger compartment air that is flowing through the outside of the evaporator. The moister in the passenger compartment air condenses on the outside of the evaporator and flows down to the bottom of the HVAC module where it drains outside the passenger compartment through a drain hose. The low pressure refrigerant gas then flows from the battery chiller and the evaporator back to the electric A/C compressor where the cycle is repeated.

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS

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