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SPECIFICATIONS

1. 2 Remove the left headlamp Refer to Headlamp Assembly or Headlamp Bulb and or Cornering Sidemarker Park Turn Signal Bulb Replacement in Lighting Systems Fig 39 Compressor Hose Nut amp Battery Box Courtesy of GENERAL MOTORS CORP 3 Remove the compressor hose nut from the battery box 4 Remove the compressor hose from the battery box Tycoon 15 mexa6pa 2008 r 11 01 08 Page 69 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 40 Removing Compressor Hose From Evaporative Hose Courtesy of GENERAL MOTORS CORP 5 On L81 vehicles remove the compressor hose nut from the suction hose jumper Separate the compressor hose from the suction hose jumper 7 Install a protective cap to the suction hose jumper to prevent contamination and desiccant saturation Tycoon 15 mexa6pa 2008 r 11 01 08 Page 70 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 41 Compressor Hose Nut amp TXV Courtesy of GENERAL MOTORS CORP 8 On L61 vehicles remove the compressor hose nut from the TXV 9 Remove the compressor hose from the TXV 10 Install a protective cap to the TXV to prevent contamination and desiccant saturation Tycoon 15 neka6pa 2008 r 11 01 08 i Page 71 2005 Mitchell Repair Information Company He 2003 Saturn Vue
2. 15 peka6pa 2008 r 11 01 07 Page 42 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Ss Fig 15 Electrical Connector amp Compressor Courtesy of GENERAL MOTORS CORP 8 Connect the engine wire harness to the compressor 9 Install the drive belt Refer to ENGINE DRIVE BELT AND TENSIONER REPLACEMENT 10 Lower vehicle 11 Evacuate and charge the refrigerant system Refer to Refrigerant Recovery and Recharging 12 Use J 39400 A to leak test the fittings See Special Tools COMPRESSOR CLUTCH COIL REPLACEMENT Tools Required e J 25031 A Puller Three Jaw See Special Tools e SA9149AC 8 Snap Ring Pliers See Special Tools Tycoon 15 geka6pa 2008 r 11 01 07 Page 43 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue e J 45504 Clutch Pulley Installer See Special Tools e J 45267 Clutch Holding Tool See Special Tools Removal Procedure 1 Remove the compressor Refer to Compressor Replacement Fig 16 Clutch Nut Disk amp Hub Assembly Courtesy of GENERAL MOTORS CORP 2 Use J 45267 to hold the disk and hub assembly See Special Tools Remove the clutch nut and the disk and hub assembly Tycoon 15 gexa6pa 2008 r 11 01 07 Page 44 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC He
3. 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 42 Compressor Hose Nut Condenser amp Protective Cap Courtesy of GENERAL MOTORS CORP 11 Remove the compressor hose nut from the condenser 12 Remove the compressor hose from the condenser 13 Install a protective cap to condenser to prevent contamination and desiccant saturation 14 Raise and support the vehicle Refer to Lifting and Jacking the Vehicle in General Information Tycoon 15 gexa6pa 2008 r 11 01 08 Page 72 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 43 Compressor Hose Bolt Compressor O Rings amp Protective Cap Courtesy of GENERAL MOTORS CORP 15 Remove the compressor hose bolt from the compressor 16 Remove the compressor hose from the compressor 17 Remove and discard the O rings from the compressor Refer to O Ring Replacement 18 Install a protective cap to the compressor to prevent contamination and desiccant saturation 19 Remove the compressor hose from the vehicle 20 Remove and discard the sealing washers from the TXV and the condenser ends of the compressor hose Refer to Sealing Washer Replacement Installation Procedure Tycoon 15 mexa6pa 2008 r 11 01 08 Page 73 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 44 Compre
4. Fig 169 Electrical Connector amp Blower Motor Courtesy of GENERAL MOTORS CORP 1 Remove the passenger side insulator closeout panel Refer to Closeout Insulator Panel Replacement Right in Instrument Panel Gages and Console 2 Disconnect the electrical connector from the blower motor Tycoon 15 nexa6pa 2008 r 11 01 13 Page 199 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 170 Blower Motor Screws amp Blower Case Assembly Courtesy of GENERAL MOTORS CORP 3 Remove the blower motor screws from the HVAC module Remove the blower motor from the HVAC module Installation Procedure Tycoon 15 mexa6pa 2008 r 11 01 13 Page 200 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 171 Blower Motor Screws amp Blower Case Assembly Courtesy of GENERAL MOTORS CORP 1 Install the blower motor to the HVAC module NOTE Refer to FASTENER NOTICE in Cautions and Notices 2 Install the blower motor screws to the HVAC module Tighten Tighten the screws to 1 N m 9 1b in Tycoon 15 mexa6pa 2008 r 11 01 13 Page 201 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 172 Electrical Connector amp Blower Motor Courtesy of GENERA
5. 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Fastener Tightening Specifications Application Air Inlet Assembly Screws 1 N m Air Outlet Duct Screws 1 N m Battery Box to Body Bolts 15 N m Blower Motor Resistor Screws 1N m Blower Motor Screws Compressor Clutch Nut Compressor Hose Assembly to Battery Box Nut L61 Compressor Hose Assembly to Compressor Bolt Compressor Hose Assembly to Condenser Nut Compressor Hose Assembly to TXV Nut L61 Compressor to Engine Block Bolts Compressor Pressure Relief Valve Compressor Thermal Protection Switch Retainer Bolt CRFM Bracket Bolts Defrost Actuator to Evaporator Case Screws Defroster Duct to HVAC Module Nuts Discharge Line Nuts Evaporator Case Assembly to Blower Case Assembly Screws Evaporator Cover Screws Evaporator Outlet Hose to Air Cleaner Bracket Bolt L66 Evaporator Outlet Hose to Compressor Hose Nut L66 Evaporator Outlet Hose to Cowl Nut L66 Evaporator Outlet Hose to TXV Nut L66 Evaporator Pipe Cover Screw Floor Actuator to Evaporator Case Screws Front of Dash to HVAC Module Seal Nuts Heater Core Cover Screws Heater Core Pipe Cover Screw Heater Core Screws Heater Duct to Heater Core Cover Screws Hold Down Bracket and Bolt HVAC Module to Cross Car Beam Nuts and Bolts Intermediate Duct Fasteners Liquid Lin
6. 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 75 TXV Bolts amp Backing Plate Courtesy of GENERAL MOTORS CORP 9 Remove the TXV bolts from the backing plate 10 Remove the TXV and the backing plate from the vehicle 11 Remove and discard the O rings from the evaporator pipes Refer to O Ring Replacement 12 Install a protective cap to the evaporator pipes to prevent contamination and desiccant saturation Installation Procedure Tycoon 15 geka6pa 2008 r 11 01 09 Page 105 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 76 TXV Bolts amp Backing Plate Courtesy of GENERAL MOTORS CORP IMPORTANT Use only lint free cloths to wipe parts Do not allow any solvent to enter evaporator or hoses 1 Remove the protective caps from the evaporator pipe and ensure the seal areas are clean dry and lint free 2 Install new O rings to the evaporator pipes Refer to O Ring Replacement 3 Remove the protective caps from the TXV 4 Install the TXV and the backing plate to the evaporator pipes NOTE Refer to FASTENER NOTICE in Cautions and Notices 5 Install the TXV bolts to the backing plate Tycoon 15 mexa6pa 2008 r 11 01 09 Page 106 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventil
7. Condenser Replacement 30 mi 1 oz Evaporator Replacement 30 ml 1 oz Receiver Dehydrator Replacement 60 ml 2 oz Thermal Expansion Valve Replacement 20 ml 0 75 oz2 e Total System PAG Oil Capacity 207 ml 7 00 oz R 134a e Refrigerant Charge 2 2L L61 0 68 kg 1 5 Ib e Refrigerant Charge 3 5L L66 0 79 kg 1 75 Ib 2 If more than the specified amount of PAG oil was drained from a component add the equal amount of oil drained DIAGNOSTIC INFORMATION AND PROCEDURES DIAGNOSTIC STARTING POINT HEATING VENTILATION AND AIR CONDITIONING The Heating Ventilation and Air Conditioning HVAC system is divided into 2 separate sections The first Tycoon 15 nexa6pa 2008 r 11 01 06 Page 2 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Heating Ventilation and Air Conditioning has all procedures that pertain to a HVAC component or function that is not specifically associated with the manual control system The second HVAC Systems Manual has all procedures specific to the Manual control system Begin the system diagnosis with the Diagnostic System Check HVAC Systems Manual in HVAC Systems Manual The Diagnostic System Check will provide the identification of the control module s which command the system The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located
8. Transmission Getrag 5 Transmission Shift Control Bracket Replacement in Automatic Transaxle AF33 5 AIR OUTLET REPLACEMENT REAR FLOOR Removal Procedure Tycoon 15 gexa6pa 2008 r 11 01 13 Page 210 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue ly WS Fig 181 Rear Floor Air Outlet amp Push Pins Courtesy of GENERAL MOTORS CORP 1 Remove the front seats Refer to Seat Replacement Front Bucket in Seats 2 Remove the floor console Refer to Console Replacement Front Floor in Instrument Panel Gages and Console 3 Partially remove the floor carpet from the front footwells to the B pillars 4 Remove the rear floor rear duct push pins from the floor pan 5 Remove the rear floor rear duct from the floor pan Installation Procedure Tycoon 15 gexa6pa 2008 r 11 01 13 Page 211 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue ly WS Fig 182 Rear Floor Air Outlet amp Push Pins Courtesy of GENERAL MOTORS CORP Install the rear floor rear duct to the floor pan Install rear floor rear duct push pins to the floor pan Install the floor carpet to the B pillars and the front footwells amp OS Install the floor console Refer to Console Replacement Front Floor in Instrument Panel Gages and
9. Ventilation and Air Conditioning Vue IMPORTANT When removing the thermal expansion valve TXV keep dirt and foreign material from getting on or into the O ring sealing surfaces Clean tools and a clean work area are important for proper service The TXV seal area should be cleaned before any repairs are performed The parts must be kept clean at all times and any parts to be assembled should be cleaned with a non petroleum based solvent and dried with air Use only lint free cloths to wipe parts Do not allow solvent to enter evaporator or hoses 2 Remove the evaporator outlet hose nut from the TXV 3 Remove the evaporator outlet hose from the TXV 4 Install a protective cap to the evaporator outlet hose to prevent contamination and desiccant saturation i D ff Fig 73 Liquid Line Nut amp TXV Courtesy of GENERAL MOTORS CORP Tycoon 15 mexa6pa 2008 r 11 01 09 Page 103 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue 5 Remove the liquid line nut from the TXV 6 Remove the liquid line from the TXV 7 Install a protective cap to the liquid line to prevent contamination and desiccant saturation Fig 74 Refrigerant Low Temperature Sensor amp Engine Harness Courtesy of GENERAL MOTORS CORP 8 Disconnect the refrigerant low temperature sensor from the engine harness Tycoon 15 geka6pa 2008 r 11 01 09 Page 104
10. 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 109 Metal Bracket amp Nut Courtesy of GENERAL MOTORS CORP 5 Push up on HVAC module at blower motor area while tightening right side HVAC module to cross car beam fasteners to seat screen assembly fresh air seal Tighten Tighten the fasteners to 8 N m 71 lb in 6 Install the left HVAC module to cross car beam stamped metal L type bracket to HVAC module and cross car beam and tighten remaining module attachment fasteners Tighten Tighten the fasteners to 8 N m 71 lb in 7 Connect I P wire harness clips to HVAC module Tycoon 15 gexa6pa 2008 r 11 01 10 Page 139 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 110 Defroster Duct amp Retainer Courtesy of GENERAL MOTORS CORP 8 Install defroster duct to HVAC module nuts and defroster duct Tighten Tighten the nuts to 2 5 N m 22 lb in Tycoon 15 nexka6pa 2008 r 11 01 10 Page 140 2005 Mitchell Repair Information Company He 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 111 Blower Motor Electrical Connector amp I P Wire Harness Courtesy of GENERAL MOTORS CORP 9 Connect I P harness to blower motor connector 10 Connect I P harness to blower motor resistor connector 11 Connect I P harness to HVAC module connector
11. 2008 r 11 01 10 Page 117 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 88 Compressor Hose Nut Condenser amp Protective Cap Courtesy of GENERAL MOTORS CORP 7 Remove compressor hose from condenser 8 Install protective cap to the compressor hose to prevent contamination and desiccant saturation Tycoon 15 nexa6pa 2008 r 11 01 10 Page 118 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Reh T I ET ins AS 3 Te Fig 89 View Of CRFM Mounting Brackets To The Radiator Support Courtesy of GENERAL MOTORS CORP 9 Remove upper CRFM bracket and mount assembly 10 Lift condenser while holding upper retention tabs forward and remove condenser Installation Procedure Tycoon 15 pexa6pa 2008 r 11 01 10 Page 119 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 90 Condenser amp Radiator Courtesy of GENERAL MOTORS CORP Tycoon 15 nexa6pa 2008 r 11 01 10 Page 120 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue 1 Check radiator to condenser seal for proper position 2 Install condenser by guiding lower and upper tabs into retention clips
12. Connect the temperature sensor to the engine harness CONDENSER REPLACEMENT Tools Required J 39400 A Halogen Leak Detector See Special Tools Removal Procedure 1 Recover the refrigerant Refer to Refrigerant Recovery and Recharging 2 Remove the front fascia Refer to Fascia Replacement Front Bumper in Bumpers Tycoon 15 peka6pa 2008 r 11 01 10 Page 114 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue vel TA MV EAA o ii D TA Fig 85 Battery Box Air Duct Courtesy of GENERAL MOTORS CORP 3 Remove battery box air duct Tycoon 15 peka6pa 2008 r 11 01 10 Page 115 2005 Mitchell Repair Information Company C 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 86 View Of CRFM Closeout Splash Panel To Condenser Courtesy of GENERAL MOTORS CORP 4 Remove condenser radiator fan module CRFM closeout panel Tycoon 15 nexa6pa 2008 r 11 01 10 Page 116 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 87 Receiver Dehydrator Protective Caps amp Liquid Line Courtesy of GENERAL MOTORS CORP 5 Remove receiver dehydrator RD line from condenser 6 Install protective cap to RD line to prevent contamination and desiccant saturation Tycoon 15 nexa6pa
13. Console 5 Install the front seats Refer to Seat Replacement Front Bucket in Seats DEFROSTER DUCT REPLACEMENT WINDSHIELD Removal Procedure Tycoon 15 gexa6pa 2008 r 11 01 13 Page 212 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 183 Defroster Duct amp Retainer Courtesy of GENERAL MOTORS CORP 1 Remove the instrument panel upper trim panel Refer to Trim Panel Replacement Instrument Panel I P Upper in Instrument Panel Gages and Console 2 Remove the windshield defrost duct nuts from the HVAC module 3 Remove the windshield defrost duct from the HVAC module Installation Procedure Tycoon 15 gexa6pa 2008 r 11 01 13 Page 213 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 184 Defroster Duct amp Retainer Courtesy of GENERAL MOTORS CORP 1 Inspect the windshield defrost duct seals If damaged replace using Kent Industries adhesive back foam tape P N 46485 or equivalent 2 Install the windshield defrost duct to the HVAC module NOTE Refer to FASTENER NOTICE in Cautions and Notices 3 Install the windshield defrost duct nuts to the HVAC module Tighten Tighten the nuts to 2 5 N m 22 lb in 4 Install the instrument panel upper trim panel Refer to Trim Panel Replacement Instrument Panel I P Uppe
14. Courtesy of GENERAL MOTORS CORP Install the heater duct Install the heater duct screws Tighten Tighten the screw to 1 N m 9 lb in 10 Install the instrument panel retainer Refer to Instrument Panel I P Retainer Replacement in Instrument Panel Gages and Console 11 Install the shift control bracket Refer to Transmission Shift Control Bracket Replacement in Manual Transmission Getrag 5 Transmission Shift Control Bracket Replacement in Automatic Transaxle AF33 5 12 Install the heater inlet hose to the heater core Refer to Heater Hose Replacement Inlet L61 or Heater Hose Replacement Inlet L81 13 Install the heater outlet hose to the heater core Refer to Heater Hose Replacement Outlet L61 or Tycoon 15 mexa6pa 2008 r 11 01 14 Page 223 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Heater Hose Replacement Outlet L81 14 Replace the engine coolant Refer to Draining and Filling Cooling System in Engine Cooling AIR OUTLET DUCT REPLACEMENT AUXILIARY Removal Procedure 1 Remove the instrument panel retainer Refer to Instrument Panel I P Retainer Replacement in Instrument Panel Gages and Console Fig 194 Center I P Air Outlet Duct amp Retainers Courtesy of GENERAL MOTORS CORP 2 Remove the auxiliary duct push pins from the cross car beam 3 Remove the auxiliary duct from
15. QF So se a YF ws Sal fe Fig 164 Air Inlet Assembly Courtesy of GENERAL MOTORS CORP 3 Install the recirculation actuator 4 Install the recirculation actuator screws Tighten Tighten the screws to 1 N m 9 1b in Tycoon 15 nexa6pa 2008 r 11 01 13 Page 194 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 165 Electrical Connector amp Recirculation Actuator Courtesy of GENERAL MOTORS CORP 5 Route the HVAC module harness through the end bracket bottom hole and install the bracket 6 Install the end bracket screws Tighten Tighten the screws to 2 N m 18 lb in 7 Install the end bracket nuts Tighten Tighten the nuts to 2 N m 18 Ib in 8 Clip the wire harness to the end bracket 9 Install the electrical connector to the recirculation actuator 10 Install the HVAC module Refer to HVAC Module Assembly Replacement Tycoon 15 mexa6pa 2008 r 11 01 13 Page 195 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue BLOWER MOTOR RESISTOR REPLACEMENT Removal Procedure Fig 166 Electrical Connector amp Blower Motor Resistor Courtesy of GENERAL MOTORS CORP 1 Remove the right side insulator closeout panel Refer to Closeout Insulator Panel Replacement Right in Instrument Panel Gages and Console 2 D
16. Remove the heater core cover screws 9 Remove the heater core cover Tycoon Page 216 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 187 Heater Core Pipe Cover Courtesy of GENERAL MOTORS CORP 10 Remove the heater core pipe cover screw 11 Remove the heater core pipe cover 12 Remove the heater core pipe foam seal Tycoon 15 peka6pa 2008 r 11 01 13 Page 217 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 188 Heater Core amp End Tanks Courtesy of GENERAL MOTORS CORP 13 Grasp the heater core at end tanks and remove heater core Spray the perimeter of the heater core seal and the heater core pipes at the front of dash with a soap and water mixture to ease removal Installation Procedure Tycoon 15 nexka6pa 2008 r 11 01 14 Page 218 2005 Mitchell Repair Information Company Le 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 189 Heater Core amp Pipe Seal Courtesy of GENERAL MOTORS CORP 1 Install the heater core Spray the perimeter of the heater core seal and the heater core pipes at the front of dash with a soap and water mixture to ease installation Tycoon E 15 geka6pa 2008 r 11 01 14 Page 219 2005 Mitchell Repair Inform
17. Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue 3 Inspect the A C refrigerant components for damage or burrs Repair if necessary IMPORTANT DO NOT reuse sealing washer 4 Discard the sealing washer Installation Procedure IMPORTANT Flat washer type seals do not require lubrication 1 Inspect the new seal washer for any signs of cracks cuts or damage Do not use a damaged seal washer 2 Remove the cap or tape from the A C refrigerant components Tycoon 15 mexa6pa 2008 r 11 01 08 Page 63 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 35 Identifying Good And Bad Sealing Washer Positions Courtesy of GENERAL MOTORS CORP 3 Using a lint free clean dry cloth clean the sealing surfaces of the A C refrigerant components 4 Carefully install the new seal washer onto the A C refrigerant component The washer must completely bottom against the surface of the fitting IMPORTANT After tightening the A C components there should be a slight sealing washer gap of approximately 1 2 mm 3 64 in between the A C line and the A C component 5 Assemble the remaining A C refrigerant components Refer to the appropriate repair procedure O RING REPLACEMENT Removal Procedure Tycoon 15 mexa6pa 2008 r 11 01 08 Page 64 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ven
18. Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 94 View Of CRFM Closeout Splash Panel To Condenser Courtesy of GENERAL MOTORS CORP 9 Install CRFM closeout panel Tycoon 15 nexa6pa 2008 r 11 01 10 Page 124 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue i NS Fig 95 Battery Box Air Duct Courtesy of GENERAL MOTORS CORP 10 Install battery box air duct 11 Install front fascia Refer to Fascia Replacement Front Bumper in Bumpers 12 Evacuate and charge the refrigerant system Refer to Refrigerant Recovery and Recharging 13 Leak test the fittings using the J 39400 A See Special Tools HVAC MODULE ASSEMBLY REPLACEMENT Tools Required e J 39400 A Halogen Leak Detector See Special Tools e SA9111E Hose Clamp Pliers See Special Tools Removal Procedure Tycoon 15 gexa6pa 2008 r 11 01 10 Page 125 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue 1 Disable the frontal and curtain air bags Refer to DISABLING amp ACTIVATING AIR BAG SYSTEM 2 Recover the refrigerant Refer to Refrigerant Recovery and Recharging 3 Drain engine coolant Refer to Draining and Filling Cooling System in Engine Cooling a n a a aa SS Fig 96 Compressor Hose Nut amp TXV Court
19. Step 11 Remove the blower motor Refer to Blower Motor Replacement Inspect the blower motor impeller for deposits of foreign material Inspect the blower motor for deposits of foreign material Tycoon 15 mexa6pa 2008 r 11 01 06 Page 22 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Did you find any foreign material on the blower motor or blower motor impeller Go to Step 8 Go to Step 7 Inspect the blower motor for the following conditions e Cracked blades e A loose impeller retainer e Improper impeller alignment Did you find any of these conditions Go to Step 9 Go to Step 10 Remove the foreign material I Is the action complete Go to Step 10 Replace the blower motor Refer to Blower Motor Replacement Is the repair complete cows Install the blower motor Refer to Blower Motor Replacement Is the action complete Go to Step 11 Operate the system in order to verify the repair Did you find and correct the condition System OK Go to Step 2 NOISE DIAGNOSIS AIR CONDITIONING A C SYSTEM Noise Diagnosis Air Conditioning A C System DEFINITION Noise originating from the A C compressor drive belt or the A C lines Were you sent here from Symptoms or another Go to Symptoms diagnostic table HVAC Systems Manual in HVAC Go to Step 2 Systems Manual A C system noises can be generally categori
20. System OK Go to Step 2 REPAIR INSTRUCTIONS ODOR CORRECTION Eliminating Air Conditioning Odor Odors may be emitted from the air conditioning system primarily at start up in hot humid climates The following conditions may cause the odor e Debris is present in the HVAC module e 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 Tycoon 15 mexa6pa 2008 r 11 01 07 Page 28 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue 2 Disable the 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 HVAC module case 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
21. Tycoon E 15 gexa6pa 2008 r 11 01 11 Page 141 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 112 Center I P Air Outlet Duct amp Retainers Courtesy of GENERAL MOTORS CORP 12 Install auxiliary duct assembly Tycoon 15 peka6pa 2008 r 11 01 11 Page 142 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 113 Center Floor Air Outlet Duct Courtesy of GENERAL MOTORS CORP 13 Install front rear duct by sliding forward on heater duct then down and rearward over rear duct 14 Install the shift control bracket Refer to Transmission Shift Control Bracket Replacement in Manual Transmission Getrag 5 Transmission Shift Control Bracket Replacement in Automatic Transaxle AF33 5 15 Install the I P retainer Refer to Instrument Panel I P Retainer Replacement in Instrument Panel Gages and Console Tycoon 15 peka6pa 2008 r 11 01 11 Page 143 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 114 Heater Inlet Hose Clamp amp Heater Core Courtesy of GENERAL MOTORS CORP 16 Install heater inlet hose to heater core inlet 17 Position the clamp at 9 o clock using SA9111E See Special Tools Tycoon 15 ge
22. bind with the cable disconnected Go to Step 20 Go to Step 10 1 Disconnect the temperature control cable from the HVAC control assembly 10 2 Operate the HVAC control module with the cable disconnected Does the HVAC control module bind now Go to Step 17 Go to Step 11 With the temperature control cable disconnected at both ends 1 1 Extend the cable in both directions 2 Inspect the cable for binding Does the temperature control cable bind Go to Step 18 Go to Step 12 1 Inspect the temperature control cable for kinks or bends from incorrect routing 2 Repair the cable or routing as necessary Does the temperature cable still bind Go to Step 18 Go to Step 13 Operate the HVAC control module with the temperature control cable disconnected Does the HVAC control module bind now Go to Step 17 Go to Step 14 Assemble the temperature control system Is the action complete Go to Step 22 Connect the temperature control cable to the temperature door linkage install the cable retainers Is the action complete Go to Step 22 Repair the lack of heating or lack of cooling condition Refer to Engine Fails To Reach Normal Operating Temperature Is the action complete Go to Step 22 Replace the HVAC control module Refer to HVAC Control Module Replacement in HVAC Systems Manual Tycoon 15 mexa6pa 2008 r 11 01 06 Page 21 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and
23. lb ft 24 Enable the frontal and curtain air bags Refer to DISABLING amp ACTIVATING AIR BAG SYSTEM 25 Fill the coolant Refer to Draining and Filling Cooling System in Engine Cooling 26 Evacuate and charge the refrigerant system Refer to Refrigerant Recovery and Recharging 27 Leak test the fittings using the J 39400 A See Special Tools EVAPORATOR CORE REPLACEMENT Tycoon 15 mexa6pa 2008 r 11 01 11 Page 147 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Tools Required J 39400 A Halogen Leak Detector See Special Tools Removal Procedure 1 Remove HVAC module Refer to HVAC Module Assembly Replacement Fig 118 TXV Bolts amp Backing Plate Courtesy of GENERAL MOTORS CORP 2 Remove TXV to backing plate attachment bolts and remove TXV and backing plate 3 Remove O rings from evaporator pipes and caps to prevent system contamination 4 Remove HVAC module front of dash seal Tycoon 15 peka6pa 2008 r 11 01 11 Page 148 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 119 Heater Duct Screws amp Heater Core Cover Courtesy of GENERAL MOTORS CORP 5 Remove heater duct Tycoon 15 gexa6pa 2008 r 11 01 11 Page 149 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC He
24. on radiator and pressing down to snap into place Fig 91 View Of CRFM Mounting Brackets To The Radiator Support Courtesy of GENERAL MOTORS CORP 3 Install upper CRFM bracket and mount assemblies NOTE Refer to FASTENER NOTICE in Cautions and Notices 4 Install upper CRFM bracket bolts Tighten Tighten the bolts to 10 N m 89 lb in Tycoon 15 gexa6pa 2008 r 11 01 10 Page 121 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue eet iS ras rae Fig 92 Compressor Hose Nut Condenser amp Protective Cap Courtesy of GENERAL MOTORS CORP Remove protective cap from the compressor hose and install a new sealing washer Refer to Sealing Washer Replacement 6 Install compressor hose to condenser with the nut Tighten Tighten the nut to 16 N m 12 lb ft Tycoon 15 pexa6pa 2008 r 11 01 10 Page 122 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 93 Receiver Dehydrator Condenser amp Seal Washer Courtesy of GENERAL MOTORS CORP 7 Install new seal washer Refer to Sealing Washer Replacement 8 Install the RD line to the condenser with the nut Tighten Tighten the nut to 16 N m 12 lb ft Tycoon 15 nexka6pa 2008 r 11 01 10 Page 123 2005 Mitchell Repair Information Company He 2003
25. rail fasteners Tycoon 15 mexa6pa 2008 r 11 01 08 Page 83 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 54 Unclipping EPS Harness From Liquid Line Courtesy of GENERAL MOTORS CORP 4 Unclip EPS harness from liquid line 5 Unclip PTU vent from liquid line Tycoon 15 geka6pa 2008 r 11 01 09 Page 84 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 55 Liquid Line Strut Tower amp Nut Courtesy of GENERAL MOTORS CORP 6 Remove nut from P clip at shock tower cap stud Tycoon 15 geka6pa 2008 r 11 01 09 Page 85 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 56 Liquid Line Nut amp TXV Courtesy of GENERAL MOTORS CORP 7 Remove liquid line to TXV nut Tycoon 15 peka6pa 2008 r 11 01 09 Page 86 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 57 Liquid Line Nut amp Receiver Dehydrator Courtesy of GENERAL MOTORS CORP 8 Remove liquid line to receiver dehydrator RD nut Use a large pair of pliers to hold fitting to prevent twisting of line if necessary 9 Remove liquid line at left shock tower and install p
26. set 2 Connect low pressure blue gage hose to suction service port located on the suction pipe Pull valve Tycoon 15 mexa6pa 2008 r 11 01 06 Page 10 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue assembly collar up place valve assembly over service port and release collar 3 Open service valve 4 Connect high pressure red gage hose to discharge service port located on the liquid line Pull valve assembly collar up place valve assembly over service port and release collar 5 Open service valve Performance Test Service Stall IMPORTANT If ambient air temperature is lower than 0 C 32 F A C compressor will not be enabled IMPORTANT This test must be performed in a service stall environment that protects the vehicle from wind that could cause incorrect pressure temperature readings 1 Open hood and leave open during entire test N Install a manifold gage set to high and low side service ports 3 Disconnect vehicle thermal expansion valve TXV temperature sensor electrical connector and connect a temperature sensor that is exposed to ambient air 4 Start engine and warm to operating temperature Use scan tool to verify coolant temperature is being thermostatically controlled approx 88 C 190 F Install thermometer into right center outlet ae Open both front doors and windows to stabilize interior air temperature
27. the blower motor fan to the blower motor 2 Install the blower motor fan retention clip to the blower motor 3 Install the blower motor to the HVAC module NOTE Refer to FASTENER NOTICE in Cautions and Notices 4 Install the blower motor screws to the HVAC module Tighten Tighten to screws to 1 N m 9 lb in Tycoon 15 mexa6pa 2008 r 11 01 13 Page 205 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 176 Electrical Connector amp Blower Motor Courtesy of GENERAL MOTORS CORP 5 Connect the electrical connector to the blower motor AIR OUTLET REPLACEMENT INSTRUMENT PANEL Removal Procedure 1 Remove the instrument panel I P upper trim panel Refer to Trim Panel Replacement Instrument Panel I P Upper in Instrument Panel Gages and Console Tycoon 15 gexa6pa 2008 r 11 01 13 Page 206 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 177 Outlet Bezel Courtesy of GENERAL MOTORS CORP 2 Depress the locking tabs on the outlet 3 Carefully slide the outlet out of the I P trim and the surrounding outlet bezel Installation Procedure Tycoon 15 peka6pa 2008 r 11 01 13 Page 207 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditionin
28. the compressor hose to the TXV 13 Install the compressor hose nut to the TXV Tighten Tighten the nut to 16 N m 12 lb ft Tycoon 15 nexka6pa 2008 r 11 01 08 l Page 76 2005 Mitchell Repair Information Company He 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 47 Compressor Hose Nut Condenser amp Protective Cap Courtesy of GENERAL MOTORS CORP 14 Remove the protective cap from the condenser 15 Install the compressor hose to the condenser 16 Install the compressor hose nut to the condenser Tighten Tighten the nut to 16 N m 12 lb ft Tycoon 15 nexka6pa 2008 r 11 01 08 Page 77 2005 Mitchell Repair Information Company He 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 48 Compressor Hose Nut amp Battery Box Courtesy of GENERAL MOTORS CORP 17 Install the compressor hose to the battery box 18 Install the compressor hose nut to the battery box Tighten Tighten the nut to 8 N m 71 1b in 19 Install left headlamp Refer to Headlamp Assembly or Headlamp Bulb and or Cornering Sidemarker Park Turn Signal Bulb Replacement in Lighting Systems 20 Evacuate and charge the A C system Refer to Refrigerant Recovery and Recharging 21 Test the affected A C joints for leaks using J 39400 A See Special Tools EVAPORATOR HOSE ASSEMBLY REPLACEMENT Tools Required Tycoon 15 mexa6pa
29. the cross car beam Tycoon 15 peka6pa 2008 r 11 01 14 Page 224 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Installation Procedure 1 Inspect the seals and replace if damaged using Kent Industries adhesive backed foam tape P N 46485 or equivalent Fig 195 Center I P Air Outlet Duct amp Retainers Courtesy of GENERAL MOTORS CORP 2 Install the auxiliary duct to the cross car beam 3 Install the auxiliary duct push pins to the cross car beam 4 Install the instrument panel retainer Refer to Instrument Panel I P Retainer Replacement in Instrument Panel Gages and Console SPECIAL TOOLS AND EQUIPMENT SPECIAL TOOLS Tycoon 15 peka6pa 2008 r 11 01 14 Page 225 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Special Tools Illustration Tool Number Description J 25031 A Three Jaw Puller J 39400 A Halogen Leak Detector J 41447 R 134A A C Tracer Dye Box of 24 J 42220 Universal 12V Leak Detection Lamp J 43600 ACR 2000 Air Conditioning Service Center Tycoon 15 mexa6pa 2008 r 11 01 14 Page 226 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue J 44020 Terminal Repair Kit J 45267 Clutch Holding Tool J 45504 Clutch Pulley Installer Tycoon 15
30. the windshield 2 Blockage of the HVAC module drain 3 Leaks around the door seals Is a leak present Go to Step 7 Go to Step 14 Repair the leak as necessary Is the repair complete Go to Step 15 Does the odor have a coolant smell Go to Step 9 Go to Step 12 Inspect the cooling system for leaks Refer to Loss of Coolant in Engine Cooling Tycoon 15 mexa6pa 2008 r 11 01 07 Page 27 2005 Mitchell Repair Information Company LLC E 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Is a leak present Go to Step 10 Go to Step 12 Inspect for coolant leaking inside the vehicle or for a 10 film build up on the windshield Is the condition present Go to Step 11 Go to Step 15 Replace the heater core Refer to Heater Core 11 Replacement Is the repair complete Go to Step 15 Does the odor have an oily smell Go to Step 13 Go to Step 15 1 Inspect the engine compartment for any leaks Refer to the following procedures e OIL LEAK DIAGNOSIS e Fluid Leak Diagnosis in Automatic 13 Transaxle AF33 5 e SYMPTOM DIAGNOSIS in Automatic Transaxle VT25 E 2 Repair any oil leaks Is the repair complete Go to Step 15 A musty odor can be caused by mold or mildew build up on the evaporator or the heater core or inside of the HVAC module Refer to Odor Correction Is the action complete Go to Step 15 Operate the system in order to verify the repair Did you find and correct the condition
31. to ease the installation of evaporator 3 Install evaporator Tycoon 15 peka6pa 2008 r 11 01 11 Page 157 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 128 Evaporator Case Assembly Screws amp Blower Case Assembly Courtesy of GENERAL MOTORS CORP 4 Install evaporator cover assembly NOTE Refer to FASTENER NOTICE in Cautions and Notices 5 Install evaporator cover assembly screws Tighten Tighten the screws to 1 N m 9 1b in Tycoon 15 peka6pa 2008 r 11 01 11 Page 158 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 129 Evaporator Pipe Cover Screw amp Blower Case Assembly Courtesy of GENERAL MOTORS CORP 6 Install evaporator pipe retainer 7 Install evaporator pipe retainer screws Tighten Tighten the screws to 1 N m 9 1b in Tycoon 15 peka6pa 2008 r 11 01 11 Page 159 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 130 Heater Core amp Pipe Seal Courtesy of GENERAL MOTORS CORP 8 Install heater core Spraying perimeter of heater core seal with a soap and water mixture will ease installation 9 Install heater core pipe seal Tycoon 15 nexka6pa 2008 r 11 01 11 Page 160 2005 Mit
32. with or damage the following components e The blower motor e The evaporator core e 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 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 clutch operation REFRIGERANT RECOVERY AND RECHARGING Tools Required J 43600 ACR 2000 Air Conditioning Service Center See Special Tools CAUTION Avoid breathing the A C Refrigerant 134a R 134a and the lubricant vapor or the mist Exposure may irritate the eyes nose and throat Work in a well ventilated area In order to remove R 134a from the A C system use service equipment that is certified to meet the requirements of SAE J 2210 R 134a recycling equipment If an accidental system discharge occurs ventilate the work area before continuing service Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers CAUTION For personal protection goggles and gloves shou
33. 03 HVAC Heating Ventilation and Air Conditioning Vue e An overcharged condition will generate a poor and or intermittent cooling complaint at higher ambient air temperatures Intermittent complaints are caused by the pressure sensor cycling the compressor OFF and ON e Reclaim the system using an approved recovery system Evacuate and recharge the system with 0 68 kg 1 5 Ib of R 134a e Run another performance test e An oil overcharge can occur if a compressor or other refrigerant system change is made without proper oil balancing Review the vehicle service history for compressor service Degrees If the ambient air temperature is Suction and the low side gage should read Discharge and the high side gage should read Outlet and the right center air temperature should be Specific System Condition Compressor No Pump Outlet 21 43 C 70 110 F 483 689 70 100 483 689 70 100 21 43 C 70 110 F IMPORTANT Ensure that the manifold gage set valves are closed Key No change in the suction and the discharge pressures with the compressor engaged The gage pressures will be almost equal Then Verify compressor clutch engagement Run the engine at 2 000 RPM and cycle the compressor ON and OFF two or three times If the pressure remains static engage the compressor and snap the engine throttle two or three times If the pressure still remains static replace the compressor After the repair return to the d
34. 1 Press A C button Indicator should light Inspect compressor for clutch engagement slippage or noise 12 Inspect electric cooling fan operation and speed as determined by system temperature and pressure 13 Turn OFF A C Compressor clutch should disengage 14 Ifany problem is found in any of the previous steps go to the complaint condition cause charts HVAC VEHICLE SET UP Identifying Refrigerant Purity Tycoon 15 mexa6pa 2008 r 11 01 06 Page 7 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 2 RI 2002DS Refrigerant Identifier Courtesy of GENERAL MOTORS CORP Tycoon 15 peka6pa 2008 r 11 01 06 Page 8 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue NOTE The purity of the system refrigerant should be confirmed before any other diagnostics are begun The RI 2002DS refrigerant identifier has the ability to identify R 12 R134a R 22 potentially dangerous hydrocarbons and non condensable gases NCG such as air If the A C system contains anything less than 98 percent pure refrigerant the refrigerant is considered contaminated and the temperature pressure charts will not be valid Contaminated refrigerant should not be recovered as it will contaminate the recovery machine and refrigerant supply tank Air is not considered a contaminate as it can be
35. 1 Page 153 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 124 Evaporator Case Assembly Screws amp Blower Case Assembly Courtesy of GENERAL MOTORS CORP 12 Remove evaporator cover assembly Tycoon 15 peka6pa 2008 r 11 01 11 Page 154 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 125 Evaporator Pipe Cover Screw amp Blower Case Assembly Courtesy of GENERAL MOTORS CORP 13 Remove evaporator pipe retainer Tycoon 15 gexa6pa 2008 r 11 01 11 Page 155 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 126 Evaporator Core amp Blower Case Assembly Courtesy of GENERAL MOTORS CORP 14 Remove evaporator Spraying perimeter of evaporator core seal with a soap and water mixture will ease removal Installation Procedure Tycoon 15 peka6pa 2008 r 11 01 11 Page 156 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 127 Evaporator Core amp Blower Case Assembly Courtesy of GENERAL MOTORS CORP 1 Inspect seal around evaporator Make sure seal is in correct position and retained properly Spray seal with a soap and water mixture
36. 11 01 08 Page 58 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 31 Clutch Nut Disk amp Hub Assembly Courtesy of GENERAL MOTORS CORP 14 Once the correct air gap is obtained install a new clutch nut Use J 45267 to hold the disk and hub assembly while tightening See Special Tools Tighten Tighten the nut to 19 N m 14 lb ft 15 Install the compressor Refer to Compressor Replacement 16 Evacuate and charge the refrigerant system Refer to Refrigerant Recovery and Recharging 17 Use J 39400 A to leak test the fittings See Special Tools COMPRESSOR PRESSURE RELIEF VALVE REPLACEMENT Tools Required Tycoon 15 gexa6pa 2008 r 11 01 08 Page 59 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue J 39400 A Halogen Leak Detector See Special Tools Removal Procedure 1 Recover the refrigerant Refer to Refrigerant Recovery and Recharging 2 Raise and support the vehicle Refer to Lifting and Jacking the Vehicle in General Information Fig 32 Removing Pressure Relief Valve From Compressor Hose Courtesy of GENERAL MOTORS CORP 3 Remove pressure relief valve from compressor hose Installation Procedure Tycoon 15 mexa6pa 2008 r 11 01 08 Page 60 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heatin
37. 2008 r 11 01 08 Page 78 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue J 39400 A Halogen Leak Detector See Special Tools Removal Procedure 1 Recover the refrigerant Refer to Refrigerant Recovery and Recharging 2 Raise the vehicle Refer to Lifting and Jacking the Vehicle in General Information Fig 49 Removing Compressor Hose From Evaporator Hose Courtesy of GENERAL MOTORS CORP 3 Remove the compressor hose from the evaporator hose Remove and discard the seal washer Tycoon 15 mexa6pa 2008 r 11 01 08 Page 79 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 50 Compressor Hose Nut amp TXV Courtesy of GENERAL MOTORS CORP 5 Remove the evaporator hose to TXV nut 6 Remove the evaporator hose from the TXV 7 Install protective cap to the TXV to prevent contamination Installation Procedure Tycoon 15 nexka6pa 2008 r 11 01 08 l Page 80 2005 Mitchell Repair Information Company He 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 51 Compressor amp Evaporator Hoses 2 2L Courtesy of GENERAL MOTORS CORP 1 Install new seal washer to the compressor hose Refer to Sealing Washer Replacement 2 Install the compressor hose to the evaporator hose NOTE Refer to FASTE
38. 32 e If any refrigerant dye contacts an exterior paint surface remove it by performing the following steps o Carefully wash affected surfaces according to the Saturn Owner s Handbook to remove any dirt and to ensure that paint is not scratched during dye removal o Mix water and isopropyl alcohol to obtain 50 50 mixture Soak a soft 100 percent cotton cloth towel with the solution and wet down the affected areas to remove dye o After dye has been removed wash affected areas and inspect to make sure that the dye has been removed Fluorescent Dye Injection IMPORTANT J 41447 is the only A C leak detection dye approved by Saturn See Special Tools Tycoon 15 mexa6pa 2008 r 11 01 06 Page 4 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue e Not all of the fluorescent dyes are compatible with PAG oil Some types of dye decrease the oil viscosity or may chemically react with the oil e R 134a leak detection dye requires time to work Depending upon the leak rate a leak may not become visible for between 15 minutes and 7 days IMPORTANT Do NOT overcharge the A C system with dye This may cause reliability problems Use only one 7 39 ml 0 25 oz charge bottle of J 41447 See Special Tools e With the A C system charged add J 41447 to the A C system using J 46297 Follow the instructions provided with J 46297 See Special Tools e To prevent fa
39. AC Heating Ventilation and Air Conditioning Vue Fig 21 Field Coil Snap Ring Courtesy of GENERAL MOTORS CORP 8 Use SA9149AC 8 to remove the field coil snap ring See Special Tools Tycoon 15 neka6pa 2008 r 11 01 07 Page 49 2005 Mitchell Repair Information Company C 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 22 A C Clutch Field Coil Courtesy of GENERAL MOTORS CORP 9 Remove the A C clutch field coil Installation Procedure 1 Clean the mounting surfaces on the A C clutch field coil and pulley Tycoon 15 peKxa6pa 2008 r 11 01 07 Page 50 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 23 A C Clutch Field Coil Courtesy of GENERAL MOTORS CORP 2 Install the A C clutch field coil Tycoon 15 peka6pa 2008 r 11 01 07 Page 51 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 24 Field Coil Snap Ring Courtesy of GENERAL MOTORS CORP 3 Use SA9149AC 8 to install the field coil snap ring with the bevel side out See Special Tools Tycoon 15 peKxa6pa 2008 r 11 01 07 Page 52 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 25 Thermal Swi
40. Air Conditioning Vue Is the repair complete Go to Step 22 Replace the temperature control cable Refer to Temperature Control Cable Replacement in HVAC Systems Manual Is the repair complete Go to Step 22 19 Secure the temperature control cable casing Is the action complete Go to Step 22 Repair the binding door Is the repair complete Go to Step 22 Remove the debris Is the action complete Go to Step 22 22 Operate the system in order to verify the repair Did you find and correct the condition System OK Go to Step 2 NOISE DIAGNOSIS BLOWER MOTOR Noise Diagnosis Blower Motor DEFINITION Noise originating from the blower motor Were you sent here from Symptoms or another Go to Symptoms diagnostic table HVAC Systems Manual in HVAC Go to Step 2 Systems Manual Inspect the air inlet Er for debris Is debris Er Go to Step 8 Go to Step 3 Sit inside the vehicle Close the vehicle doors and windows Turn ON the ignition with the engine OFF Cycle the blower motor through all of the speeds and modes in order to determine where and when the noise occurs Is a noise evident during the blower operation Go to Step 4 Go to Step 11 Inspect for excessive vibration at each blower motor speed by feeling the blower case Is excess vibration present Go to Step 6 Go to Step 5 Listen to the blower motor at each speed Is the blower motor making a squeaking or chirping noise Go to Step 9 Go to
41. Cooling System in Engine Cooling Remove the battery box Refer to Battery Box Replacement in Battery Move the outlet hose splice clamp forward away from splice gee Separate the front heater outlet hose from the rear heater outlet hose Tycoon 15 peKxa6pa 2008 r 11 01 12 Page 180 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 151 Heater Outlet Hose Clamp amp Heater Core Courtesy of GENERAL MOTORS CORP 6 Remove the rear heater outlet hose clamp from the heater core outlet pipe 7 Remove the heater outlet hose from the heater core outlet pipe Tycoon 15 nexka6pa 2008 r 11 01 12 Page 181 2005 Mitchell Repair Information Company He 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 152 Removing Front Heater Outlet Hose Clamp From Engine Port Courtesy of GENERAL MOTORS CORP 8 Remove the front heater outlet hose clamp from the engine port 9 Remove the front heater outlet hose clamp from the engine port Installation Procedure Tycoon 15 nexa6pa 2008 r 11 01 12 Page 182 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 153 Installing Front Heater Outlet Hose Clamp To Engine Port Courtesy of GENERAL MOTORS CORP 1 Install the heater o
42. Engine Harness Courtesy of GENERAL MOTORS CORP 1 Disconnect the thermal expansion valve TXV temperature sensor from the engine harness Tycoon 15 geka6pa 2008 r 11 01 09 Page 111 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 82 Temperature Sensor amp TXV Courtesy of GENERAL MOTORS CORP 2 Remove the temperature sensor from the TXV Installation Procedure Tycoon 15 nexa6pa 2008 r 11 01 09 Page 112 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 83 Temperature Sensor amp TXV Courtesy of GENERAL MOTORS CORP IMPORTANT The TXV cavity for temperature sensor must be packed with thermal grease to ensure functionality 1 Fill the temperature sensor housing in the TXV with the thermal grease included with the service kit 2 Install the temperature sensor and wipe away the excess grease NOTE Refer to FASTENER NOTICE in Cautions and Notices 3 Install the temperature sensor bolt Tighten Tighten the bolt to 5 N m 44 lb in Tycoon 15 gexa6pa 2008 r 11 01 10 Page 113 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 84 Refrigerant Low Temperature Sensor amp Engine Harness Courtesy of GENERAL MOTORS CORP 4
43. Installation Procedure Tycoon 15 neka6pa 2008 r 11 01 12 Page 177 2005 Mitchell Repair Information Company C 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 148 Connecting Heater Inlet amp Outlet Hoses To Thermostat Housing 2 2L Courtesy of GENERAL MOTORS CORP 1 Install the heater outlet hose to the engine port 2 Install the heater outlet hose clamp to the engine port Tycoon 15 peka6pa 2008 r 11 01 12 Page 178 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 149 Heater Outlet Hose Clamp amp Heater Core Courtesy of GENERAL MOTORS CORP 3 Install the heater outlet hose to the heater core 4 Install the heater outlet hose clamp to the heater core 5 Fill the engine coolant Refer to Draining and Filling Cooling System in Engine Cooling HEATER HOSE REPLACEMENT OUTLET L81 Removal Procedure Tycoon 15 peka6pa 2008 r 11 01 12 Page 179 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 150 Front Heater Outlet Hose amp Rear Heater Outlet Hose Courtesy of GENERAL MOTORS CORP 1 Disconnect the negative battery cable Refer to Battery Negative Cable Disconnect Connect Procedure in Battery Drain the engine coolant Refer to Draining and Filling
44. L MOTORS CORP 3 Connect the electrical connector to the blower motor 4 Install the passenger side insulator closeout panel Refer to Closeout Insulator Panel Replacement Right in Instrument Panel Gages and Console BLOWER MOTOR IMPELLER REPLACEMENT Removal Procedure Tycoon 15 gexa6pa 2008 r 11 01 13 Page 202 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 173 Electrical Connector amp Blower Motor Courtesy of GENERAL MOTORS CORP 1 Disconnect the electrical connector from the blower motor Tycoon 15 peka6pa 2008 r 11 01 13 Page 203 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 174 Blower Motor Screws amp Blower Case Assembly Courtesy of GENERAL MOTORS CORP Remove the blower motor screws from the HVAC module 2 3 Remove the blower motor from the HVAC module 4 Remove the blower motor fan retention clip from the blower motor 5 Remove the blower motor fan from the blower motor Installation Procedure Tycoon 15 mexa6pa 2008 r 11 01 13 Page 204 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 175 Blower Motor Screws amp Blower Case Assembly Courtesy of GENERAL MOTORS CORP 1 Install
45. Low Key e Near vacuum for suction pressure e Low discharge pressure e Right center air outlet near ambient Then The thermal expansion valve TXV may be restricted or closed e Replace the TXV e After the repair return to the diagnostic flow chart Degrees If the ambient air temperature is Suction and the low side gage should read Discharge and the high side gage should read Outlet and the right center air temperature should be General System Condition High or Low Side Restrictions 21 43 C 70 110 F Key e Temperature drop across restriction in line or component e Frost may be observed near the restriction Then Confirm the condition by a thorough physical and visual inspection of all lines and components e The temperature will be much colder on the down stream side of the restriction Also look for possible frost Tycoon 15 geka6pa 2008 r 11 01 06 Page 16 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue e Replace the restricted part e After the repair return to the diagnostic flow chart Degrees If the ambient air temperature is Suction and the low side gage should read Discharge and the high side gage should read Outlet and the right center air temperature should be HEATING PERFORMANCE DIAGNOSTIC Heating Performance Diagnostic DEFINITION Heating system performa
46. NER NOTICE in Cautions and Notices 3 Install the nut to the compressor hose Tighten Tighten the nut to 20 N m 15 1b ft Tycoon 15 gexa6pa 2008 r 11 01 08 Page 81 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 52 Compressor Hose Nut amp TXV Courtesy of GENERAL MOTORS CORP 4 Remove cap from TXV and install a new seal washer to the evaporator hose Refer to Sealing Washer Replacement 5 Install the evaporator hose to the TXV 6 Install the evaporator hose to TXV nut Tighten Tighten the nut to 16 N m 12 lb ft 7 Evacuate and charge the refrigerant system Refer to Refrigerant Recovery and Recharging 8 Leak test the fittings using the J 39400 A See Special Tools LIQUID LINE REPLACEMENT Tools Required Tycoon 15 gexa6pa 2008 r 11 01 08 Page 82 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue J 39400 A Halogen Leak Detector See Special Tools Removal Procedure 1 Recover the refrigerant Refer to Refrigerant Recovery and Recharging 2 Remove left headlamp Refer to Headlamp Assembly or Headlamp Bulb and or Cornering Sidemarker Park Turn Signal Bulb Replacement in Lighting Systems Fig 53 Heater Outlet Hose Clamp amp Surge Tank Courtesy of GENERAL MOTORS CORP 3 Remove surge tank to upper motor
47. Page 89 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 60 Liquid Line Strut Tower amp Nut Courtesy of GENERAL MOTORS CORP 7 Install liquid line P clip and nut to the shock tower cap stud Tighten Tighten the nut to 8 N m 71 1b in Tycoon 15 gexa6pa 2008 r 11 01 09 Page 90 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 61 Clipping EPS Harness To Liquid Line Courtesy of GENERAL MOTORS CORP 8 Clip EPS harness to liquid line 9 Clip PTU vent hose to liquid line Tycoon 15 neka6pa 2008 r 11 01 09 Page 91 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 62 Heater Outlet Hose Clamp amp Surge Tank Courtesy of GENERAL MOTORS CORP 10 Install surge tank and bolts Tighten Tighten the bolt to 6 N m 53 lb in 11 Install left headlamp Refer to Headlamp Assembly or Headlamp Bulb and or Cornering Sidemarker Park Turn Signal Bulb Replacement in Lighting Systems 12 Evacuate and charge the refrigerant system Refer to Refrigerant Recovery and Recharging 13 Leak test the fittings using the J 39400 A See Special Tools SERVICE PORT VALVE CORE REPLACEMENT Tools Required Tycoon 15 geka6pa 2008 r 11 01 09 Pa
48. RAL MOTORS CORP 3 Install the heater inlet hose to the heater core 4 Install the heater inlet hose clamp to the heater core 5 Fill the cooling system Refer to Draining and Filling Cooling System in Engine Cooling HEATER HOSE REPLACEMENT INLET L81 Removal Procedure 1 Disconnect the negative battery cable 2 Drain the coolant Refer to Draining and Filling Cooling System in Engine Cooling 3 Remove the battery box UHFB assembly Refer to Battery Cooling Box procedure in the Electrical Service Manual Tycoon 15 gexa6pa 2008 r 11 01 12 Page 169 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 140 Front Heater Outlet Hose amp Rear Heater Outlet Hose Courtesy of GENERAL MOTORS CORP 4 Separate the front heater outlet hose from the rear heater outlet hose by moving the clamp at the splice forward then separating the hoses Tycoon 15 gexa6pa 2008 r 11 01 12 Page 170 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 141 Heater Outlet Hose Clamp amp Heater Core Courtesy of GENERAL MOTORS CORP 5 Ifremoving the rear heater outlet hose remove the clamp and hose from the heater core outlet pipe Tycoon 15 nexka6pa 2008 r 11 01 12 Page 171 2005 Mitchell Repair Information Company H
49. Refer to HVAC Module Assembly Replacement Tycoon 15 peka6pa 2008 r 11 01 12 Page 191 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 162 Electrical Connector amp Recirculation Actuator Courtesy of GENERAL MOTORS CORP 2 Disconnect the electrical connector from the recirculation actuator 3 Unclip the wire harness from the HVAC module end bracket 4 Remove the end bracket screws from the air inlet assembly 5 Remove the end bracket nuts from the blower case assembly 6 Remove the end bracket from the blower case assembly Tycoon 15 mexa6pa 2008 r 11 01 12 Page 192 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 163 Air Inlet Assembly Courtesy of GENERAL MOTORS CORP 7 Remove the recirculation actuator screws 8 Remove the recirculation actuator 9 Remove the air inlet assembly screws 10 Remove the air inlet assembly Installation Procedure 1 Install the air inlet assembly NOTE Refer to FASTENER NOTICE in Cautions and Notices 2 Install the air inlet assembly screws Tycoon 15 gexa6pa 2008 r 11 01 13 Page 193 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Tighten Tighten the screws to 1 N m 9 1b in
50. Review the Description and Operation information to help you determine the correct symptom diagnostic procedure when a malfunction exists Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation The HVAC Description and Operation information is divided into e Air Delivery Description and Operation in HVAC Systems Manual e Air Temperature Description and Operation in HVAC Systems Manual The Air Delivery Description and Operation contains the following topics e Air Speed e Air Distribution The Air temperature Description and Operation contains the following topics e Heater Mode e A C Mode e A C Cycle LEAK TESTING Refrigerant Leak Testing Tools Required e J 39400 A Halogen Leak Detector See Special Tools e J 41447 R 134a A C Tracer Dye Box of 24 See Special Tools e J 42220 Universal 12V Leak Detection Lamp See Special Tools e J 46297 A C Dye Injector Kit See Special Tools e J 46297 12 Replacement Dye Cartridges See Special Tools IMPORTANT Saturn vehicles are now manufactured with fluorescent dye installed directly into the A C system The preferred method of leak testing is with the use of fluorescent dye J 41447 is the only fluorescent dye Tycoon 15 mexa6pa 2008 r 11 01 06 Page 3 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue appro
51. add to the A C refrigerant system refer to Refrigerant System Capacities COMPRESSOR OIL BALANCING Draining Procedure Tycoon 15 nexa6pa 2008 r 11 01 07 Page 30 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue IMPORTANT Drain and measure as much of the refrigerant oil as possible from the removed compressor 1 Drain the oil from both the suction and discharge ports of the removed compressor into a clean graduated container Rotate the compressor shaft to assist in draining the compressor Fig 4 Draining A C Refrigerant Oil From Compressor Courtesy of GENERAL MOTORS CORP Tycoon 15 mexa6pa 2008 r 11 01 07 Page 31 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue 2 Measure and record the amount of oil drained from the removed compressor This measurement will be used during installation of the replacement compressor IMPORTANT During the oil removal procedure the condition of the oil should be evaluated Compressor oil never breaks down unless something is wrong with the compressor or air conditioning A C system If one or more of the following conditions exist replace the compressor and receiver dehydrator 3 Inspect the polyalkylene glycol PAG oil for the following conditions e The color of the oil is dark brown or black e There is a pres
52. age 185 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 156 Push Pins amp Air Filter Access Panel Courtesy of GENERAL MOTORS CORP 1 Remove the push pins from the air filter access panel 2 Lift the air filter access panel and disconnect the washer nozzle hose from the washer nozzle 3 Remove the air filter access panel Tycoon 15 peka6pa 2008 r 11 01 12 Page 186 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 157 Filter Housing amp Nuts Courtesy of GENERAL MOTORS CORP 4 Remove the filter housing nuts from the body 5 Remove the filter housing from the body Installation Procedure Tycoon 15 peka6pa 2008 r 11 01 12 Page 187 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 158 Filter Housing amp Nuts Courtesy of GENERAL MOTORS CORP 1 Inspect the foam seal If the seal is damaged replace the seal using Kent Industries adhesive back foam tape P N 46485 or equivalent 2 Install the filter housing to the body NOTE Refer to FASTENER NOTICE in Cautions and Notices IMPORTANT New seal nuts must be used when installing passenger compartment air filter housing to prevent leaks 3 Install the new seal nuts to the
53. ak Refer to OIL LEAK 17 DIAGNOSIS Is the repair complete Go to Step 26 Replace the drive belt Refer to ENGINE DRIVE 18 BELT AND TENSIONER REPLACEMENT Is the repair complete Go to Step 26 Replace the drive belt tensioner Refer to ENGINE 19 DRIVE BELT AND TENSIONER REPLACEMENT Is the repair complete Go to Step 26 Repair or replace the A C compressor mounting 20 component Is the repair complete Go to Step 26 Repair or replace the component which is causing the moaning concern as needed Is the repair complete Go to Step 26 Correctly route or insulate the A C component feine mepai compie Gowsep26 Replace the A C compressor clutch Refer to s Compressor Clutch Coil Replacement Is the repair complete Go to Step 26 Replace the A C compressor Refer to Compressor Replacement s Is the repair complete Go to Step 26 The concern may be caused by an engine related component Refer to Vibration Analysis Engine in Vibration Diagnosis and Correction Did you find and correct the condition Go to Step 26 e aa aa Did you find and correct the condition System OK Go to Step 2 NOISE DIAGNOSIS HVAC MODULE Noise Diagnosis HVAC Module DEFINITION Noise originating from the HVAC module Were you sent here from Symptoms or another Go to Symptoms diagnostic table HVAC Systems Manual in HVAC Go to Step 2 Systems Manual 1 Start the engine 2 Cycle thr
54. arge pressure and the outlet temperature High humidity is defined as a relative humidity higher than 70 percent at 21 C 70 F 60 percent at 27 C 80 F 50 percent at 32 C 90 F 40 percent at 38 C 100 F and 20 percent at 43 C 110 F e This chart illustrates the effect the high humidity has on the Saturn VUE air conditioning system Use this chart to determine the normal system performance under high humidity conditions General System Condition Low Refrigerant Charge 21 43 C 70 110 F Normal to High Low Slightly Cool to Warm Key Poor Cooling at Higher Ambients Then The system is operating with a low charge e Leak test all the components and connections e Ifthe refrigerant charge level is unknown reclaim evacuate and recharge the system with 0 68 kg 1 5 lb of R 134a e Run another performance test Degrees If the ambient air temperature is Suction and the low side gage should read Discharge and the high side gage should read Outlet and the right center air temperature should be General System Condition Refrigerant Oil Overcharge 21 43 C 70 110 F Normal to Slightly High Key The high pressures cause the pressure sensor to cycle the compressor on and off at high ambient air temperatures Then The System may be operating in an overcharged condition Tycoon 15 gekaOpa 2008 r 11 01 06 Page 13 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 20
55. ating Ventilation and Air Conditioning Vue Fig 120 Panel Defrost amp Floor Mode Actuators Courtesy of GENERAL MOTORS CORP 6 Disconnect HVAC module harness from all three mode actuators 7 Remove panel defrost and floor mode actuators If blower case assembly is being replaced mode actuators do not need to be removed Tycoon 15 peka6pa 2008 r 11 01 11 Page 150 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 121 Heater Core Cover Screws amp Evaporator Case Assembly Courtesy of GENERAL MOTORS CORP 8 Remove heater core cover Tycoon 15 peka6pa 2008 r 11 01 11 Page 151 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 122 Heater Core Pipe Cover Courtesy of GENERAL MOTORS CORP 9 Remove heater core pipe cover 10 Remove heater core pipe seal Tycoon 15 nexa6pa 2008 r 11 01 11 Page 152 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 123 Heater Core amp End Tanks Courtesy of GENERAL MOTORS CORP 11 Grasp heater core at end tanks and remove Spraying perimeter of heater core seal with a soap and water mixture will ease removal Tycoon 15 nexa6pa 2008 r 11 01 1
56. ating Ventilation and Air Conditioning Vue Fig 17 Compressor Clutch Assembly amp Spacer Courtesy of GENERAL MOTORS CORP 3 Remove the spacer Tycoon 15 peka6pa 2008 r 11 01 07 Page 45 fe 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 18 Pulley Snap Ring Courtesy of GENERAL MOTORS CORP 4 Use SA9149AC 8 to remove the pulley snap ring See Special Tools Tycoon 15 peka6pa 2008 r 11 01 07 Page 46 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 19 A C Clutch Pulley Courtesy of GENERAL MOTORS CORP 5 Use J 25031 A to remove the A C clutch pulley See Special Tools Tycoon 15 gexa6pa 2008 r 11 01 07 Page 47 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue A O LS Fig 20 Thermal Switch Bolt amp Hold Down Bracket Courtesy of GENERAL MOTORS CORP 6 Remove the thermal switch bolt and the hold down bracket IMPORTANT It may be necessary to pry the switch lightly with a small screwdriver 7 Lift out the thermal switch while lightly twisting and pulling up on the sensor Tycoon 15 gexa6pa 2008 r 11 01 07 Page 48 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HV
57. ation Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 190 Heater Core Pipe Cover Courtesy of GENERAL MOTORS CORP 2 Install the heater core pipe seal 3 Install the heater core pipe cover NOTE Refer to FASTENER NOTICE in Cautions and Notices 4 Install the heater core pipe cover screw Tighten Tighten the screw to 1 N m 9 lb in Tycoon 15 gexa6pa 2008 r 11 01 14 Page 220 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 191 Spraying Front Dash Seal At Drain Tube Opening Courtesy of GENERAL MOTORS CORP 5 Spray the front of dash seal at the drain tube opening to aid in heater core cover installation Tycoon 15 peKxa6pa 2008 r 11 01 14 Page 221 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 192 Heater Core Cover Screws amp Evaporator Case Assembly Courtesy of GENERAL MOTORS CORP 6 Install the heater core cover 7 Install the heater core cover screws Tighten Tighten the screw to 1 N m 9 lb in Tycoon 15 gexa6pa 2008 r 11 01 14 Page 222 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 193 Heater Duct Screws amp Heater Core Cover
58. ation and Air Conditioning Vue Tighten Tighten the bolts to 9 N m 80 Ib in Eh l AS Fig 77 Liquid Line Nut amp TXV Courtesy of GENERAL MOTORS CORP Remove the protective cap from the liquid line Install a new seal washer to the liquid line Refer to Sealing Washer Replacement Install the liquid line to the TXV Install the liquid line nut to the TXV SOO E Tighten Tighten the nut to 16 N m 12 lb ft Tycoon 15 nexa6pa 2008 r 11 01 09 Page 107 2005 Mitchell Repair Information Company LLC 10 11 12 13 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 78 Compressor Hose Nut amp TXV Courtesy of GENERAL MOTORS CORP Remove the protective cap from the evaporator outlet hose Install a new seal washer to the evaporator outlet hose Refer to Sealing Washer Replacement Install the evaporator outlet hose to the TXV Install the evaporator outlet hose nut to the TXV Tighten Tighten the nut to 16 N m 12 1b ft Tycoon 15 peka6pa 2008 r 11 01 09 Page 108 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 79 Refrigerant Low Temperature Sensor amp Engine Harness Courtesy of GENERAL MOTORS CORP 14 Connect the refrigerant low temperature sensor to the engine harness 15 Evacuate and charge the A C system Refer to Refrigeran
59. aximum blower speed Does sufficient air flow from the defroster outlets Go to Step 3 Go to Step 11 Measure the engine operating temperature Does engine reach normal operating temperature Go to Step 4 Go to Step 9 1 Select the minimum blower speed 2 Select the warmest temperature setting 3 Feel the temperature of the inlet and outlet hoses at the heater core Does the inlet heater hose feel warmer than the outlet heater hose Go to Step 12 Is the vehicle equipped with air conditioning Go to Step 6 Test the operation of the A C compressor clutch Does the A C compressor clutch engage Go to Step 8 Repair the A C compressor clutch Refer to HVAC Compressor Clutch Does Not Engage in HVAC Systems Manual Is the repair complete Go to Step 15 Perform the A C system performance test Refer to Air Conditioning A C System Performance Test Is the A C system operating within the specifications Go to Step 10 Repair the low engine temperature concern Refer to Engine Fails To Reach Normal Operating Temperature in Engine Cooling Go to Step 5 Go to Step 14 5 Go to Step 7 Go to Step 13 Is the repair complete Go to Step 15 Inspect for correct operation of the recirculation door Is the recirculation door operating correctly Go to Step 15 Repair the air delivery concern Refer to Air Delivery Improper in HVAC Systems Manual Is the repair complete Go to Step 15 Repair the heating concern Refe
60. chell Repair Information Company He 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 131 Heater Core Pipe Cover Courtesy of GENERAL MOTORS CORP 10 Install heater core pipe cover 11 Install heater core pipe cover screws Tighten Tighten the screws to 1 N m 9 1b in Tycoon 15 nexa6pa 2008 r 11 01 11 Page 161 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 132 Heater Core Cover Screws amp Evaporator Case Assembly Courtesy of GENERAL MOTORS CORP 12 Install heater core cover 13 Install heater core cover screws Tighten Tighten the screws to 1 N m 9 1b in Tycoon 15 gexa6pa 2008 r 11 01 11 Page 162 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 133 Panel Defrost amp Floor Mode Actuators Courtesy of GENERAL MOTORS CORP 14 Install panel defrost and floor mode actuators 15 Install actuator screws Tighten Tighten the screws to 1 N m 9 1b in Tycoon 15 peka6pa 2008 r 11 01 11 Page 163 2005 Mitchell Repair Information Company He 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 134 Heater Duct Screws amp Heater Core Cover Courtesy of GENERAL MOTORS CORP 16 Install
61. drive belt Refer to ENGINE DRIVE BELT AND TENSIONER REPLACEMENT 3 Raise and support the vehicle Refer to Lifting and Jacking the Vehicle in General Information AEE Fig 6 Electrical Connector amp Compressor Courtesy of GENERAL MOTORS CORP 4 Disconnect the engine harness from the compressor Tycoon 15 aeka6pa 2008 r 11 01 07 Page 34 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 7 Disconnecting Oxygen Sensor From Engine Harness Courtesy of GENERAL MOTORS CORP 5 On L81 vehicles disconnect the oxygen sensor from the engine harness Tycoon 15 neka6pa 2008 r 11 01 07 Page 35 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 8 Front Oxygen Sensor amp Front Exhaust Manifold Courtesy of GENERAL MOTORS CORP 6 On L81 vehicles remove the oxygen sensor from the exhaust Tycoon 15 neka6pa 2008 r 11 01 07 Page 36 2005 Mitchell Repair Information Company C 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 9 Removing amp Discarding Sealing Washers Courtesy of GENERAL MOTORS CORP 7 Loosen the bolt that secures the suction discharge to the compressor by 7 8 turns and remove the block from the compressor by moving the block forward t
62. e 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 142 Removing Clamp amp Hose From Engine Port Courtesy of GENERAL MOTORS CORP 6 Ifremoving the front heater outlet hose remove the clamp and hose from the engine port Installation Procedure Tycoon 15 peka6pa 2008 r 11 01 12 Page 172 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 143 Installing Clamp amp Hose To Engine Port Courtesy of GENERAL MOTORS CORP 1 If installing the front heater outlet hose install the hose and clamp to the engine port Position the clamp at 3 o clock Tycoon 15 peka6pa 2008 r 11 01 12 Page 173 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 144 Heater Outlet Hose Clamp amp Heater Core Courtesy of GENERAL MOTORS CORP 2 If installing the rear heater outlet hose install the hose and clamp to the heater core outlet pipe Position the clamp at 9 o clock Tycoon 15 nexka6pa 2008 r 11 01 12 Page 174 2005 Mitchell Repair Information Company He 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 145 Front Heater Outlet Hose amp Rear Heater Outlet Hose Courtesy of GENERAL MOTORS CORP 3 Install the f
63. e Courtesy of GENERAL MOTORS CORP 1 Drain the coolant Refer to Draining and Filling Cooling System in Engine Cooling 2 Remove the heater inlet hose clamp from the heater core 3 Remove the heater inlet hose from the heater core Tycoon 15 peka6pa 2008 r 11 01 11 Page 166 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 137 Heater Inlet amp Hose Clamp Courtesy of GENERAL MOTORS CORP 4 Remove the heater inlet hose clamp from the engine 5 Remove the heater inlet hose from the engine Installation Procedure Tycoon 15 peka6pa 2008 r 11 01 12 Page 167 2005 Mitchell Repair Information Company LLC O i gt a G O 2 w E E Q a xo S Lo A 00 v A 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Bor REO 7 pae FEE s PIA gt Z i HON RY A NR SY is PON ha aa are og pam Fig 138 Heater Inlet amp Hose Clamp Courtesy of GENERAL MOTORS CORP Install the heater inlet hose to the engine 2 Install the heater inlet hose clamp to the engine l 15 aeka6pa 2008 r 11 01 12 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 139 Heater Inlet Hose Clamp amp Heater Core Courtesy of GENE
64. e compressor to the engine block bracket with the attachment bolts Tighten Tighten the bolts to 22 N m 16 1b ft Tycoon 15 geka6pa 2008 r 11 01 07 Page 39 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 12 Installing New Seal Washers Courtesy of GENERAL MOTORS CORP 4 Remove the shipping cap from the compressor and the compressor hose assembly Install new seal washers Refer to Sealing Washer Replacement 5 Install the compressor hose assembly to the compressor Tighten the attachment bolt while holding the hose block flush Tighten Tighten the bolts to 27 N m 20 lb ft Tycoon 15 geka6pa 2008 r 11 01 07 Page 40 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 13 Front Oxygen Sensor amp Front Exhaust Manifold Courtesy of GENERAL MOTORS CORP 6 On L81 vehicles install the oxygen sensor to the exhaust pipe Tighten Tighten the bolts to 45 N m 33 1b ft Tycoon 15 neka6pa 2008 r 11 01 07 Page 41 2005 Mitchell Repair Information Company C 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 14 Connecting Oxygen Sensor To Engine Wire Harness Courtesy of GENERAL MOTORS CORP 7 On L81 vehicles connect the oxygen sensor to the engine wire harness Tycoon
65. e refrigerant Refer to Refrigerant Recovery and Recharging 2 Remove the left headlamp assembly Refer to Headlamp Assembly or Headlamp Bulb and or Cornering Sidemarker Park Turn Signal Bulb Replacement in Lighting Systems Fig 65 Receiver Dehydrator Nut amp Condenser Courtesy of GENERAL MOTORS CORP IMPORTANT Use a large pair of pliers to hold the fitting Be careful not to twist the line 3 Remove the receiver dehydrator nut from the condenser Tycoon 15 peka6pa 2008 r 11 01 09 Page 95 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 66 Liquid Line Nut amp Receiver Dehydrator Courtesy of GENERAL MOTORS CORP IMPORTANT Use a large pair of pliers to hold the fitting Be careful not to twist the line 4 Remove the receiver dehydrator nut from the liquid line Tycoon 15 geka6pa 2008 r 11 01 09 Page 96 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 67 Receiver Dehydrator Nut amp Condenser Courtesy of GENERAL MOTORS CORP 5 Remove the receiver dehydrator bracket bolt from the vehicle Tycoon 15 peka6pa 2008 r 11 01 09 Page 97 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 68 Receiver Dehydrator Protect
66. e to Receiver Dehydrator Nut Tycoon Z 3 O o0 Z ajlnxj i5 ZZZ ZZZ ZZ z BIBIBIB BIBIB S 4 oo Z 15 mexa6pa 2008 r 11 01 19 Page 1 2005 Mitchell Repair Information Company LLC 5 5 5 5 5 2 8 n l 4 2 5 N m 16 N m Specifications Metric English 9 Ib in 9 Ib in 11 Ib ft 9 Ib in 9 Ib in 14 lb ft 71 Ib in 20 lb ft 12 lb ft 12 lb ft 16 lb ft 89 Ib in 53 Ib in 89 Ib in 9 Ib in 22 lb in 12 lb ft 9 Ib in 9 Ib in 62 lb in 12 lb ft 71 Ib in 12 lb ft 9 Ib in 9 Ib in 70 lb in 9 Ib in 9 Ib in 9 Ib in 18 Ib in 53 Ib in 70 lb in 22 lb in 12 Ib ft 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Liquid Line to Strut Tower Nut L61 5 N m 44 lb in Receiver Dehydrator to Condenser Nut 12 lb ft Recirc Assembly Screws Refrigerant Low Temperature Sensor Bolt to TXV 45 lb in Refrigerant Pressure Sensor to Compressor Hose Assembly 89 Ib in TXV Backing Plate Bolts 80 Ib in REFRIGERANT SYSTEM CAPACITIES Refrigerant System Capacities Application Specification Metric English PAG Oil Saturn P N 22695048 Abrupt Refrigerant Loss 103 ml 3 5 oz Compressor Replacement e The Visteon model SC105V service compressor is precharged with the specified amount of PAG oil 120 mi 2 2L L61 e The Visteon model SC100V service compressor is precharged with the specified amount of PAG oil 120 m1 3 5L L66
67. ence of foreign substances metal fillings etc in the oil If the receiver dehydrator is not replaced damage to A C compressor will occur 4 Properly discard the used refrigerant oil Balancing Procedure IMPORTANT The refrigerant oil in the A C system must be balanced during compressor replacement 1 The replacement compressor is shipped with 120 ml 4 0 oz of refrigerant oil Tycoon 15 geka6pa 2008 r 11 01 07 Page 32 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 5 Draining A C Refrigerant Oil From Compressor Courtesy of GENERAL MOTORS CORP 2 Compare the amount of refrigerant oil recorded during compressor removal to the amount of refrigerant oil shipped in the replacement compressor If the amount of refrigerant oil drained and recorded from the removed compressor is e Less than 120 ml 4 0 oz leave the 120 ml 4 0 oz in the replacement compressor e More than 120 ml 4 0 oz add to the compressor the difference between the 120 ml 4 0 oz and the amount drained COMPRESSOR REPLACEMENT Tycoon 15 mexa6pa 2008 r 11 01 07 Page 33 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Tools Required J 39400 A Halogen Leak Detector See Special Tools Removal 1 Recover the refrigerant Refer to Refrigerant Recovery and Recharging 2 Remove the
68. erature control from the coldest setting to the warmest setting Does the temperature change from cold to hot Go to Step 17 Go to Step 4 Inspect the connections of the temperature control cable Is the temperature control cable disconnected from the temperature door Go to Step 15 Go to Step 5 Inspect the temperature control cable and linkage at the temperature door while operating the temperature controls Does the temperature door move while operating the temperature controls Go to Step 22 Go to Step 6 Inspect the cable casing while operating the temperature controls Does the cable casing move instead of the cable while operating the temperature controls Go to Step 19 Go to Step 16 Inspect the HVAC control module for any debris or obstructions that would increase the effort to operate the temperature controls Are there any obstructions Go to Step 21 Go to Step 8 1 Disconnect the temperature control cable from as Tycoon 15 mexa6pa 2008 r 11 01 06 Page 20 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue the temperature door 2 Operate the HVAC control module with the 8 temperature control cable disconnected Does the HVAC control module bind now Go to Step 10 Go to Step 9 With the temperature control cable disconnected 1 Manually operate the temperature door 2 Inspect the door for binding Does the temperature door
69. esy of GENERAL MOTORS CORP 4 Remove suction line at TXV and install protective cap to suction line Tycoon 15 gexa6pa 2008 r 11 01 10 Page 126 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 97 Liquid Line Nut amp TXV Courtesy of GENERAL MOTORS CORP IMPORTANT Place protective cover over A C lines and TXV to prevent contamination of A C system 5 Remove liquid line at TXV and install protective cap to liquid line and TXV Tycoon 15 nexa6pa 2008 r 11 01 10 Page 127 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 98 Refrigerant Low Temperature Sensor amp Engine Harness Courtesy of GENERAL MOTORS CORP 6 Disconnect TXV temperature sensor connector Tycoon 15 nexa6pa 2008 r 11 01 10 Page 128 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 99 Heater Outlet Hose Clamp amp Heater Core Courtesy of GENERAL MOTORS CORP 7 Reposition the heater inlet hose at the heater core using SA9111E See Special Tools 8 Remove heater hose at heater core outlet Tycoon 15 nexka6pa 2008 r 11 01 10 Page 129 2005 Mitchell Repair Information Company He 2003 Saturn Vue 2003 HVAC Heating Ventilation and Ai
70. ew O ring seal with mineral base 525 viscosity refrigerant oil IMPORTANT DO NOT reuse O ring seals 5 Carefully slide the new O ring seal onto the A C refrigerant component Tycoon 15 mexa6pa 2008 r 11 01 08 Page 66 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 37 Identifying Proper Seating Of A C Refrigerant O Ring Courtesy of GENERAL MOTORS CORP 6 The O ring seal must be fully seated Tycoon 15 mexa6pa 2008 r 11 01 08 Page 67 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Ce Fig 38 Disassembling Reassembling A C Line Fittings Courtesy of GENERAL MOTORS CORP 7 Assemble the A C components Refer to the appropriate repair procedure e For compression style fittings use a back up wrench on the fitting 2 and tighten the fitting nut 1 to specification e For banjo style fittings install the bolt retaining the banjo type fitting and tighten to specification COMPRESSOR HOSE ASSEMBLY REPLACEMENT L61 Tools Required Tycoon 15 mexa6pa 2008 r 11 01 08 Page 68 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue J 39400 A Halogen Leak Detector See Special Tools Removal Procedure 1 Recover the refrigerant Refer to Refrigerant Recovery and Recharging
71. filter housing Tighten Tighten the nuts to 9 N m 80 Ib in Tycoon 15 gexa6pa 2008 r 11 01 12 Page 188 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 159 Push Pins amp Air Filter Access Panel Courtesy of GENERAL MOTORS CORP 4 Connect the washer nozzle hose to the washer nozzle 5 Install the air filter access panel 6 Install the push pins to the air filter access panel PASSENGER COMPARTMENT AIR FILTER REPLACEMENT Removal Procedure Tycoon 15 peka6pa 2008 r 11 01 12 Page 189 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 160 Push Pins amp Air Filter Access Panel Courtesy of GENERAL MOTORS CORP 1 Remove the push pins from the air filter access panel 2 Remove the air filter access panel 3 Remove the air filter from the housing Installation Procedure Tycoon 15 peka6pa 2008 r 11 01 12 Page 190 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 161 Push Pins amp Air Filter Access Panel Courtesy of GENERAL MOTORS CORP 1 Install the air filter into the housing 2 Install the air filter access panel 3 Install the air filter access panel push pins AIR INLET ASSEMBLY REPLACEMENT Removal Procedure 1 Remove the HVAC module
72. g Vue Fig 178 Outlet Bezel Courtesy of GENERAL MOTORS CORP 1 Install the outlet to the I P trim panel The outlet will snap into place 2 Install the I P upper trim panel Refer to Trim Panel Replacement Instrument Panel I P Upper in Instrument Panel Gages and Console AIR OUTLET REPLACEMENT FLOOR Removal Procedure Tycoon 15 gexa6pa 2008 r 11 01 13 Page 208 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 179 Center Floor Air Outlet Duct Courtesy of GENERAL MOTORS CORP 1 Remove the shift control bracket Refer to Transmission Shift Control Bracket Replacement in Manual Transmission Getrag 5 Transmission Shift Control Bracket Replacement in Automatic Transaxle AF33 5 2 Slide the floor air duct forward on heater duct enough to clear the rear floor air duct and then up and rearward to remove Installation Procedure Tycoon 15 gexa6pa 2008 r 11 01 13 Page 209 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 180 Center Floor Air Outlet Duct Courtesy of GENERAL MOTORS CORP 1 Slide the floor air duct forward on heater duct enough to clear rear floor air duct and then down and rearward to install 2 Install the shift control bracket Refer to Transmission Shift Control Bracket Replacement in Manual
73. g Ventilation and Air Conditioning Vue Fig 33 Installing Pressure Relief Valve To Compressor Hose Courtesy of GENERAL MOTORS CORP IMPORTANT Use R 12 refrigerant oil mineral to lubricate O rings Use of R 134a PAG oil will cause premature corrosion of fitting joints 1 Lubricate the pressure relief valve O ring with new R 12 mineral compressor oil Refer to O Ring Replacement NOTE Refer to FASTENER NOTICE in Cautions and Notices 2 Install the pressure relief valve to the compressor hose Tighten Tighten the pressure relief valve to 10 N m 89 in ft 3 Lower the vehicle Tycoon 15 mexa6pa 2008 r 11 01 08 Page 61 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue 4 Evacuate and charge the A C system Refer to Refrigerant Recovery and Recharging 5 Test the affected A C joint for leaks using J 39400 A See Special Tools SEALING WASHER REPLACEMENT Removal Procedure Fig 34 Identifying Good And Bad Sealing Washer Positions Courtesy of GENERAL MOTORS CORP 1 Remove the seal washer from the A C refrigerant component IMPORTANT Cap or tape the open A C refrigerant components immediately to prevent system contamination 2 Inspect the seal washer for signs of damage to help determine the root cause of the failure Tycoon 15 mexa6pa 2008 r 11 01 08 Page 62 2005 Mitchell Repair Information Company LLC 2003
74. g for noise concerns using a stethoscope Are any of these components loose damaged or excessively worn Go to Step 20 Go to Step 11 Does a vibration or rattle noise exist when the A C clutch is engaged Go to Step 13 Go to Step 14 Does the noise stop when the A C clutch is disengaged Go to Step 15 Go to Step 25 1 Idle the engine in PARK with the A C compressor clutch engaged Using a stethoscope move around the entire A C system testing for any abnormal noises caused by a component Do any of the A C components cause an abnormal noise Go to Step 21 Go to Step 25 Verify that the A C system is properly charged ee ee Idle the engine Engage the A C compressor clutch Using a stethoscope move around the entire il refrigerant plumbing system Listening for any abnormal noises caused by a component of the A C system touching another component Are any of the A C components grounding out and causing a vibration noise Go to Step 22 Go to Step 13 Tycoon 15 mexa6pa 2008 r 11 01 07 Page 24 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Refer to Refrigerant System Capacities Is the A C system properly charged Go to Step 26 Go to Step 16 15 Recharge the A C system to specification Refer to 16 Refrigerant Recovery and Recharging Is the abnormal compressor noise still present Go to Step 24 Go to Step 26 Repair the oil le
75. ge 92 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue e J 39400 A Halogen Leak Detector See Special Tools e J 46246 Valve Core Removal Tool See Special Tools Removal Procedure 1 Recover the refrigerant Refer to Refrigerant Recovery and Recharging Fig 63 Equivalent amp Valve Core Courtesy of GENERAL MOTORS CORP 2 Use J 46246 or equivalent to remove the valve core See Special Tools Installation Procedure Tycoon 15 mexa6pa 2008 r 11 01 09 Page 93 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 64 Equivalent amp Valve Core Courtesy of GENERAL MOTORS CORP 1 Use J 46246 or equivalent to install and tighten the valve core See Special Tools 2 Evacuate and charge the A C system Refer to Refrigerant Recovery and Recharging IMPORTANT To prevent loss of refrigerant charge tighten the cap Replace the cap if the seal is missing or damaged 3 Test the affected A C fittings for leaks using J 39400 A See Special Tools RECEIVER DEHYDRATOR REPLACEMENT Tools Required J 39400 A Halogen Leak Detector See Special Tools Tycoon 15 nexa6pa 2008 r 11 01 09 Page 94 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Removal Procedure 1 Recover th
76. he I P center trim bezel Refer to Trim 11 Bezel Replacement Center in Instrument Panel Gages and Console Is the action complete Go to Step 12 12 Operate the system to verify the repair Did you find and correct the condition System OK Go to Step 2 Tycoon 15 peka6pa 2008 r 11 01 07 Page 26 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue ODOR DIAGNOSIS Odor Diagnosis DEFINITION Odor originating or noticed through the HVAC system Go to Symptoms Were you sent here from Symptoms or another HVAC Systems diagnostic table Manual in HVAC Go to Step 2 Systems Manual Sit inside the vehicle Close all of the doors and windows Start the engine Allow the engine idle at normal operating temperature Select the maximum blower speed Select the PANEL air outlet mode Select the coldest temperature setting Cycle through all of the blower speeds modes and temperatures to define what type of odor is present e Musty smell e Coolant smell e Oil smell Does the odor have a musty smell Go to Step 3 Go to Step 8 Inspect the HVAC filter and the air inlet grille for debris Is debris present Go to Step 4 Go to Step 5 Remove any debris Is the action complete Go to Step 15 Inspect for wet carpeting Is the carpet wet Go to Step 6 Go to Step 14 Inspect for the following conditions 1 Water leaks around
77. heater duct 17 Install heater duct screws Tighten Tighten the screws to 1 N m 9 1b in Tycoon 15 nexa6pa 2008 r 11 01 11 Page 164 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 135 TXV Bolts amp Backing Plate Courtesy of GENERAL MOTORS CORP 18 Install HVAC module front of dash seal Inspect and if damaged replace IMPORTANT Use only R 12 refrigerant oil mineral to lubricate O rings Use of R 134a PAG oil will cause premature corrosion of fitting joints Use only clean lint free cloths with non petroleum based solvents to clean refrigerant system sealing surfaces Allow solvent to dry with air Do not allow solvents to enter refrigerant system 19 Remove evaporator pipe caps and insure seal areas are clean dry and lint free 20 Install new O rings to evaporator lubricating with mineral oil Refer to O Ring Replacement 21 Remove shipping caps and install TXV to evaporator pipes with backing plate and bolts Tighten Tighten the bolts to 9 N m 80 Ib in Tycoon 15 mexa6pa 2008 r 11 01 11 Page 165 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue 22 Install the HVAC module Refer to HVAC Module Assembly Replacement HEATER HOSE REPLACEMENT INLET L61 Removal Procedure Fig 136 Heater Inlet Hose Clamp amp Heater Cor
78. hen up 8 Remove and discard the sealing washers 9 Install the shipping cap on the compressor hose assembly to prevent moisture or contamination 10 Install the compressor shipping cap before removal to prevent oil spillage and contamination Tycoon 15 geka6pa 2008 r 11 01 07 Page 37 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 10 Compressor Bolts amp Engine Courtesy of GENERAL MOTORS CORP 11 Remove the bolts that secure the compressor to the engine block Remove the compressor Installation NOTE Do NOT mix refrigerant oils Use of incorrect refrigerant oil will cause compressor failure This compressor uses a low viscosity refrigerant oil Saturn P N 22695048 IMPORTANT NEW compressor assemblies are shipped with a partial poly alkylene glycol PAG refrigerant oil charge Use of the incorrect PAG oil can result in compressor failure 1 Ifreplacing the compressor refer to Compressor Oil Balancing Tycoon 15 mexa6pa 2008 r 11 01 07 Page 38 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue 2 Install caps on the compressor to prevent oil spillage during installation 36 gt egi Fig 11 Compressor Bolts amp Engine Courtesy of GENERAL MOTORS CORP NOTE Refer to FASTENER NOTICE in Cautions and Notices 3 Install th
79. iagnostic flow chart Degrees If the ambient air temperature is Suction and the low side gage should read Discharge and the high side gage should read Outlet and the right center air temperature should be Specific System Condition Compressor at Minimum Displacement Outlet 21 C 70 F 165 207 kPa 24 30 psi 720 1007 106 146 4990 35 47 F 27 C 80 F imaia 121 161 3 900 37 49 F 33 C 90 F 199 241 kPa 29 35 psi V N 135 175 5906 42 49 F 38 C 100 F 220 275 kPa 32 40 psi 11457142 a 166 206 719 C 45 54 F 43 C 1 10 F 220 275 kPa 32 40 psi 1158 1434 kPa 168 208 7 12 C 45 54 F Tycoon 15 geka6pa 2008 r 11 01 06 Page 14 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue psi Key e Increased suction pressure for a relatively low discharge pressure e High outlet temperatures Then The compressor may be at minimum displacement e This condition will be most noticeable at high ambients e Confirm the charge level before replacing the compressor e After the repair return to the diagnostic flow chart Specific System Condition Compressor at Maximum Displacement 21 43 C 70 110 F Key e Lower than normal suction pressure and outlet temperature at lower ambients e Higher than normal discharge pressures Then The compressor may be at maximum displacement Thi
80. ide gage should read Discharge and the high side gage should read Outlet and the right center air temperature should be IMPORTANT To ensure accurate pressure and temperature readings make sure the vehicle is properly set up to run the performance test Refer to vehicle set up section in this manual ALL TEST PARAMETERS MUST BE FOLLOWED TO OBTAIN ACCURATE READINGS IMPORTANT Use a refrigerant identifier to verify refrigerant purity Non condensable gases or refrigerant substitutes will affect system pressure temperature readings Tycoon 15 mexa6pa 2008 r 11 01 06 Page 12 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Normal System Performance Service Stall High Humidit Outlet 21 C 70 F 98103 kPa ODODE pa a 117 163 4 9 36 48 F 27 C 80 F 138 193 kPa 20 28 psi a 156 197 410 C 36 50 F 33 C 90 F 144 193 kPa 21 28 psi ee 216 260 519 C 40 53 F 38 C 100 F 144 193 kPa 21 28 psi e 236 289 6130 43 55 F 43 C 110 F 144 200 kPa 21 29 psi a 278 934 644 C 43 56 F Degrees If the ambient air temperature is Suction and the low side gage should read Discharge and the high side gage should read Outlet and the right center air temperature should be e High humidity conditions affect the system performance by increased heat load on the system This extra heat load will increase the disch
81. isconnect the electrical connector from the blower motor resistor Tycoon 15 nexa6pa 2008 r 11 01 13 Page 196 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 167 Blower Motor Resistor Screws amp Blower Case Assembly Courtesy of GENERAL MOTORS CORP 3 Remove the blower motor resistor screws from the HVAC module 4 Remove the blower motor resistor from the HVAC module Installation Procedure Tycoon 15 gexa6pa 2008 r 11 01 13 Page 197 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 168 Blower Motor Resistor Screws amp Blower Case Assembly Courtesy of GENERAL MOTORS CORP 1 Install the blower motor resistor to the HVAC module NOTE Refer to FASTENER NOTICE in Cautions and Notices 2 Install the blower motor resistor screws to the HVAC module Tighten Tighten the screws to 1 N m 9 lb in 3 Connect the electrical connector to the blower motor resistor 4 Install the right side insulator closeout panel Refer to Closeout Insulator Panel Replacement Right in Instrument Panel Gages and Console BLOWER MOTOR REPLACEMENT Tycoon 15 mexa6pa 2008 r 11 01 13 Page 198 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Removal Procedure
82. ive Caps amp Liquid Line Courtesy of GENERAL MOTORS CORP 6 Remove the receiver dehydrator from the vehicle 7 Install protective caps to the condenser the liquid line and the receiver dehydrator to prevent contamination and desiccant saturation Installation Procedure Tycoon 15 geka6pa 2008 r 11 01 09 Page 98 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 69 Receiver Dehydrator Protective Caps amp Liquid Line Courtesy of GENERAL MOTORS CORP 1 Remove the protective caps from the condenser the liquid line and the receiver dehydrator 2 Add the specified amount of PAG oil to the receiver dehydrator Refer to Refrigerant System Capacities 3 Install new seal washers to the receiver dehydrator Refer to Sealing Washer Replacement 4 Install the receiver dehydrator to the vehicle Tycoon 15 geka6pa 2008 r 11 01 09 Page 99 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 70 Liquid Line Nut amp Receiver Dehydrator Courtesy of GENERAL MOTORS CORP NOTE Refer to FASTENER NOTICE in Cautions and Notices IMPORTANT Use a large pair of pliers to hold the fitting Be careful not to twist the line 5 Install the receiver dehydrator nut to the liquid line Tighten Tighten the nut to 16 N m 12 lb ft Tycoon 15
83. ld be worn and a clean cloth wrapped around fittings valves and connections when doing work that includes opening the refrigerant system If R 134a comes in contact with any part of the body severe frostbite and personal injury can result The exposed area should be flushed Tycoon 15 nexa6pa 2008 r 11 01 07 Page 29 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue immediately with cold water and prompt medical help should be obtained NOTE R 134a is the only approved refrigerant for use in this vehicle The use of any other refrigerant may result in poor system performance or component failure NOTE To avoid system damage use only R 134a dedicated tools when servicing the A C system NOTE Use only Polyalkylene Glycol Synthetic Refrigerant Oil PAG for internal circulation through the R 134a A C system and only 525 viscosity mineral oil on fitting threads and O rings If lubricants other than those specified are used compressor failure and or fitting seizure may result NOTE R 12 refrigerant and R 134a refrigerant must never be mixed even in the smallest of amounts as they are incompatible with each other If the refrigerants are mixed compressor failure is likely to occur Refer to the manufacturer instructions included with the service equipment before servicing The J 43600 is a complete air conditioning service center for R 134a See Special T
84. lse diagnosis in the future thoroughly clean the residual dye from any area where leaks were found Clean any refrigerant dye on components with brake and choke cleaner Saturn P N 210074372 e The dye injection package contains a notice sticker Complete the leak detection information and place the sticker near the charge label Halogen Leak Detector CAUTION Do not operate the detector in a combustible atmosphere since its sensor operates at high temperatures or personal injury and or damage to the equipment may result Ensure that the vehicle has at least 0 41 kg 0 9 1b of refrigerant in the A C refrigeration system in order to perform a leak test Refer to Refrigerant Recovery and Recharging for recharging the A C system IMPORTANT Halogen leak detectors are sensitive to the following items e Windshield washing solutions e Many solvents and cleaners e Some adhesives used in the vehicle Clean and dry all surfaces in order to prevent a false warning Liquids will damage the detector IMPORTANT Follow a continuous path in order to ensure that you will not miss any possible leaks Test all areas of the system for leaks Follow the instructions supplied with the J 39400 A See Special Tools HVAC PRELIMINARY CHECKS Most A C system problems can be detected by a thorough visual and physical inspection of the system IMPORTANT The importance of this inspection cannot be stressed enough because proper heating and cooling depend
85. mexa6pa 2008 r 11 01 09 Page 100 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 71 Receiver Dehydrator Nut amp Condenser Courtesy of GENERAL MOTORS CORP IMPORTANT Use a large pair of pliers to hold the fitting Be careful not to twist the line 6 Install the receiver dehydrator nut to the condenser Tighten Tighten the nut to 16 N m 12 lb ft 7 Position the receiver dehydrator in the vehicle 8 Install the receiver dehydrator nut to the vehicle Tighten Tighten the bolt to 10 N m 89 lb in Tycoon 15 gexa6pa 2008 r 11 01 09 Page 101 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Sidemarker Park Turn Signal Bulb Replacement in Lighting Systems 10 Evacuate and charge the A C system Refer to Refrigerant Recovery and Recharging 11 Test the affected A C joints for leaks using J 39400 A See Special Tools THERMAL EXPANSION VALVE REPLACEMENT FIRST DESIGN Tools Required J 39400 A Halogen Leak Detector See Special Tools Removal Procedure 1 Recover the refrigerant Refer to Refrigerant Recovery and Recharging Fig 72 Compressor Hose Nut amp TXV Courtesy of GENERAL MOTORS CORP Tycoon 15 gexa6pa 2008 r 11 01 09 Page 102 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating
86. mexa6pa 2008 r 11 01 14 Page 227 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue J 46246 Valve Core Tool J 46297 A C Dye Injector Kit J 46297 12 Replacement Dye Cartridges SA 9111E Hose Clamp Pliers SA 9149AC 8 Snap Ring Pliers Tycoon 15 mexa6pa 2008 r 11 01 14 Page 228 2005 Mitchell Repair Information Company LLC
87. nce Were you sent here from Symptoms or another Go to Symptoms diagnostic table HVAC Systems Manual in HVAC Go to Step 2 Systems Manual 1 Start the engine 2 Allow the engine to idle Does the engine reach a normal operating temperature Go to Step 3 Go to Step 9 Allow the engine to idle Select the FLOOR mode Select the minimum blower speed 3 Select the warmest temperature setting Feel the temperature of the inlet and outlet heater hoses at the heater core Does the inlet heater hose feel warmer than the outlet heater hose Go to Step 7 Go to Step 4 Install a thermometer into the center I P PANEL air outlet Secure a thermometer to the heater core outlet hose Select the PANEL mode Select the maximum blower speed Select the warmest temperature setting Record the temperature at the following locations e The center I P PANEL air outlet e The heater core outlet hose 7 Compare the recorded temperatures Tycoon 15 mexa6pa 2008 r 11 01 06 Page 17 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Are the two temperature readings about equal Go to Step 5 Go to Step 6 1 Inspect and repair the following areas of the vehicle for cold air leaks e The cowl e The recirculation door e The HVAC module case 2 Perform the necessary repairs Are the repairs complete Go to Step 10 1 Inspect the temperature do
88. oe 232 281 319 C 37 51 F IMPORTANT 27 C 80 F 131 186 kPa 19 27 psi 1 9 C 33 49 F Statements contain additional information to help you confirm your diagnosis and lead you to a corrective action When ALL pressure and temperature readings fall within the ranges of a given chart use that chart to repair the vehicle Key Statements are used to interpret the pressure and temperature readings compared to normal system performance If testing above or below ambient temperatures listed rely on key statements to diagnose system Then Statements contain additional information to help you confirm your diagnosis and lead you to a corrective action When all pressure and temperature readings fall within the ranges of a given chart use that chart to repair the vehicle Degrees If the ambient air temperature is Suction and the low side gage should read Discharge and the high side gage should read Outlet and the right center air temperature should be Normal System Performance Service Stall Outlet 21 C 70 F 131 186 kPa 19 27 psi emai call 1 8 C 33 46 F 27 C 80 F 31 186 Pa oo7 pay aA 130 173 1_9 33 49 F 33 C 90 F 131 186 kPa 19 27 psi Am 167 212 4 990 34 49 F 38 C 100 F 144 193 kPa 21 28 psi 1496 175 P 211 254 310 C 37 51 F 43 C 110 F 144 193 kPa 21 28 psi ae 232 281 319 C 37 51 F Degrees If the ambient air temperature is Suction and the low s
89. ools The ACR 2000 recovers recycles evacuates and recharges A C refrigerant quickly accurately and automatically The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover recycle evacuate and recharge operations R 134a is recovered into and charged out of an internal storage vessel The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5 45 6 82 kg 12 15 Ibs of A C refrigerant The ACR 2000 has a built in A C refrigerant identifier that will test for contamination prior to recovery and will notify the technician if there are foreign gases present in the A C system If foreign gases are present the ACR 2000 will not recover the refrigerant from the A C system The ACR 2000 also features automatic air purge single pass recycling and an automatic oil drain Refer to the J 43600 ACR 2000 manual for operation and setup instruction See Special Tools Always recharge the A C System with the proper amount of R 134a Refer to Refrigerant System Capacities for the correct amount A C Refrigerant System Oil Charge Replenishing If oil was removed from the A C system during the recovery process or due to component replacement the oil must be replenished Oil can be added to the system by pouring the correct amount into the replaced component or into an open refrigerant line For the proper quantities of oil to
90. or operation Refer to Diagnostic System Check HVAC Systems Manual in HVAC Systems Manual 2 Perform any necessary repairs Are the repairs complete Go to Step 10 Turn OFF the engine Backflush the heater core Start the engine Select the FLOOR mode Select the minimum blower speed Select the warmest temperature setting Feel the temperature of the inlet and outlet heater hoses at the heater core Does the inlet heater hose feel warmer than the outlet heater hose Go to Step 8 Go to Step 10 Replace the heater core Refer to Heater Core Replacement D Is the repair complete Go to Step 10 Repair the low engine temperature concern Refer to Engine Fails To Reach Normal Operating Temperature in Engine Cooling Is the repair complete Go to Step 10 10 Operate the system in order to verify the repair Did you find and correct the condition System OK Go to Step 2 DEFROSTING INSUFFICIENT Defrosting Insufficient Yes DEFINITION Time required to defrost the windshield is longer than usual Were you sent here from Symptoms or another Go to Symptoms diagnostic table HVAC Systems Manual in HVAC Tycoon 15 mexa6pa 2008 r 11 01 06 Page 18 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Go to Step 2 Systems Manual 1 Start the engine 2 Select the DEFROST mode 3 Select the m
91. oss car beam and front of dash fasteners and remove HVAC module Installation Procedure Tycoon 15 gexa6pa 2008 r 11 01 10 Page 136 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 107 HVAC Module Bolts amp Cross Car Beam Courtesy of GENERAL MOTORS CORP IMPORTANT Make sure seals on HVAC module are flush and even as the meet their mating surfaces This will reduce the chance of leaks and insure proper fit 1 Check front of dash seal for proper alignment 2 Check seal mating surfaces to insure there are no obstructions IMPORTANT Make sure center molded in case HVAC to cross car beam bracket is forward of cross car beam down flange 3 Loose hang HVAC module from cross car beam Tycoon 15 mexa6pa 2008 r 11 01 10 Page 137 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 108 HVAC Module Seal amp Nuts Courtesy of GENERAL MOTORS CORP IMPORTANT New front of dash seal nuts must be used to prevent leaks NOTE Refer to FASTENER NOTICE in Cautions and Notices 4 Install front of dash to HVAC module seal nuts draw module to FOD evenly with nuts and tighten Tighten Tighten the nuts to 8 N m 71 Ib in Tycoon E 15 geka6pa 2008 r 11 01 10 Page 138 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue
92. ough all of the following Tycoon 15 gnexaOpa 2008 r 11 01 07 Page 25 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue e Blower motor speeds e HVAC modes e Temperature control settings 3 Determine the type of noise 2 e Scrape pop e Tick click chirp or groaning e Air rush whistle Is a scrape or pop noise evident when selecting modes or temperature settings Go to Step 6 Go to Step 3 Is a tick click chirping groaning or scraping noise 3 present but decreases as blower motor speed is decreased Go to Step 6 not all temperature settings Go to Step 6 floor mode Go to Step 6 Go to Step 4 Go to Step 5 Go to Step 6 1 Remove the instrument panel center trim bezel Refer to Trim Bezel Replacement Center in Instrument Panel Gages and Console 2 Remove the center air outlet duct Is the action complete Go to Step 7 1 Inspect the air flow doors for proper operation 2 Inspect the ducts for obstructions or foreign 7 materials Were any of these conditions found Go to Step 10 Go to Step 8 Inspect the mode and temperature doors and seals for warping or cracking Are the doors in normal condition Go to Step 11 Replace the appropriate door and or seals Remove any obstructions or foreign material found Is the action complete Go to Step 11 Go to Step 9 10 Install the center air outlet duct Install t
93. purged 1 Turn ON refrigerant identifier and let it reach operating temperature 3 5 minutes 2 When display reads HOSE and with the vehicle turned OFF attach the hose to the low side suction port and open service valves 3 Press ENTER button 4 The display will read GAS as a sample of refrigerant is taken and analyzed 5 When analysis is complete display will show by percentage the make up of gases e If refrigerant is less than 98 percent pure the temperature pressure charts will not be accurate for system diagnosis e If refrigerant is pure but contains air system should be recovered and recharged with virgin refrigerant before proceeding Installing Manifold Gage Set Tycoon 15 mexa6pa 2008 r 11 01 06 Page 9 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 3 Manifold Gage Set Courtesy of GENERAL MOTORS CORP If an A C system problem still exists after you have completed the preliminary inspects more diagnostic tests must follow These include manifold gage set readings Follow the steps listed below for installing a manifold gage set CAUTION Always wear goggles and wrap a clean cloth around fittings valves and connections when performing work that involves opening the refrigerant system IMPORTANT Inspect to make sure gages read zero before installing manifold gage set 1 Close both hand valves of manifold gage
94. r Conditioning Vue Fig 100 Heater Inlet Hose Clamp amp Heater Core Courtesy of GENERAL MOTORS CORP 9 Reposition the heater outlet hose at the heater core using SA9111E See Special Tools 10 Remove heater hose at heater core inlet 11 Plug heater core pipes with clean towels to prevent spillage when removing module 12 Remove the instrument panel I P retainer Refer to Instrument Panel I P Retainer Replacement in Instrument Panel Gages and Console 13 Remove the shift control bracket Refer to Transmission Shift Control Bracket Replacement in Manual Transmission Getrag 5 or Transmission Shift Control Bracket Replacement in Automatic Transaxle AF33 5 Tycoon 15 gexa6pa 2008 r 11 01 10 Page 130 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 101 Center Floor Air Outlet Duct Courtesy of GENERAL MOTORS CORP 14 Remove front rear duct by sliding forward on heater duct then up at rear and then rearward Tycoon 15 gexa6pa 2008 r 11 01 10 Page 131 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 102 Center I P Air Outlet Duct amp Retainers Courtesy of GENERAL MOTORS CORP 15 Remove auxiliary duct assembly Tycoon 15 nexa6pa 2008 r 11 01 10 Page 132 2005 Mitchell Repair Info
95. r Conditioning Vue Fig 27 Field Coil Snap Ring Courtesy of GENERAL MOTORS CORP 9 Use SA9149AC 8 to install the pulley snap ring with the bevel side out See Special Tools Tycoon 15 peka6pa 2008 r 11 01 08 Page 55 2005 Mitchell Repair Information Company inte 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 28 Compressor Clutch Assembly amp Spacer Courtesy of GENERAL MOTORS CORP 10 Install the spacer Tycoon 15 peka6pa 2008 r 11 01 08 Page 56 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 29 Clutch Nut Disk amp Hub Assembly Courtesy of GENERAL MOTORS CORP IMPORTANT Align the block tooth on the disk and hub assembly with the groove in the shaft 11 Install the drive plate and nut Use the old nut to evaluate the clearances Tycoon E 15 geka6pa 2008 r 11 01 08 Page 57 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 30 Measuring Clearance Between Pulley amp Drive Plate Using Feeler Gauge Courtesy of GENERAL MOTORS CORP 12 Using a feeler gauge verify that the clearance is 0 35 0 75 mm 0 014 0 030 in 13 Ifnecessary adjust the clearance by adding or removing clutch hub spacers Tycoon 15 neka6pa 2008 r
96. r in Instrument Panel Gages and Console Tycoon 15 gexa6pa 2008 r 11 01 13 Page 214 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue HEATER CORE REPLACEMENT Removal Procedure 1 Drain the engine coolant Refer to Draining and Filling Cooling System in Engine Cooling 2 Remove the heater outlet hose from the heater core Refer to Heater Hose Replacement Outlet L61 or Heater Hose Replacement Outlet L81 3 Remove the heater inlet hose from the heater core Refer to Heater Hose Replacement Inlet L61 or Heater Hose Replacement Inlet L81 4 Remove the instrument panel retainer Refer to Instrument Panel I P Retainer Replacement in Instrument Panel Gages and Console 5 Remove the shift control bracket Refer to Transmission Shift Control Bracket Replacement in Manual Transmission Getrag 5 Transmission Shift Control Bracket Replacement in Automatic Transaxle AF33 5 Fig 185 Heater Duct Screws amp Heater Core Cover Tycoon 15 mexa6pa 2008 r 11 01 13 Page 215 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Courtesy of GENERAL MOTORS CORP 6 Remove the heater duct screws 7 Remove the heater duct Fig 186 Heater Core Cover Screws amp Evaporator Case Assembly Courtesy of GENERAL MOTORS CORP 8
97. r to Heating Performance Diagnostic Is the repair complete Go to Step 15 Repair the A C performance concern Refer to Air Conditioning A C System Performance Test Is the repair complete Go to Step 15 Repair the recirculation door concern Refer to Air Recirculation Malfunction in HVAC Systems Go to Step 14 2 3 4 7 10 11 12 13 14 Manual Is the repair complete Go to Step 15 Tycoon 15 nexa6pa 2008 r 11 01 06 Page 19 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue 15 Operate the system in order to verify the repair Did you find and correct the condition System OK Go to Step 2 HIGH OR LOW TEMPERATURE CONTROL EFFORT High or Low Temperature Control Effort DEFINITION The temperature control operates with either too much or too little effort Were you sent here from Symptoms or another Go to Symptoms diagnostic table HVAC Systems Manual in HVAC Go to Step 2 Systems Manual Is one of the following a concern of the customer e The temperature control operates with little or no resistance e The HVAC outlet air temperature is constant regardless of the temperature control setting e While driving the vehicle the temperature control setting changes Does the temperature control operate too freely Go to Step 3 Go to Step 7 1 Idle the engine at normal operating temperature 3 2 Cycle the temp
98. rmation Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 103 Blower Motor Electrical Connector amp I P Wire Harness Courtesy of GENERAL MOTORS CORP 16 Disconnect I P harness at blower motor connector 17 Disconnect I P harness at blower motor resistor connector 18 Disconnect I P harness at HVAC module connector Tycoon E 15 geka6pa 2008 r 11 01 10 Page 133 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 104 Defroster Duct amp Retainer Courtesy of GENERAL MOTORS CORP 19 Remove defroster duct to HVAC module nuts and defroster duct 20 Disconnect I P wire harness clips from HVAC module Tycoon 15 nexka6pa 2008 r 11 01 10 Page 134 2005 Mitchell Repair Information Company He 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 105 Metal Bracket amp Nut Courtesy of GENERAL MOTORS CORP 21 Remove left HVAC module to cross car beam stamped metal L type bracket from HVAC module and cross car beam Tycoon 15 neka6pa 2008 r 11 01 10 Page 135 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 106 HVAC Module Bolts amp Cross Car Beam Courtesy of GENERAL MOTORS CORP 22 Remove remaining HVAC module to cr
99. ront heater outlet hose to the rear and install the clamp at 2 o clock 4 Install the air outlet duct assembly 5 Install the battery box UHFB assembly Refer to Battery Cooling Box procedure in the Electrical Service manual NOTE Refer to FASTENER NOTICE in Cautions and Notices 6 Connect the negative battery cable Tighten Tighten the negative battery cable bolt to 17 N m 13 1b ft 7 Fill the cooling system Refer to Draining and Filling Cooling System in Engine Cooling Tycoon 15 gexa6pa 2008 r 11 01 12 Page 175 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue HEATER HOSE REPLACEMENT OUTLET L61 Removal Procedure Fig 146 Heater Outlet Hose Clamp amp Heater Core Courtesy of GENERAL MOTORS CORP 1 Drain the engine coolant Refer to Draining and Filling Cooling System in Engine Cooling 2 Remove the heater outlet hose clamp from the heater core 3 Remove the heater outlet hose from the heater core Tycoon 15 peka6pa 2008 r 11 01 12 Page 176 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 147 Connecting Heater Inlet amp Outlet Hoses To Thermostat Housing 2 2L Courtesy of GENERAL MOTORS CORP 4 Remove the heater outlet hose clamp from the engine 5 Remove the heater outlet hose from the engine
100. rotective caps to RD and TXV to prevent contamination and desiccant saturation Installation Procedure Tycoon 15 geka6pa 2008 r 11 01 09 Page 87 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 58 Liquid Line Nut amp Receiver Dehydrator Courtesy of GENERAL MOTORS CORP 1 Remove protective cap from RD and RD end of liquid line and install new seal washer Refer to Sealing Washer Replacement 2 Feed RD end of liquid line down front of shock tower beneath the surge return hose and under negative battery cable and battery box 3 From headlamp opening guide RD end of liquid line to RD fitting and install nut NOTE Refer to FASTENER NOTICE in Cautions and Notices 4 Install liquid line nut using a large pair of pliers hold fitting while tightening Be careful not to twist line Tighten Tighten the nut to 16 N m 12 lb ft Tycoon 15 nexa6pa 2008 r 11 01 09 Page 88 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 59 Liquid Line Nut amp TXV Courtesy of GENERAL MOTORS CORP 5 Remove protective cap from TXV and TXV end of liquid line install new seal washers Refer to Sealing Washer Replacement 6 Install liquid line to TXV with nut Tighten Tighten the nut to 16 N m 12 lb ft Tycoon 15 nexa6pa 2008 r 11 01 09 i
101. s condition will be most noticeable at low ambients This condition could create a compressor cycling complaint due to the Evaporator Low Ambient Protection ELAP cycling the compressor to prevent evaporator freeze On L61 equipped vehicles this cycling condition may not be duplicated in the service stall testing Replace the compressor After the repair return to the diagnostic flow chart Degrees If the ambient air temperature is Suction and the low side gage should read Discharge and the high side gage should read Outlet and the right center air temperature should be Specific System Condition TXV Open 21 43 C 70 110 F _ Normal to Slightly High Normal to Slightly High Key e Higher than normal suction pressure e Higher than normal outlet temperature e Hissing or gurgling noise may be observed near the TXV Tycoon 15 gekaOpa 2008 r 11 01 06 Page 15 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Then The thermal expansion valve TXV may be open e Replace the TXV e After the repair return to the diagnostic flow chart Degrees If the ambient air temperature is Suction and the low side gage should read Discharge and the high side gage should read Outlet and the right center air temperature should be Specific System Condition TXV Restricted or Closed 21 43 C 70 110 F Low
102. s upon adequate front air flow Tycoon 15 mexa6pa 2008 r 11 01 06 Page 5 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue 1 Inspect air deflector A C condenser splash shield condenser to radiator seal and rear hood seal for missing or damaged parts 2 Inspect outer surfaces of radiator and condenser cores to be sure air flow is not blocked by dirt leaves or other foreign material 3 Inspect for kinks in hoses and lines Also inspect for refrigerant leaks using a blacklight or an electronic leak detector Inspect for worn loose drive belt or malfunctioning belt tensioner Inspect blower motor operation at all speeds With blower on high inspect for equal distribution of air from all outlets Inspect operation of mode control knob and distribution of air from designated outlets PS Press recirc button with blower on high A noticeable increase in air flow and sound should occur Indicator should light 9 Start engine and run until it is up to operating temperature 10 Inspect operation of temperature control knob and air outlet temperature from hot to cold Tycoon 15 gexa6pa 2008 r 11 01 06 Page 6 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 1 Identifying Air Conditioning Compressor Pulley Courtesy of GENERAL MOTORS CORP 1
103. ssor Hose Bolt Compressor O Rings amp Protective Cap Courtesy of GENERAL MOTORS CORP 1 Install new seal washers to the TXV and the condenser ends of the compressor hose Refer to Sealing Washer Replacement Position the compressor hose in the vehicle Remove the protective cap from the compressor Install new O rings to the compressor Refer to O Ring Replacement ee oS Install the compressor hose to the compressor NOTE Refer to FASTENER NOTICE in Cautions and Notices 6 Install the compressor hose bolt to the compressor Tighten Tighten the bolt to 27 N m 20 lb ft Tycoon 15 nexa6pa 2008 r 11 01 08 Page 74 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue 7 Lower vehicle Fig 45 Installing Compressor Hose To Evaporator Hose Courtesy of GENERAL MOTORS CORP 8 On L81 vehicles remove the protective cap from the suction hose jumper 9 Connect the compressor hose to the suction hose jumper 10 Install the compressor hose nut to the suction hose jumper Tighten Tighten the nut to 16 N m 12 lb ft Tycoon 15 mexa6pa 2008 r 11 01 08 Page 75 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 46 Compressor Hose Nut amp TXV Courtesy of GENERAL MOTORS CORP 11 Remove the protective cap from the TXV 12 Install
104. t Recovery and Recharging 16 Test the affected A C joints for leaks using J 39400 A See Special Tools AIR CONDITIONING A C REFRIGERANT PRESSURE SENSOR REPLACEMENT Removal Procedure Tycoon 15 geka6pa 2008 r 11 01 09 Page 109 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 80 Compressor Hose Bolt Compressor O Rings amp Protective Cap Courtesy of GENERAL MOTORS CORP 1 Disconnect pressure sensor electrical connector 2 With open end wrench remove pressure sensor Installation Procedure IMPORTANT Use R 12 refrigerant oil mineral to lubricate O rings Use of R 134a PAG oil will cause premature corrosion of fitting joints 1 Lubricate pressure sensor O ring with mineral oil Refer to O Ring Replacement NOTE Refer to FASTENER NOTICE in Cautions and Notices 2 Hand start pressure sensor onto the pressure port taking care not to pinch the O ring and tighten Tycoon 15 mexa6pa 2008 r 11 01 09 Page 110 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Tighten Tighten the pressure sensor to 10 N m 89 Ib in 3 Connect the engine harness connector to the pressure sensor AIR CONDITIONING A C REFRIGERANT LOW TEMPERATURE SENSOR REPLACEMENT FIRST DESIGN Removal Procedure Fig 81 Refrigerant Low Temperature Sensor amp
105. tch Bolt amp Hold Down Bracket Courtesy of GENERAL MOTORS CORP IMPORTANT It is important to use Saturn Sealant P N 22681632 as a thermal conductive material Failure to use this sealant may affect the function of the switch 4 Clean the thermal switch pocket if necessary 5 Apply thermal switch sealant approximately the size of a pea into the switch pocket 6 Install the thermal switch by pushing the switch into place and wetting out the sealant while holding the switch in place Wipe away any excess sealant NOTE Refer to FASTENER NOTICE in Cautions and Notices 7 Install the thermal switch hold down bracket and bolt Tycoon 15 mexa6pa 2008 r 11 01 08 Page 53 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Tighten Tighten the bolt to 6 N m 53 lb in Fig 26 Clutch Bearing Pulley Assembly amp Hub Courtesy of GENERAL MOTORS CORP IMPORTANT The A C clutch bearing and pulley is a slip fit on the compressor If correctly aligned the pulley should slip on easily If difficulty is encountered install using the pulley installer tool 8 Use J 45504 to align the clutch bearing pulley assembly over the hub See Special Tools Gently tap on the assembly to install Tycoon 15 gexa6pa 2008 r 11 01 08 Page 54 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Ai
106. tilation and Air Conditioning Vue Ce Fig 36 Disassembling Reassembling A C Line Fittings Courtesy of GENERAL MOTORS CORP 1 Disassemble the A C refrigerant components Refer to the appropriate repair procedure e For compression style fittings use a back up wrench on the fitting 2 and loosen the fitting nut 1 e For banjo style fittings remove the bolt retaining the banjo type fitting 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 IMPORTANT Cap or tape the open A C refrigerant components immediately to prevent system contamination Tycoon 15 mexa6pa 2008 r 11 01 08 Page 65 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue 5 6 Cap or tape the A C refrigerant components 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 IMPORTANT DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O ring seal to enter the refrigerant system 4 Lightly coat the n
107. utlet hose to the engine port 2 Install the heater outlet hose clamp to the engine port The clamp should at the 3 o clock position Tycoon 15 peka6pa 2008 r 11 01 12 Page 183 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 154 Heater Outlet Hose Clamp amp Heater Core Courtesy of GENERAL MOTORS CORP 3 Install the heater outlet hose to the heater outlet pipe 4 Install the heater outlet hose clamp to the heater outlet pipe The clamp should at the 9 o clock position Tycoon 15 peKxa6pa 2008 r 11 01 12 Page 184 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 155 Front Heater Outlet Hose To Rear Heater Outlet Hose Courtesy of GENERAL MOTORS CORP Install the front heater outlet hose to the rear heater outlet hose Install the outlet hose splice clamp rearward to splice joint The clamp should at the 9 o clock position Install the battery box Refer to Battery Box Replacement in Battery RO Oe Connect the negative battery cable Refer to Battery Negative Cable Disconnect Connect Procedure in Battery 9 Fill the engine coolant Refer to Draining and Filling Cooling System in Engine Cooling PASSENGER COMPARTMENT AIR FILTER HOUSING REPLACEMENT Removal Procedure Tycoon 15 peka6pa 2008 r 11 01 12 P
108. ved by Saturn See Special Tools The fluorescent dye mixes and flows with the PAG oil throughout the refrigerant system Verifying some passive leaks may require using the J 39400 A even though the A C system contains fluorescent dye See Special Tools The only time that adding additional fluorescent dye is required is after flushing the A C system Fluorescent Leak Detector Fluorescent dye will assist in locating any leaks in the A C system IMPORTANT PAG oil is water soluble e Condensation on the evaporator core or the refrigerant lines may wash the PAG oil and fluorescent dye away from the actual leak Condensation may also carry dye through the HVAC module drain e 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 o All fittings or connections that use seal washers or O rings o All of the A C components o The A C compressor shaft seal o The A C hoses and pressure switches o The HVAC module drain tube if the evaporator core is suspected of leaking o The service port sealing caps The sealing cap is the primary seal for the service ports e Follow the instructions supplied with the J 42220 See Special Tools e To prevent false diagnosis in the future thoroughly clean the residual dye from any area where leaks were found Clean any refrigerant dye on components with brake and choke cleaner Saturn P N 210074
109. with outside ambient temperature 7 Press re circulation button so that indicator light is lit 8 Set temperature knob to full cold position 9 Set mode knob to I P outlet position 10 Set blower to third speed 11 Press A C button 12 Using Tech 2 command fan to HIGH speed 13 Using accelerator pedal increase engine speed to 2 000 RPM and hold 14 Continue running until system pressures and outlet temperature stabilizes Usually 4 to 8 minutes 15 Record A C system pressures and outlet temperature every minute for five minutes 16 Exit out of the scan tool test and return engine to idle 17 Release Tech 2 control of engine cooling fans 18 Compare recorded values to system performance charts then continue down diagnostic flow chart 19 When test is complete re connect the electrical connector for the vehicle TXV temperature sensor AIR CONDITIONING A C SYSTEM PERFORMANCE TEST System Condition Charts Definition and Usage Outlet 21 C CoD 131 186 kPa 19 27 131 186 KPa 19 27 psi 10 oad eae Aot 1 8 C FEC GHeF 46 F i a 15 gekaOpa 2008 r 11 01 06 Page 11 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue 896 1193 kPa 130 173 psi 33 C 90 F 131 186 kPa 19 27 psi mae 167 212 4 990 34 49 F 38 C 100 F 144 193 kPa 21 28 psi ae 211 254 10 C 37 51 F 43 C 110 F 144 193 kPa 21 28 psi
110. xa6pa 2008 r 11 01 11 Page 144 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 115 Heater Outlet Hose Clamp amp Heater Core Courtesy of GENERAL MOTORS CORP 18 Install heater outlet hose to heater core outlet 19 Position the clamp at 9 o clock position using SA9111E See Special Tools Tycoon 15 nexka6pa 2008 r 11 01 11 Page 145 2005 Mitchell Repair Information Company He 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 116 Liquid Line Nut amp TXV Courtesy of GENERAL MOTORS CORP 20 Insure mating surfaces are clean and free of debris and install a new seal washer to the liquid line Refer to Sealing Washer Replacement 21 Install the liquid line and nut to the thermal expansion valve TXV Tighten Tighten the nut to 16 N m 12 lb ft Tycoon 15 gexa6pa 2008 r 11 01 11 Page 146 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Fig 117 Compressor Hose Nut amp TXV Courtesy of GENERAL MOTORS CORP 22 Insure mating surfaces are clean and free of debris and install a new seal washer to the suction hose Refer to Sealing Washer Replacement 23 Install the suction hose and nut to the thermal expansion valve TXV Tighten Tighten the nut to 16 N m 12
111. zed into 3 areas e Screeching Squealing Chirping noises e Moaning noises e Vibration Rattle noises 2 1 Start the engine 2 Ensure that the A C is ON Is a screeching squealing noise heard when the A C is engaged Go to Step 3 Go to Step 9 PT With the engine OFF inspect the drive belt for excessive wear Is the drive belt excessively worn Go to Step 18 Go to Step 4 DOO O S k Tycoon 15 peka6pa 2008 r 11 01 06 Page 23 2005 Mitchell Repair Information Company LLC 2003 Saturn Vue 2003 HVAC Heating Ventilation and Air Conditioning Vue Inspect the drive belt tension Refer to ENGINE DRIVE BELT AND TENSIONER TROUBLESHOOTING CHART Is the drive belt tension correct Go to Step 5 Go to Step 19 5 Inspect the drive belt for excessive oil coverage Is the drive belt covered with oil Go to Step 17 Go to Step 6 1 Start the engine 2 Ensure that the A C is ON 3 Inspect the compressor and the clutch Is the A C compressor locked up Go to Step 24 Go to Step 7 Is the A C compressor clutch slipping Go to Step 23 Go to Step 8 CAUTION Refer to MOVING PARTS amp HOT SURFACES CAUTION in Cautions and Notices Using a stethoscope listen to the A C compressor for any abnormal noises Is the compressor causing an abnormal noise Go to Step 15 Go to Step 10 Does a moaning noise exist when the A C clutch is engaged Go to Step 10 Go to Step 12 Listen to the A C compressor components and mountin

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