DAEWOO NUBIRA 2004 Service Repair Manual

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 29
DAEWOO V–121 BL4
EVAPORATOR CORE
(Left–Hand Drive Shown, Right–Hand Drive
Similar)
Removal Procedure
1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to ”Discharging, Add-
ing Oil, Evacuating, and Charging Procedures for
A/C System” in this section.
3. Remove the heater/air distributor case assembly.
Refer to Section 7A, Heating and Ventilation Sys-
tem.
4. Remove the wiring harness and electrical connec-
tors from the heater/air distributor case assembly.
5. Remove the screws that connect the heater core
housing and the evaporator housing.
6. Remove evaporator core cover screws from the
evaporator core housing.
7. Remove the evaporator core.
Installation Procedure
1. Install the evaporator core into the case.
2. Install the screws on the evaporator core housing.
Tighten
Tighten the evaporator core cover screws to 1.2 NSm
(11 lb–in).

7B – 30IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
3. Install the screws that connect the heater core
housing and the evaporator housing.
Tighten
Tighten the screws to 1.2 NSm (11 lb–in).
4. Connect the wiring harness and electrical connec-
tors to the heater/air distributor case assembly.
5. Install the heater/air distributor case assembly. Re-
fer to Section 7A, Heating and Ventilation System.
6. Evacuate and recharge the A/C system. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.
7. Connect the negative battery cable.
A/C SUCTION HOSE ASSEMBLY
Removal Procedure
1. Disconnect the negative battery cable.
2. Discharge and recover the refrigerant. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.
3. Remove the air cleaner housing bolts and the air
filter housing aseembly.
4. Disconnect the elsctrical connector at the pressure
transducer.
5. Remove the suction hose block retaining nut at the
fire wall.
6. Cap the openings to the expansion valve to prevent
contamination.
7. Remove the suction hose support clamp bolts.
8. Remove the retaining nut from the hose connecting
block and disconnect the air conditioning hose as-
sembly connector block from the compressor.
9. Remove the A/C suction hose assembly.
10. Cap the openings to the compressor to prevent
contamination.

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 31
DAEWOO V–121 BL4
Installation Procedure
1. Position the A/C suction hose into the vehicle.
2. Insert the suction hose block–to–compressor to the
compressor.
Tighten
Tighten the retaining nut at the suction hose block to
33 NSm (24 lb–ft).
3. Install the suction hose support clamp–to–longitudi-
nal member.
Tighten
Tighten the suction hose support clamp–to–longitudi-
nal member bolt to 8 NSm (71 lb–in).
4. Install the suction hose support clamp–to–engine
bracket.
Tighten
(1.4 DOHC, 1.6DOHC only)
Tighten the suction hose support clamp–to–engine
bracket bolt to 4 NSm (35 lb–in).
Tighten
(1.8 DOHC, 2.0 DOHC only)
Tighten the suction hose support clamp–to–engine
bracket bolt to 14 NSm (10 lb–ft).
5. Install the suction hose block–to–expansion valve
retaining nut at the fire wall.
Tighten
Tighten the suction hose block–to–expansion valve
retaining nut to 14 NSm (10 lb–ft).
6. Connect the electrical connector at the pressure
transducer.
7. Install the air cleaner housing bolts and the air filter
housing assembly.
8. Connect the negative battery cable.
9. Evacuate and recharge the A/C system. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.

7B – 32IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
A/C DISCHARGE
HOSE–COMPRESSOR TO
CONDENSER
Removal Procedure
1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to ”Discharging, Add-
ing Oil, Evacuating, and Charging Procedures for
A/C System” in this section.
3. Remove the nut at the discharge hose block con-
nected to compressor.
4. Remove the headlamp housing at the left–hand
side. Refer to Section 9B, Lighting Systems.
5. Remove the nut at the condenser connecting block.
6. Remove the refrigerant discharge hose.
Installation Procedure
1. Install new sealing washers at the compressor con-
necting block end and a new O–ring at the con-
denser connecting block end.
2. Position the hose into the vehicle, and install the
nut at the condenser connecting block.
Tighten
Tighten the refrigerant discharge hose block–to–con-
denser retaining nut to 16 NSm (12 lb–ft).
3. Make the hose connecting the connecting block to
the compressor, and install the retaining nut.
Tighten
Tighten the refrigerant discharge hose block–to–
compressor retaining nut to 33 NSm (24 lb–ft).
4. Connect the negative battery cable.
5. Evacuate and recharge the A/C system. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 33
DAEWOO V–121 BL4
RECEIVER–DRYER
Removal Procedure
1. Disconnect the negative battery cable.
2. Discharge and recover the refrigerant. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.
3. Remove the condenser. Refer to ”Condenser” in
this section.
4. Remove the receiver–dryer–to–condenser pipe
block bolt.
5. Loosen the bolt that secures the receiver–dryer
band clamp.
Notice : Hold the receiver–dryer–to–condenser pipe to
support it so that the pipe is not damaged while being re-
moved from the receiver–dryer.
6. Remove the receiver–dryer by sliding it up and out
of the band clamp.
7. Cap all open connections to prevent contamination.
8. Drain the oil from the receiver–dryer into a graduat-
ed container. Record the amount of oil drained.
9. Discard the used oil.
Installation Procedure
Important : Do not uncap the new receiver–dryer until just
prior to installation.
1. Add the new oil to the new receiver–dryer. Use the
exact amount of oil that you drained from the old
receiver–dryer.
2. Install new O–rings onto the two pipes that connect
to the receiver–dryer.
3. Install the receiver–dryer into the band clamp. Sup-
port the receiver–dryer–to–condenser pipe while
pushing the receiver–dryer downward until the pipe
is fully installed.
4. Tighten the bolt on the band clamp.
Tighten
Tighten the band clamp bolt to 5 NSm (44 lb–in).
5. Install the receiver dryer–to–condenser pipe block
bolt.
Tighten
Tighten the receiver–dryer–to–condenser pipe block
bolt to 5 NSm (44 lb–in).
6. Install the condenser. Refer to ”Condenser” in this
section.
7. Evacuate and recharge the A/C system. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.

7B – 34IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
COMPRESSOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Discharge and recover the refrigerant. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.
3. Remove the discharge hose mounting nut.
4. Lift the discharge hose mounting block and the suc-
tion hose from the compressor.
5. Raise and suitably support the vehicle.
6. Remove the engine under cover. Refer to Section
9N, Frame and Underbody.
7. Remove the accessory drive belt.
8. Disconnect the electrical connector at the compres-
sor.
9. Remove the compressor–to–bracket bolts. (1.4
DOHC shown, others similar)
10. Remove the compressor.
11. Drain the oil from the compressor into a container.
Measure the amount of the oil that is drained. Then
discard the used oil.
Installation Procedure
1. Add oil to the new compressor. Use the exact
amount of oil that you drained from the old com-
pressor.
2. Install the compressor.
3. Install the compressor–to–bracket mounting bolts.
Tighten
(1.4 DOHC, 1.6 DOHC only)
Tighten the upper compressor–to–bracket mounting
bolts(M8) to 25 NSm (18 lb–ft).
Tighten the lower compressor–to–bracket mounting
bolts(M10) to 45 NSm (33 lb–ft).

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 35
DAEWOO V–121 BL4
Tighten
(1.8 DOHC, 2.0 DOHC only)
Tighten the front compressor–to–bracket mounting
bolts to 35 NSm (26 lb–ft).
Tighten the rear compressor–to–bracket mounting
bolts to 20 NSm (15 lb–ft).
4. Install new sealing washers to the suction hose and
the discharge hose mounting.
5. Connect the electrical connector at the compressor.
6. Install the accessory drive belt.
7. Install the engine under cover. Refer to Section 9N,
Frame and Underbody.
8. Lower the vehicle.
9. Place the suction hose into its cavity in the com-
pressor and install the discharge hose mounting
block to clamp it into place. Hold this all together
while tightening the retaining nut.
Tighten
Tighten the refrigerant discharge hose block–to–
compressor retaining nut to 33 NSm (24 lb–ft).
10. Connect the negative battery cable.
11. Evacuate and recharge the A/C system. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.
CONDENSER
Removal Procedure
1. Disconnect the negative battery cable.
2. Discharge and recover the refrigerant. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System”in this section.
3. Remove the front bumper. Refer to Section 9O,
Bumpers and Fascias.
4. Remove the discharge hose block–to–condenser
retaining nut.
5. Remove the discharge hose from the condenser.
6. Remove the liquid pipe block–to–receiver–dryer
cretaining nut.
7. Remove the liquid pipe from the receiver–dryer.

7B – 36IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
8. Remove the condenser mount bolts.
9. Remove the condenser.
10. Cap all the open lines and the fittings to prevent
contamination.
Installation Procedure
1. Position the condenser into the vehicle.
2. Install the condenser mount bolts.
Tighten
Tighten the condenser mount bolts to 4 NSm (35 lb–
in).
3. Install a new O–ring onto the high–pressure pipe
mounting block fitting on the receiver–dryer.
4. Install the liquid pipe into the receiver–dryer.
5. Install the liquid pipe block–to–receiver–dryer re-
taining nut.
Tighten
Tighten the liquid pipe block–to–receiver–dryer re-
taining nut to 14 NSm (10 lb–ft).
6. Install a new O–ring onto the discharge hose con-
necting block fitting.
7. Install the discharge hose fitting into the condenser.
8. Install the discharge hose connecting block–to–con-
denser retaining nut at the condenser connecting
block.
Tighten
Tighten the refrigerant discharge hose block–to–con-
denser retaining nut to 16 NSm (12 lb–ft).
9. Install the front bumper. Refer to Section 9O,
Bumpers and Fascias.
10. Connect the negative battery cable.
11. Evacuate and recharge the A/C system. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.
12. Operate the HVAC control to verify the proper func-
tion of the heating and cooling systems.

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 37
DAEWOO V–121 BL4
UNIT REPAIR
COMPONENT LOCATOR
V5 COMPRESSOR
1. Rear Head Compressor
2. Control Valve O–Ring
3. Rear Head Gasket
4. Valve Plate
5. Suction Reed
6. Clutch Coil
7. Retaining Ring
8. Drive Plate Clutch
9. Pulley Bearing
10. Clutch Hub Key
11. Shaft Nut
12. Seal Retaining Ring
13. Shaft Lip Seal
14. Shaft Seal O–Ring
15. Compressor Housing16. Compressor Control Valve
17. Pulley Bearing–to–Head Retaining Ring
18. Rotor Pulley
19. Through–Bolt
20. Through–Gasket
21. Compressor Housing–to–Cylinder O–Ring
22. Shaft and Guide Pin Assembly Cylinder
23. Rear Head O–Ring
24. Thrust Washer
25. Race
26. Bearing
27. Oil Drain Plug
28. Clutch and Hub Keyway
29. Compressor Shaft

7B – 38IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
V5 AIR CONDITIONING COMPRESSOR OVERHAUL
CLUTCH PLATE AND HUB
ASSEMBLY
Tools Required
J–33013–B Hub and Drive Plate Remover/Installer
J–33022 Shaft Nut Socket
J–33027 Clutch Hub Holding Tool
J–34992 Compressor Holding Fixture
Disassembly Procedure
1. Remove the compressor. Refer to ”Compressor” in
this section.
2. Install the compressor holding fixture J–34992 to
the compressor and hold the compressor holding
fixture using a bench vise.
3. Use the clutch hub holding tool J–33027 to keep
the clutch drive plate and the hub assembly from
turning.
4. Remove the shaft nut using the shaft nut socket
J–33022.
5. Thread the hub and drive plate remover J–33013–B
into the hub. Hold the body of the remover with a
wrench and turn the center screw into the remover
body to remove the clutch drive plate and the hub
assembly.
6. Remove the clutch hub key. Retain the key for as-
sembly.
Assembly Procedure
1. Install the clutch hub key into the hub keyway. Al-
low the key to project approximately 3.2 mm (1/8
inch) out of the keyway. The hub key is curved
slightly to provide an interference fit in the hub key
groove.
2. Be sure the frictional surface of the clutch plate and
the pulley rotor are clean before installing the clutch
drive plate and the hub assembly.
Notice : Do not drive or pound on the clutch hub or the
shaft. Internal damage to the compressor may result.