2007 Chevrolet Optra Service & Repair Manual

SECTION : 7D AUTOMATIC TEMPERATURE CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM CAUTION : Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted. TABLE OF CONTENTS SPECIFICATIONS 7D–2 . . . . . . . . . . . . . . . . . . . . . . . . . . Fastener Tightening Specifications 7D–2 . . . . . . . . . . . SCHEMATIC AND ROUTING DIAGRAMS 7D–3 . . . . . A/C Sensors/Defoggers and A/C Compressor Controls Diagram 7D–3 . . . . . . . . . . . . . . . . . . . . . . . . A/C Blower and Motor Controls Diagram 7D–4 . . . . . . DIAGNOSIS 7D–5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL A/C DIAGNOSTICS 7D–5 . . . . . . . . . . . . . . . V5 SYSTEM AIR CONDITIONING AND AUTOMATIC TEMPERATURE CONTROL (ATC) 7D–5 . . . . . . . . . . Self–Diagnostic Circuit Check 7D–5 . . . . . . . . . . . . . . . Automatic Temperature Controller Does Not Operate When Ignition Is ON 7D–6 . . . . . . . . . . . . . . Controller Does Not Illuminate When Light Switch Is ON 7D–7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No Hot Air From Blower 7D–8 . . . . . . . . . . . . . . . . . . . . No Cool Air From Blower 7D–10 . . . . . . . . . . . . . . . . . . Blower Motor Does Not Run At All 7D–12 . . . . . . . . . . Mode Control Do Not Work 7D–14 . . . . . . . . . . . . . . . . Air Source Selection Not Controlled 7D–16 . . . . . . . . . Compressor Magnetic Clutch Does Not Engage 7D–17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DIAGNOSTIC TROUBLE CODES 7D–18 . . . . . . . . . . . . Code 1 – In–Car Sensor Error 7D–18 . . . . . . . . . . . . . Code 2 – Ambient Air Temperature Sensor Error 7D–20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Code 3 – Water Sensor Error 7D–22 . . . . . . . . . . . . . . . Code 4 – Air Mix Door Error 7D–24 . . . . . . . . . . . . . . . . Code 5 – Sun Sensor Error 7D–27 . . . . . . . . . . . . . . . . Code 6 – Power Transistor Error 7D–29 . . . . . . . . . . . . Code 7 – Max–Hi Relay Error 7D–31 . . . . . . . . . . . . . . MAINTENANCE AND REPAIR 7D–32 . . . . . . . . . . . . . . ON–VEHICLE SERVICE 7D–32 . . . . . . . . . . . . . . . . . . . . GENERAL A/C SYSTEM SERVICE PROCEURES 7D–32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Service Procedures 7D–32 . . . . . . . . . . . . . . . SERVICEABLE COMPONENTS 7D–33 . . . . . . . . . . . . . Common HVAC Components 7D–33 . . . . . . . . . . . . . . . Automatic Temperature Control Assembly 7D–33 . . . . Inlet Air Door Motor 7D–34 . . . . . . . . . . . . . . . . . . . . . . . Mode Door Motor 7D–35 . . . . . . . . . . . . . . . . . . . . . . . . . Air Mix Door Motor 7D–35 . . . . . . . . . . . . . . . . . . . . . . . . Water Sensor 7D–36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ambient Air Temperature Sensor 7D–36 . . . . . . . . . . . In–Car Temperature Sensor 7D–37 . . . . . . . . . . . . . . . . Sun Sensor 7D–37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNIT REPAIR 7D–39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V5 AIR CONDITIONING COMPRESSOR OVERHAUL 7D–39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Overhaul 7D–39 . . . . . . . . . . . . . . . . . . . . . GENERAL DESCRIPTION AND SYSTEM OPERATION 7D–40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 7D–40 . . . . . . . . . . . . . . . . . . The V5 System 7D–40 . . . . . . . . . . . . . . . . . . . . . . . . . . . System Components – Control 7D–40 . . . . . . . . . . . . .

7D – 2IAUTOMATIC TEMPERATURE CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM DAEWOO V–121 BL4 SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application NSm Lb–Ft Lb–In Blower Motor Resistor Screws 1.2 – 11 Control Assembly Retaining Screws 2 – 18

AUTOMATIC TEMPERATURE CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7D – 3 DAEWOO V–121 BL4 SCHEMATIC AND ROUTING DIAGRAMS A/C SENSORS/DEFOGGERS AND A/C COMPRESSOR CONTROLS DIAGRAM

7D – 4IAUTOMATIC TEMPERATURE CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM DAEWOO V–121 BL4 A/C BLOWER AND MOTOR CONTROLS DIAGRAM

AUTOMATIC TEMPERATURE CONTROL HEATING, VENTILATION, AND AIR CONDITIONING SYSTEM 7D – 5 DAEWOO V–121 BL4 DIAGNOSIS GENERAL A/C DIAGNOSTICS Refer to Section 7B, Manual Control Heating, Ventilation, and Air Conditioning System for details of the following procedures: S A/C Performance Test. S Insufficient Cooling ”Quick Check” Procedure. S Insufficient Cooling Diagnosis. S Leak Testing the Refrigerant System. S Low– and High–Side Pressure Relationship Chart. S Pressure Test Chart (R–134a System). S Pressure–Temperature Relationship of R–134a. S Testing the Refrigerant System. V5 SYSTEM AIR CONDITIONING AND AUTOMATIC TEMPERATURE CONTROL (ATC) SELF–DIAGNOSTIC CIRCUIT CHECK The Daewoo fully automatic temperature controller (FATC) contains a self–diagnosis function to aid in finding any problem with the system. To enter the diagnostic mode, perform the following procedure: 1. Turn the ignition to ON. 2. Set the temperature control to 26°C (79°F). 3. Within 3 seconds, push the AUTO and the OFF switches simultaneously, more than three times. 4. Count the number of times the temperature indica- tor screen blinks. 5. If there are no error codes set, the screen will not blink. When the controller indicates an error code, proceed to the table for that code. 6. Push the OFF switch to return the controller to its normal functions.

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2007 Chevrolet Optra Service & Repair Manual

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