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Home >> Chevrolet >> 2005 >> Aveo Base, 4D Hatchback >> Repair and Diagnosis >> Heating, Ventilation & A/C (HVAC) >> HVAC Control Systems >> Heating, Ventilation And Air Conditioning >> Repair Instructions >> Rear Head, Gasket, Valve Plate and O-Ring Replacement >> Assembly Procedure

Assembly Procedure

  1. Place the rear head on a clean, flat surface. Position the head with the control valve at the 6 o'clock position.
  2. Install the J 34993  in the mounting holes at the 11 o'clock and the 5 o'clock positions. See Special Tools .
  3. Install the head gasket over the J 34993  with the elongated hole at the upper left pin, the 11 o'clock position. See Special Tools .
  4. Install the rear head valve plate over the J 34993  with the elongated hole at the upper left alignment rod. See Special Tools . Lower the rear head valve plate into place.
  5. Install the suction reed plate over the J 34993  . See Special Tools . Remove the alignment rod at the 5 o'clock position.
  6. Lubricate the cylinder to the new rear head O-ring with clean polyalkaline glycol (PAG) refrigerant oil.
  7. Install the O-ring in the cylinder O-ring groove. The O-ring seal surface of the head may be lubricated to ease assembly.
  8. With the O-ring in place on the rear of the cylinder assembly, locate the relief boss for the alignment rod at the 6 o'clock position, directly above the hole in the side of the rear head. Carefully lower the cylinder and the front head assembly over the cylinder alignment rods to the rear head.
  9. Press the cylinder and the compressor housing assembly down onto the rear head using both hands.
    10. NOTE: Refer to Fastener Notice in Cautions and Notices.
  10. Add the new through-bolt gasket to the through-bolts and install it into the compressor assembly. Four of the through-bolts must thread into the rear head before removing the alignment rods.

    Tighten:  Alternately tighten the compressor front head-to-rear head through-bolts in progressive tighten sequence to 10 N.m (89 lb in).

  11. Add new PAG refrigerant oil as determined in Step 1.
  12. Place the shaft nut on the shaft and rotate the compressor shaft several times.
  13. Perform a leak test on the compressor. Refer to Compressor Leak Testing .
  14. Install the clutch coil. Refer to Compressor Clutch Coil Install .
  15. Install the clutch rotor and bearing. Refer to Clutch Rotor and/or Bearing Install .
  16. Install the clutch plate and hub assembly. Refer to Compressor Clutch Plate/Hub Assembly Install .
  17. Install the compressor. Refer to Compressor Replacement .
  18. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .
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