My 2010 Aveo5 AC project

******EDITED 7-18-2012**********
Install cliff notes:
Disconnect the temp control cable down at the heater box and remove it with the HVAC controls.

The air box, right headlight, and right inner fender must come out.

I removed the filler panel above the grill to better see the condenser connections. may not be necessary but I think it was worth it.

The power steering belt does not have an adjustment; the belt needs to be worked off as you turn the pulley. It takes a 3/8" (I think) hex key / allen wrench to turn it.

The main belt adjuster is released with a 12 point (17mm I think) socket. The only way I could get to it was from the bottom.

******END EDIT**********


With the info that 67ss350camaro has posted I've ordered the parts and plan to have Air Conditioning in my heap within a couple of weeks. (depending on work and weather)

I got the HVAC controls from a 2007 sedan yesterday and installed it. A word of advice for anyone else...disconnect the temperature control cable down by the accelerator pedal before trying to get it off the back of the HVAC controls.

My used compressor (supposed to be from a 2010 with 2k miles) should be here today. The compressor bolts and AC lines should be here today or early next week; I picked up the belt, relay, and pressure sensor/switch yesterday. I was able to get all the bolts except for the 3 compressor mounting bolts from my local Ace hardware.

Buying a used compressor and HVAC control with everything else being new, I think is going to put this project at about $600 including having it evacuated, activated, and charged.

My car came with the prep package. I paid about $200 more than the car beside it that didn't have the prep and it was well worth it....providing this project goes as planned.

More to come....and a few pics if I don't get too lazy.

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We like pics. Good luck with the project.

All the parts are here:
1 HVAC control (used from a 2007 Aveo sedan)
1 Compressor with clutch (used from a 2010 Aveo)
1 AC hose GM part # 96940408
1 AC hose GM part # 96802198
1 AC hose GM part # 94831199
1 Belt GM part # 96476110
1 Relay GM part # 96590287
1 AC pressure sensor GM part # 96448991
3 Compressor bolts GM part # 94500308
3 M6X1.0 flange nuts (from Ace hardware)
1 M8X1.25 flange nut (from Ace hardware)
1 M6X1.0 20mm long flange bolt (from Ace hardware)
1 M6X1.0 25mm long flange bolt (from Ace hardware)
1 M8X1.25 35mm long flange bolt (from Ace hardware)
1 10 amp fuse (from the spare slot in the fuse box....need to replace the spare later)

I also picked up some external tooth lock washers from Home Depot. Not sure if I'll use them or not...I probably will.

http://www.aveoforum.com/forum/attac...o-ac-parts-jpg

The lines and compressor are installed. I tried to take a picture of the line routing but my camera battery died. I ended up with an extra M8 nut and short 1 M6 nut so I updated my parts list above.

Parts total is about $550 so I guess I'll be a little over $600 after I get the system charged.

looks like you got it done.. i am not as far along as you, i need to install it all, but decided to maybe not run it.. as i am pulling the power steering out this summer though for added pep. so dont know if i can add ac and delete power steering.

I see you bought everything new except the compressor. Thats about what i did. i appreciate the parts list, if you get a chance, the measure of the compressor bolts would be great. even though you already put them in.

The power steering runs off the water pump completely independent of the AC.

Pretty sure the compressor bolts are M8X1.25 85mm long....not very easy to find in my area.

awesome news there. I thought from the location (because i didnt put it in) that the ac pulley was added to the waterpump/power steering belt... i guess i can put it in and eliminate power steering!

Thanks for the info.. its going back on the list for later this spring.

Just as an FYI, R134a is being phased out, it is already discontinued in the EC countries. GM is going to be using a new refrigerant starting in some models next year. Unlike the R-12 to R134a conversions, they are saying that the new refrigerant will be able to replace R134a in our current systems with no problems but if you weigh charge in like you should anticipate that the charge weights will be different (as in on an R-12 to R134a retrofit the correct 134a charge only weighs 85% what the same volume f R-12 did.)

Well, I almost got the AC charged this morning. Took the heap in for an oil change and AC charge...and I got the oil change. The AC system wouldn't hold a vacuum....I gots a leak.:banghead:


It turned out to be the condenser itself so it will be covered under warranty but it's still a pita. I'll have to try again next week after the condenser comes in.

Quote:

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Originally Posted by wylee

Well, I almost got the AC charged this morning. Took the heap in for an oil change and AC charge...and I got the oil change. The AC system wouldn't hold a vacuum....I gots a leak.:banghead:


It turned out to be the condenser itself so it will be covered under warranty but it's still a pita. I'll have to try again next week after the condenser comes in.

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Any updates ?

Quote:

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Originally Posted by respdoc

Any updates ?

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Yep. I got it fixed under warranty a few days after my last post and have been enjoying the AC the last few days now that summer has finally arrived.

I had intended to post pics but my camera battery died when I was doing the work under the hood.

Install cliff notes:
Disconnect the temp control cable down at the heater box and remove it with the HVAC controls.

The air box, right headlight, and right inner fender must come out.

I removed the filler panel above the grill to better see the condenser connections. may not be necessary but I think it was worth it.

The power steering belt does not have an adjustment; the belt needs to be worked off as you turn the pulley. It takes a 3/8" (I think) hex key / allen wrench to turn it.

The main belt adjuster is released with a 12 point (17mm I think) socket. The only way I could get to it was from the bottom.

Thanks...all the pointers will def come in handy when I attempt the install (not on the car in my profile) but a new 2011 Aveo Sedan :)

I do have a question.

I've been looking around eBay for the replacement HVAC unit and from what I can tell..most of the units seem to have the temp control cables cut (assume it from when they removed them from the donor car)...

For the new install...full, uncut cables on the replacement unit are needed, correct ?

No, you actually want them cut. If they cut them they probably didn't break the clips trying to get the cables out. You will just snap the existing cables into the replacement hvac control.

Quote:

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Originally Posted by wylee

No, you actually want them cut. If they cut them they probably didn't break the clips trying to get the cables out. You will just snap the existing cables into the replacement hvac control.

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Thanks..think I got all the parts narrowed down..besides the compressor. I'm trying to figure out if the one's needed for the 2011's are the same compressors from 09-on.

Ok..wanted to ask if anyone happened to know which A/C compressor does fit a 2011 Aveo Sedan. I did try doing my own research but when I called the dealership they stated they had 8 part numbers for the compressor alone and had no idea without the VIN. Since I'm installing it in a car that originally does not have A/C..that won't help. I even contacted A/C Delco but they again said they did not know since the vehicle did not have A/C to begin with. My best guess is any U.S. unit from 09-on will work..but I'm not 100% sure.

Any help would be appreciated..

Check the GM accessories AC kit. If the part number is the same for 09-11 you should have your answer.

Screw it! I can't get the damn links to work.

According to the GM accessories site, 2010 & 2011 use the same kit. http://www.gmaccessorieszone.com

I'm trying to build up the courage to do this same project.

Quote:

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Originally Posted by wylee

Screw it! I can't get the damn links to work.

According to the GM accessories site, 2010 & 2011 use the same kit. Home

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Thanks..after some more research..found that units made after '09 VIN's of 003693 will work for 10-11's.

where did you find that? thats only 3000 cars into the build year.

what ever you do, do not buy the one that says its cross compatible with a 3800. IT IS NOT THE RIGHT ONE.

but when i bought all my stuff (ac fog lights etc), I went out to the showroom and took the vin off the car that had what i wanted..
the salesmen even let me climb under the aveo to compare engine blocks etc.

Quote:

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Originally Posted by petrified.rabbit

where did you find that? thats only 3000 cars into the build year.
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There were only 3000 Aveo's built in '09 ?

As for the cross-check..I contacted two additional places (one dealership and the other a large salvage yard) which confirmed the same thing. The yard did provide, in writing, that because his system stated it would work..that the part would be covered or my money back. He did also state the '09 VIN's starting before the one I previously posted would not work..so from what I could gather...he seemed to know his stuff.

not 3000 built, but only the first 3000 or so built (each one is numbered) would have a different compressor.

I know when i bought my ac stuff i took pictures at the dealer, and compared those with actuals of the one i was buying.
they listed one that worked in the system but was the wrong compressor for the aveo..

i was just curious what system you were using for verification.

Quote:

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Originally Posted by petrified.rabbit

not 3000 built, but only the first 3000 or so built (each one is numbered) would have a different compressor.

I know when i bought my ac stuff i took pictures at the dealer, and compared those with actuals of the one i was buying.
they listed one that worked in the system but was the wrong compressor for the aveo..

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Ya, that sounds like a mess you had to go thru. I post back when I get the A/C fully installed to confirm it was the right compressor model for anyone else looking at adding it to an '11 model..

Almost finished...anyone know what weight of oil the A/C compressor takes ? (did a search couldn't find the answer )

Update:

Everything installed and working fine...hardest part was getting the dealer to correctly turn on the unit (even after given the instructions).

yeah? what was the hold up with the dealer?

i am going to go get mine turned on next week or the week after. What did they ultimately charge you?
wish i could just do it myself, but gm and their prized computer..

Quote:

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Originally Posted by petrified.rabbit

yeah? what was the hold up with the dealer?

i am going to go get mine turned on next week or the week after. What did they ultimately charge you?
wish i could just do it myself, but gm and their prized computer..

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I have to dig out the paperwork again..but believe it was with the ICS (?) portion of the turn-on. I think if you bring the step-by-step print out of the Tech2 prompts you should be fine. When I made the apoint. my dealer made it sound like they already know what they needed to do, so I didn't bring it...obviously that wasn't the case.

Does anyone know how to remove the trim around the radio? I need to get at the HAVC controls and hate to mess some thing up getting it out. This trim covers the top screws. Thanks

The horseshoe shaped piece? It comes straight out...I'll see if i can find the youtube clip...


Here ya go: http://www.aveoforum.com/forum/f81/s...tml#post159866

Thanks for the infor about the trim worked just fine. Man that trim came out hard.

Quote:

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Originally Posted by wylee

The horseshoe shaped piece? It comes straight out...I'll see if i can find the youtube clip...


Here ya go: http://www.aveoforum.com/forum/f81/s...tml#post159866

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