Cleaning and Cooling Coil Coating Application Procedure

(for both C60 and C68 HVAC Systems)

Before starting the following procedure, obtain the following equipment and supplies:

^ A/C System Cooling Coil Coating (P/N 12346390; P/N 10953503 in Canada)

^ Cleaning Gun, OTC Tool SA9216NE

Caution:
WHEN APPLYING COOLING COIL COATING (P/N 12346390; P/N 10953503 in Canada), ORDINARY SAFETY GLASSES ARE NOT SUFFICIENT.

Safety goggles

^ When applying cooling coil coating (P/N 12346390; P/N 10953503 in Canada), National Institute of Occupational Safety and Health (NIOSH) approved acid gas/organic vapor respirator with chlorine dioxide cartridges (3M(R) P/N 5103-small, 5203-medium, 5303-large), which are to be used with a pre-filter (P/N 5010) and retainer (P/N 501), or equivalents.

^ Rubber gloves

^ Pedestal fan

1. Dry evaporator:

1.1. Adjust HVAC controls to hottest temperature setting.

^ For models with manual HVAC (RPO C60), adjust temperature to full hot (highest setting). Set mode to heater only, turn RECIRC on, and make sure A/C button is off.

^ For models with automatic climate control (RPO C68), adjust temperature to 32°C (90°F) in AUTO mode.

1.2. Set fan control to highest setting (for models with manual HVAC, RPO C60), or AUTO (for models with automatic climate control, RPO C68).

1.3. Close all windows and doors.

1.4. Start engine and allow to reach operating temperature.

1.5. When engine reaches operating temperature, set blower motor to HI for 5 minutes.

2. Raise vehicle on hoist. Refer to "Lifting, Jacking, and Support Points" in the appropriate model year Saturn L-Series Chassis Service Manual.

Caution:
MAKE SURE VEHICLE IS PROPERLY SUPPORTED AND SQUARELY POSITIONED ON HOIST. TO HELP AVOID PERSONAL INJURY, PROVIDE ADDITIONAL SUPPORT TO OPPOSITE END OF VEHICLE THAT COMPONENTS ARE REMOVED FROM.





3. Check the HVAC module drain for blockage. If necessary, clear drain hole with a soft blunt tool such as the eraser end of a pencil.

4. Lower vehicle from hoist.

5. Place a drain pan directly below the HVAC drain to collect disinfectant or cooling coil coating and rinse water runoff.

6. Open all doors and windows in the vehicle.

7. Position pedestal fan so that it provides cross ventilation through the vehicle during the cleaning/coating procedure.

8. Cover interior of vehicle with suitable protective coverings to protect surfaces from overspray.

9. Allow vehicle to cool down before performing cooling coil coating procedure.

Caution:
THE FOLLOWING PROCEDURE SHOULD ONLY BE PERFORMED ON A COLD VEHICLE. IT HAS BEEN DEMONSTRATED THAT IRRITATING VAPORS WILL BE FORMED IN THE ENGINE COMPARTMENT IF THE COOLING COIL COATING COMING OUT OF THE DRAIN OUTLET CONTACTS HOT ENGINE COMPONENTS.

COOLING COIL COATING CAN CAUSE SUBSTANTIAL, BUT TEMPORARY EYE INJURY. DO NOT GET COOLING COIL COATING IN EYES OR ON CLOTHING. WASH THOROUGHLY WITH SOAP AND WATER AFTER HANDLING.

FIRST AID: IF COOLING COIL COATING GETS INTO EYES, HOLD EYELIDS OPEN AND FLUSH WITH A STEADY, GENTLE STREAM OF WATER FOR 15 MINUTES. OBTAIN MEDICAL ATTENTION IF IRRITATION PERSISTS.





10. Remove right side console extension.





11. Remove right side I/P lower dash insulator retainers.

Important:
Steps 11-13 should be skipped if vehicle does not have the I/P lower dash insulator.

12. Pull insulator rearward to detach from forward insulator support.

13. Remove insulator support from front of dash studs by pulling rearward.





14. Remove right side heater duct assembly retainer and remove duct.





15. Locate evaporator access door location on the right side of the module.





16. Using a sharp utility knife, cut through module wall, following inside of raised bead as a guide. The entire area inside the raised lip needs to be cut out. Several passes may be necessary to do this.

Note:
TO AVOID CUTTING INTERNAL COMPONENTS, CUT ONLY INSIDE THE RAISED BEAD AREA. Do not cut through or damage raised bead. This bead will be used as a sealing surface when completing procedure.

17. Carefully clean out any moisture or debris that may be inside the module.

Note:
Use care when cleaning and removing debris around the evaporator to avoid damage to the fins.

18. Put on rubber gloves, safety goggles, and NIOSH approved acid gas/organic vapor respirator.

19. Using cleaning gun, OTC Tool SA9216NE (or equivalent siphon-type parts cleaning spray gun capable of delivering 60 ml (2 ounces) per minute of liquid with shop air at 552-620 kPa [80-90 psi]), insert siphon hose into container of cooling coil coating. Take care to place the bottle in a secure upright position to avoid spilling contents.

20. Regulate shop air to 276-414 kPa (40-60 psi).





21. Insert nozzle tip of spray gun so spray pattern will be parallel to the evaporator face.

22. Apply cooling coil coating using short bursts and rotating the nozzle tip up and down. This will allow for an even distribution and to ensure full coverage of the evaporator.





23. Apply provided sealant in kit to service door at tongue and groove location as shown.

Note:
Proper sealing is important to prevent condensation from leaking into passenger compartment.





24. Install evaporator core service door (P/N 22679783) to module and install screws.

Tighten

Tighten the Evaporator Core Service Door-to-HVAC Module Fasteners to 1 N.m (9 in-lbs).





25. Install right side heater duct assembly and retainer.





26. Install insulator support to front-of-dash studs by sliding forward.

27. Install right side I/P lower dash insulator and retainers.

Important:
Step 27 should be skipped if vehicle does not have the I/P lower dash insulator.

28. Install right side console extension.

29. Allow evaporator core to soak for 15 minutes.

30. Dry evaporator:

30.1. Adjust HVAC controls to hottest temperature setting.

^ For models with manual HVAC (RPO C60), adjust temperature to full hot (highest setting). Set mode to heater only, turn RECIRC on, and make sure A/C button is off.

^ For models with automatic climate control (RPO C68), adjust temperature to 32°C (90°F) in AUTO mode.

30.2. Set fan control to highest setting (for models with manual HVAC, RPO C60), or AUTO (for models with automatic climate control, RPO C68).

30.3. Close doors and open windows 12.7 mm (0.5 in).

30.4. Start engine and allow to reach operating temperature.

30.5. When engine reaches operating temperature, allow blower motor to operate on HI blower for 5 minutes.

31. Properly dispose of cooling coil coating runoff collected in drain pan into approved container.

32. Remove protective coverings from interior of vehicle.

33. Remove pedestal fan from area.