File in Section:

Service Bulletin

Bulletin No.:
Date:

PI1121
December, 2013

PRELIMINARY INFORMATION
Subject:

A/C Inoperable, Blows Warm Air

Models:

2013-2014 Chevrolet Spark

Condition/Concern
Some customers may comment that the A/C blows warm air or that the A/C is inoperable.
This may be caused by the evaporator freezing, causing poor circulation and/or compressor failure.

Recommendation/Instructions
Prior to performing this PI, be sure the most current version of PI1013 has been performed.
Replace the air conditioning evaporator hose assembly, a new low side pressure switch to the hose and install a new
harness lead following the steps below:
1. Recover the A/C system. Refer to Refrigerant Recovery and Recharging in SI.
2. Remove air conditioning evaporator hose assembly.
2.1. Remove the air inlet snorkel.
2.2. Remove the windshield washer fill tube.
2.3. Remove the radiator surge tank mounting bolts and block heater connecting plug holder (if equipped) and
reposition.

3653927

2.4. Mark each line as shown and using a pipe cutter or suitable tool, cut the A/C evaporator hose for easy
removal.
2.5. Remove the air conditioning evaporator hose assembly nut to air conditioning evaporator thermal
expansion valve.
2.6. Remove the air conditioning evaporator hose assembly nut to air conditioning condenser.
2.7. Remove the air conditioning evaporator hose assembly bolt to air conditioning compressor.
2.8. Remove the air conditioning evaporator hose assembly mounting bracket nuts.
2.9. Remove the air conditioning evaporator hose assembly.
3. Remove the glove box assembly.
4. Remove the front side door sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement.

3653899

3653901

Legend
(1)
(2)

Inline Body Connector
IP connector

5. Under the dash, disconnect the inline body connector and IP connector from the harness and disconnect the
washer hose.

3655568

6. Remove the harness clip shown above.

3650563

7. Locate the harness grommet under the hood and remove from the opening. Pull through the harness and
connectors from the interior of the vehicle.
Important: DO NOT pull the harness through opening by the grommet.

3654455

8. Remove the tape from the harness at the grommet and slide down past the conduit.

3654012

9. With the new supplied harness with the connector shown above, insert the harness with terminal ends through
the center of the grommet and pull through up to the conduit.

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3653894

10. Insert the terminals into IP in-line connector. Refer to the pictures above.
11. Insert the wiring harness back through the I/P opening and install the grommet.

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12. Position the grommet back to its original position and tape the harness to the grommet.
13. Insert the wiring harness back through the I/P opening and install the grommet.

3654460

14. Inside the vehicle, disconnect the EVAP TEMP sensor connector.

3654138

15. With the second part of the new harness kit, install the pigtail connector to the EVAP TEMP sensor connector.

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16. Install the terminals into the FWD in-line connector as shown above.

3653906

17. Wrap sponge tape around the EVAP TEMP connector as shown above.
18. Connect the remaining harness connectors and washer hose and install harness clip.
19. Install the front side door sill trim plate. Refer to Front Side Door Sill Trim Plate Replacement.

3650599

3650597

20. Route the wires along the A/C system wiring harness under the HVAC module assembly and attach with four
evenly spaced zip ties.
21. Secure the wiring harness with tie straps to secure in place.
22. Route the wire harness on the side of the brake pressure modulator and with five or six evenly spaced zip ties
attach to the factory installed harness.
23. Disconnect the left rear (LR) and right rear (RR) brake pipes from the brake pressure modulator valve (BPMV)
and plug the lines and valve.
24. Install the new air conditioning evaporator hose assembly.
24.1. Install the new air conditioning evaporator hose assembly under the brake pipes and place into position.

3653912

24.2. Move the coolant surge tank hose out of the way for clearance to the air conditioning evaporator thermal
expansion valve stud.
Note: Do not install the A/C evaporator hose onto the air conditioning evaporator thermal expansion valve stud yet.
24.3. Install front of the A/C hose past the radiator cross bar support into position.

3653923

24.4. Place the hose into position (with the expansion valve stud in between the lines as shown) and gently pull
back and install onto the air conditioning evaporator thermal expansion valve stud.
24.5. Make sure the front part of the hose is in proper position for compressor mounting and brackets.
24.6. Install the air conditioning evaporator hose assembly nut to air conditioning evaporator thermal expansion
valve.

Tighten
Tighten the nut to 22 Y (16 lb ft).
24.7. Install the air conditioning evaporator hose assembly nut to air conditioning condenser.

Tighten
Tighten the nut to 22 Y (16 lb ft).
24.8. Install the air conditioning evaporator hose assembly bolt to air conditioning compressor.

Tighten
Tighten the bolt to 22 Y (16 lb ft).
24.9. Install the air conditioning evaporator hose assembly mounting bracket nuts.

Tighten
Tighten the nuts to 10 Y (89 lb in).
24.10. Install the radiator surge tank mounting bolts and block heater connecting plug holder (if equipped).

Tighten
Tighten the bolts to 8Y (71 lb in).
24.11. Install the air inlet snorkel.
25. Connect the left rear (LR) and right rear (RR) brake pipes to the brake pressure modulator valve (BPMV).

Tighten
Tighten to 18Y (13 lb ft).

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3654151

26. Install the new low pressure switch to the hose assembly.

Tighten
Tighten to 3-5 Y (26-44 lb in).
27. Connect the new harness connector to the low pressure switch.

3655569

28. Install the C-Clip to the hose assembly.
29. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding.
30. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging in SI.

Parts Information
The parts kit can be obtained from the Warranty Parts Center (WPC). Please use the form at the end of this bulletin
to order the parts.
Part Number

Description

WPC# 739

Air Conditioning Evaporator Hose Assembly, Low Pressure Switch and Wiring
Harness Kit

Warranty Information
For vehicles repaired under warranty, use:
Labor Operation

Description

Labor Time

4480108*

Replace Air Conditioning Evaporator Hose Assembly and Install Switch
and Harness

1.9 hrs

*This is a unique labor operation for bulletin use only. It will not be published in the Labor Time Guide.

Parts Request Form – Warranty Parts Center
Use this form ONLY for U.S., Canadian and Mexico Dealers. Export markets located outside of North America must
contact their regional Technical Assistance Center for assistance.
To: Warranty Parts Center
e-mail: [email protected]
or WPC Fax: 248-371-0192
Attn: Amina Winfrey
Part Being Requested: WPC# 739 Air Conditioning Evaporator Hose Assembly, Low Pressure Switch and Wiring Harness Kit
Dealer BAC (U.S.) /Dealer Code (Canada)/Dealer Number (Mexico):
Dealer Name:
Dealer Address:

Dealer Contact Person:
Dealer Phone Number:
Repair Order Number:
Vehicle VIN:
Important: If you do not receive the part within 2 business days after e-mailing or faxing your part request to the Warranty Parts
Center, please call WPC Customer Assistance at 248-371-9901/9902.