Subject: | Odor from A/C at Vehicle Start-Up (Remove Debris from Evaporator Case, Disinfect Evaporator or Apply Cooling Coil Coating, and Install Delayed Blower Motor Control Module) |
Models: | 1991-1994 Saturns equipped with A/C |
· This bulletin is being revised to include instructions for using cooling coil coating on A/C evaporators and a new part number for cooling coil coating.
· Depending on part availability, use A/C system disinfectant kit or cooling coil coating when performing the procedures in this bulletin.
· This bulletin supersedes bulletin 92-T-40B, which should be discarded.
A musty odor from A/C system, most noticeable at vehicle start-up.
An unpleasant (musty) odor from A/C outlets at vehicle start-up can be the result of microbial growth on the evaporator core. This bacteria feeds on the organic matter and moisture that is present on the evaporator core.
Remove any debris from evaporator case, clean evaporator with disinfectant or apply cooling coil coating, and install delayed blower motor control module according to the following procedures.
Important: Before installing delayed blower motor control module, the following information on the next page must be explained to the customer .
• | The delayed blower motor control module will not affect normal A/C or blower motor operation. However, the delayed blower motor control module will activate the blower motor on high speed for approximately five minutes, if the A/C compressor clutch has been continuously engaged for four minutes or more. The delayed blower motor control module will wait approximately fifty minutes after the ignition is turned Off before activating the blower motor. It is during this blower run time that condensate, that causes microbial growth, is removed from the evaporator core. The blower motor will be turned On with NO driver input if the conditions as stated above are met. The air rush sound created by the blower motor is noticeable from outside of the vehicle. |
• | The parasitic current draw of the delayed blower motor control module, combined with the blower motor load, will lower the state of charge of the vehicle's battery, and may negatively impact battery life depending on the driving habits of the customer. |
A/C EVAPORATOR DISINFECTING/COOLING COIL COATING APPLICATION
Depending on part availability, use A/C system disinfectant kit or cooling coil coating when performing this procedure.
Before starting procedures, obtain the following equipment and supplies:
• | A/C System Disinfectant Kit (P/N 21030784; P/N 10953503 for Canada) or Cooling Coil Coating (P/N 12346390) |
• | Cleaning Gun, OTC Tool SA9216NE |
Caution: WHEN USING DISINFECTANT KIT (P/N 21030784), ORDINARY SAFETY GLASSES ARE NOT SUFFICIENT. |
• | If using Disinfectant Kit (P/N 21030784; P/N 10953503 for Canada), safety goggles or face shield |
• | If using Disinfectant Kit (P/N 21030784; P/N 10953503 for Canada), National Institute of Occupational Safety and Health (NIOSH) approved acid gas/organic vapor respirator with chlorine dioxide cartridges (3M®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 |
• | If using Cooling Coil Coating (P/N 12346390), safety glasses |
• | Rubber gloves |
• | Pedestal fan |
• | Plug (P/N 21121827) |
• | Adjusting temperature to full hot |
• | Turning RECIRC On |
• | Making sure A/C button is Off |
• | Close all doors and windows |
• | Start engine and allow to reach operating temperature |
• | Allow blower motor to operate on HI blower for 5 minutes, once engine reaches operating temperature |
Important: Use care when removing debris from front of evaporator so no damage is done to the fins.
Tighten
Tighten the blower motor mounting screws to 1.7 N·m (15 lb-in).
Notice: Running the drill bit in more than 4 mm (5/32 in.) can damage the evaporator.
Important: Depending on part availability, two different products may be available for use on A/C evaporators. Select the appropriate procedure to follow based on the product you will be using: |
• | If using the Disinfectant Kit (P/N 21030784; P/N 10953503 for Canada), continue to the "Evaporator Disinfecting Using Disinfectant Kit (P/N 21030784; P/N 10953503 for Canada)" procedure in this bulletin. |
• | If using the Cooling Coil Coating (P/N 12346390), continue to the "Applying Cooling Coil Coating (P/N 12346390) to Evaporator" procedure in this bulletin. |
Perform this procedure only if you are using A/C System Disinfectant Kit (P/N 21030784; P/N 10953503 for Canada).
Caution: THIS PROCEDURE SHOULD ONLY BE PERFORMED ON A COLD CAR. IT HAS BEEN DEMONSTRATED THAT IRRITATING VAPORS WILL BE FORMED IN THE ENGINE COMPARTMENT IF THE DISINFECTANT COMING OUT OF THE DRAIN OUTLET CONTACTS HOT ENGINE COMPONENTS. DISINFECTANT CAN CAUSE SUBSTANTIAL, BUT TEMPORARY EYE INJURY. DO NOT GET DISINFECTANT IN EYES OR ON CLOTHING. WASH THOROUGHLY WITH SOAP AND WATER AFTER HANDLING.
FIRST AID: IF DISINFECTANT GETS INTO EYES, HOLD EYELIDS OPEN AND FLUSH WITH A STEADY, GENTLE STREAM OF WATER FOR 15 MINUTES. OBTAIN MEDICAL ATTENTION IF IRRITATION PERSISTS.Important: Before enabling afterblow function, refer to Customer Information on page 2 of this bulletin and review operation of afterblow function with customer.
Perform this procedure only if you are using Cooling Coil Coating (P/N 12346390).
Caution: COOLING COIL COATING CAN CAUSE 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.• | Adjusting temperature to full hot |
• | Turning RECIRC On |
• | Making sure A/C button is Off |
• | Open windows 1/2 in. and close doors |
• | Start engine and allow to reach operating temperature |
• | Allow blower motor to operate on HI blower for 5 minutes once engine reaches operating temperature |
Important: Before enabling afterblow function, refer to Customer Information on page 2 of this bulletin and review operation of afterblow function with customer.
Important: Before proceeding with the installation of the delayed blower motor control module, make sure the customer is fully aware of its function and operation.
The following parts are required to install the delayed blower motor control module:
Part Number | Description |
---|---|
21031158 | Delayed Blower Motor Control Module Kit |
12112245 | Ring Terminal |
Caution: WHEN PERFORMING SERVICE ON OR AROUND SIR COMPONENTS OR SIR WIRING, FOLLOW THE CAUTIONS AND PROCEDURES IN THE APPROPRIATE YEAR SIR SERVICE MANUAL TO TEMPORARILY DISABLE THE SIR SYSTEM. FAILURE TO FOLLOW THE DISABLE PROCEDURES COULD RESULT IN POSSIBLE AIR BAG DEPLOYMENT, PERSONAL INJURY OR OTHERWISE UNNEEDED SIR SYSTEM REPAIRS.
13.1. | Insert delayed blower motor control module, with pigtail harness end first and hook and loop retainer down, into cavity above forward end of heater duct. |
13.2. | Slide delayed blower motor control module in until rear edge is flush with heater duct edge on driver's side of vehicle. |
13.3. | Press down on blower motor control module to engage hook and loop retainer. (Delayed blower motor control module should fit securely if engagement of hook and loop retainer has been achieved.) |
14.1. | Route delayed blower motor control module pigtail harness between forward edge of heater duct and carpet. |
14.2. | Attach delayed blower motor control module pigtail harness connector to the lower forward edge of the heater duct. Place clip as far forward as possible. |
Notice: To prevent any possibility of a short circuit, replace any tape that is pushed back or removed from any wiring harness that is moved.
Important: For information on splicing wires, refer to "Wire Splicing" instructions in this bulletin.
22.1. | At terminal F7 of IPJB black 46-way connector, splice ORN wire from delayed blower motor control module into ORN wire (circuit 340A-battery feed) from 46-way connector. |
22.2. | At terminal B of IPJB black 6-way connector, splice RED wire from delayed blower motor control module into BRN wire (circuit 50-ignition) from 6-way connector. |
22.3. | At terminal D of IPJB black 6-way connector, locate ORN wire (circuit 52-HVAC blower control switch), and cut wire 51 mm (2 in.) from 6-way connector, then: |
• | Splice BLK/ORN wire from delayed blower motor control module to length of ORN wire (circuit 52) that goes to black IPJB 6-way connector. |
• | Splice TAN/ORN wire from delayed blower motor control module to length of ORN wire (circuit 52) that goes to HVAC blower control switch. |
Tighten
Tighten the ring terminal-to-ground to 2.2 N·m (20 lb-in).
25.1. | At terminal J2B04 of PCM 24-way connector, splice one end of wire to DK BLU wire (circuit 604 [SOHC], 604A [DOHC]-A/C relay control). |
25.2. | Route wire to the IPJB as follows (using electrical tape, spot tape wire to harnesses approximately every 51-77 mm (2-3 in.): |
• | Tape wire to DLC connector harness branch. |
• | From top of I/P, route wire between I/P harness splice packs and I/P harness channel. |
• | Route through conduit on I/P harness at left side bracket of HVAC module. |
• | Reaching through radio opening, pull wire rearward, and spot tape to radio harness. |
• | Route wire downward, forward of I/P carrier radio support bracket. |
• | Follow HVAC module harness branch downward, then rearward to IPJB connector. |
25.3. | Splice wire to WHT wire from delayed blower motor control module and spot tape to HVAC module harness. |
Tighten
Tighten the IPJB connector to IPJB to 6.5 N·m (58lb-in).
Tighten
Tighten the battery cable to 17 N·m (13 lb-ft).
Important: Do not install parts that have been removed, except for black 46-way connector, until correct operation of the delayed blower motor control module has been verified.
Important: For 1992-1994 vehicles, the I/P upper trim panel screw caps are interchangeable.
Tighten
Tighten the battery cable to 17 N·m (13 lb-ft).
With the wiring used in the Saturn vehicles, it is recommended that approved Packard Electric Crimp and Seal Splice Sleeves (or equivalent) be used.
Important: When using the salmon splice sleeve with 0.35 mm2 (22 gage) wire, remove 19 mm (3/4 in.) of insulation. Bend the stripped portion in half to double the thickness of the wire going into the splice sleeve. Twist the stripped, doubled wire and insert into the splice sleeve.
Important: When splicing three wire ends into one splice sleeve, insert one cut wire end from vehicle harness and new splice wire end into one side of the splice sleeve until wires hit stop. Hand crimp using approved crimping tool. Insert remaining cut wire end from vehicle harness into other side of splice sleeve and crimp.
Caution: DO NOT USE A MATCH OR OPEN FLAME TO APPLY HEAT TO SPLICE SLEEVE.
A full functional check of the delayed blower motor control module is required to assure that all electrical connections are connected properly and it is functioning as designed.
Important: Do not disconnect the jumper harness connector from the delayed blower motor control module pigtail connector or system test will not function.
VEHICLE RUNNING, HIGH BLOWER SETTING DOES NOT OPERATE | |
Cause | Solution |
The blower in and blower out wires to the module are not properly connected | Verify that the TAN/ORN wire of delayed blower motor control module is connected to ORN wire (circuit 52) coming from blower fan switch. Verify that the BLK/ORN wire of delayed blower motor control module is connected to ORN wire (circuit 52), connected to wire going to the high-blower relay. |
BLOWER DOES NOT OPERATE AFTER SPECIFIED DELAY TIME (MAKE SURE THAT ALL WIRES TO MODULE ARE PROPERLY CONNECTED. USE A VOLTMETER TO CHECK THAT THE PROPER SIGNAL IS APPLIED TO EACH WIRE.) | |
Cause | Solution |
(Test Mode Only) GRN test wire from delayed blower motor control module is not properly connected to vehicle battery source. | Connect or jumper GRN test wire (pin H) to the vehicle's battery (not ignition). |
Proper signal not received from A/C compressor. | Make sure A/C compressor is connected electrically. Secondly, use a voltmeter to verify that A/C compressor low signal is zero volts when A/C is turned On. |
A/C compressor was not in operation long enough to trigger delayed blower motor control module. | Start engine and turn On A/C. Make sure A/C compressor clutch is continuously engaged for at least four minutes to trigger delayed blower motor control module. For test mode, run A/C for 30 seconds before turning Off engine. |
Part Number | Description |
---|---|
21031158 | Module Kit - Delayed Blower Motor Control |
12112245 | Terminal - Ring |
21030784 | Kit - A/C Disinfectant (P/N 10953503 for Canada) |
12346390 | Coating - A/C Evap Organic Matl Growth Prev |
21121827 | Plug |
To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System as follows: | |||
Case Type | Description | Labor Operation Code | Time |
VW | Disinfect A/C System | T9555 | 1.3 hrs. |
VW | Disinfect A/C System and Install Delayed Blower Motor Control Module | T9709 | 305 hrs. |