ION L4-2.2L VIN F (2004)
Housing Assembly HVAC: All Technical Service Bulletins
A/C - Knobs Won't Rotate/Restricted Air Flow
Bulletin No.: 04-01-38-011
Date: August 09, 2004
TECHNICAL
Subject:
Temperature/Mode Control Knobs May Not Rotate, Air Flow Restricted, or HVAC Mode Door Gasket or Temperature Door Gasket Foam Comes Off
(Replace A/C Evaporator Case/Heater Case Assembly)
Models:
2003-2004 Saturn ION Vehicles Built Up to and Including VIN Breakpoint 4Z211388
Attention:
Fixed Operations Manager and Technician
Condition
Some customers may comment that the heater-ventilation-air conditioning (HVAC) control assembly temperature control knob or the mode control knob
may not rotate or the knob(s) may bind. Customers may also comment that the air flow is restricted or that they cannot shut off the air flow completely
from one or more of the mode positions.
Cause
Important:
For ION vehicles equipped with A/C (RPO C60), the component containing the mode and temperature doors is referred to as the A/C evaporator
case assembly; for vehicles without A/C (RPO C41), this component is referred to as the heater case assembly.
The foam gaskets located on the air conditioning (A/C) evaporator case or heater case assembly mode or temperature doors may have come loose, which
may cause the door(s) to bind. The loose/missing foam gaskets may also allow air to leak past one of the mode doors when that door is closed.
Correction
Evaluate vehicle, and if necessary, replace the A/C evaporator case assembly or heater case assembly with a new A/C evaporator case assembly, P/N
15211498, or heater case assembly, P/N 15211557.
Service Procedure
1.
Verify customer concern. Once customer concern has been verified and it has been determined that the vehicle is within the vehicle identification
number (VIN) range as indicated in this bulletin, proceed to next step.
^
If customer concern cannot be duplicated, collect additional information from the customer regarding their concern. Proceed to "Diagnostic
Starting Point - Heating, Ventilation and Air Conditioning" in the HVAC section of the 2003 or 2004 Saturn ION Service Manual, Vol. 1.
^
If VIN is higher than 4Z211388, proceed to "Diagnostic Starting Point- Heating, Ventilation and Air Conditioning" in the HVAC section of
the 2004 Saturn ION Service Manual, Vol. 1.
2.
Prior to removing the HVAC module assembly, disconnect temperature and mode door cables from temperature cam and mode cam. To
disconnect the mode and temperature cables, refer to "Mode Cam Replacement" procedure in the HVAC section of the 2003 or 2004 Saturn ION
Service Manual, Vol. 1.
3.
Once the cables are disconnected, manually rotate temperature and mode cams.
^
If cams rotate freely, the issue may be caused by either the cables or the HVAC controller. Diagnose and repair as necessary. Refer to
"Symptoms - HVAC Systems - Manual" in the HVAC section of the 2003 or 2004 Saturn ION Service Manual, Vol. 1.
^
If the cam(s) are still binding, proceed to the HVAC module removal procedure in Step 4.
4.
Remove HVAC module assembly. Refer to "HVAC Module Assembly Replacement" procedure in the HVAC section of the 2003 or 2004 Saturn
ION Service Manual, Vol. 1.
Important:
Only the A/C evaporator case assembly or heater case assembly (upper part of HVAC module) need to be replaced. The blower case (lower
