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Eric
Eric, Master Technician/shop foreman
Category: Chevy
Satisfied Customers: 846
Experience:  ASE Master Technician, 25 years experience, Over400 General Motors certifications
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2005 Chevy Cobalt: A/C Leaks on the inside of car..blown..clogged

Customer Question

2005 Chevy Cobalt A/C Leaks on the inside of car, already had the drain tube blown out, don''t know if it is still clogged up or not, need to know how to find it on the vehicle.
Submitted: 8 years ago.
Category: Chevy
Expert:  Eric replied 8 years ago.

Hi, there is a tsb(technical service bulletin) that talks about your concern. This may be the problem.

#05-01-38-016B: Water Leaking on Front Passenger Side Floor of Vehicle, Water Blowing Out of Vents (Seal Heater Core Cover) - (Aug 16, 2006)

Subject:Water Leaking on Front Passenger Side Floor of Vehicle, Water Blowing Out of Vents (Seal Heater Core Cover)

Models:2005-2006 Chevrolet Cobalt
2006 Chevrolet HHR
2005-2006 Pontiac Pursuit (Canada Only)

 


This bulletin is being revised to provide the part number of the screw that is required for the Cobalt and Pursuit models. Please discard Corporate Bulletin Number 05-01-38-016A (Section 01 -- HVAC).


Built Prior to the Following VIN Breakpoints:

Model

VIN Breakpoint

Cobalt/Pursuit

67661747

HHR

6S551004

Condition

Some customers may comment on water leaking on the front passenger side floor of the vehicle. This leak would occur under high ambient temperatures and high humidity situations when the customer has the air conditioning on high. Leaks will appear to be coming from the HVAC module where the heater core cover and lower case come together. Also, some customers may comment on water droplets blowing out of the vents when the A/C is on high.

Cause

This condition may be due to water condensing in the HVAC case that adheres to the upper surface in the tongue and groove area of the lower case and then leaking out.

Correction

Install the foam gasket between the heater core cover and the lower HVAC case at the location of the leak using the procedure listed below.

  1. Remove the right side insulator/closeout panel retainers and the panel, if equipped.
    Object Number:(NNN) NNN-NNNN Size: MF
    Click here for detailed picture of above imageidth=
  2. Remove the 5 screws (1) (HHR) or break the 4 welds (2) (Cobalt/Pursuit) from the heater core cover at the specified locations.
    Object Number:(NNN) NNN-NNNN Size: MF
    Click here for detailed picture of above imageidth=
  3. Carefully pry apart the heater core cover and the lower HVAC case to achieve a 12.7 mm (0.5 in) gap.
    Object Number:(NNN) NNN-NNNN Size: MF
    Click here for detailed picture of above imageidth=

    Object Number:(NNN) NNN-NNNN Size: MF
    Click here for detailed picture of above imageidth=
  4. Install the foam gasket, P/N 15878211, using a flat rigid tool (feeler gauge shown) into the sump area (1) of the heater core cover.
  5. Reassemble the case using the 5 screws that were removed (HHR) or with new screws (Cobalt/Pursuit), P/N 11609829. For Cobalt/Pursuit, add an additional screw (2) at rear of sump area.
  6. Install the right side insulator/closeout panel and retainers, if equipped
  7. Let me know if i can help you further. Please click on accept. Thanks ERic
Customer: replied 8 years ago.
Reply to Eric's Post: I appreciate you taking the time to gather this information for me but i needed to know where to find the drain tube on the vehicle.
Expert:  Eric replied 8 years ago.
The ac drain tube is on passenger side of the firewall, near the bottom behind engine, its tough to see from the top sometimes, it usually has a short rubber hose on it pointing to the ground for drainage. The most likely cause of your concern is not a plugged drain tube, but the tsb i previously gave you. Good Luck, and let me know if i can help you further, thanksEric