Malibu 2001-2005

Removal & Installation

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2.2L (L61) Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Recover the refrigerant.
  4.  
  5. Raise the vehicle.
  6.  
  7. Remove the right front fender liner.
  8.  
  9. Remove the right radiator air deflector retainers.
  10.  
  11. Remove the right radiator air deflector.
  12.  
  13. Remove the engine drive belt.
  14.  
  15. Remove the compressor hose nut from the compressor.
  16.  
  17. Remove the compressor hose from the compressor. Cap A/C components.

    Click image to see an enlarged view

    Fig. Compressor hose, nut, and sealing washers

  18.  
  19. Remove the compressor wire harness connector.
  20.  
  21. Remove the 2 compressor mounting bolts and 1 mounting nut.
  22.  
  23. Remove the compressor.
    NOTE
    Cap all A/C components immediately to prevent system contamination.



    Click image to see an enlarged view

    Fig. A/C compressor and mounting bolts shown

  24.  
  25. Remove and discard the sealing washers
  26.  

To install:


NOTE
If replacing the compressor, refer to Compressor Oil Balancing.

  1. Uncap A/C components.
  2.  
  3. Install new sealing washers.
  4.  
  5. Install the compressor.
  6.  
  7. Install the compressor mounting bolts and tighten to 37 ft. lbs. (50 Nm).
  8.  
  9. Install the compressor wire harness connector.
  10.  
  11. Install the compressor hose to the compressor.
  12.  
  13. Install the compressor hose nut to the compressor and tighten to 15 ft. lbs. (20 Nm).
  14.  
  15. Install the engine drive belt.
    WARNING
    Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur.

  16.  
  17. Install the right radiator air deflector.
  18.  
  19. Install the right radiator air deflector retainers.
  20.  
  21. Install the right front fender liner.
  22.  
  23. Lower the vehicle.
  24.  
  25. Evacuate and charge the A/C system.
  26.  
  27. Leak test the fittings.
  28.  

2.2L Engine




WARNING
Before beginning this procedure, refer to the precautions at the beginning of this section. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

  1. Recover the refrigerant.
  2.  
  3. Raise the vehicle.

    Click image to see an enlarged view

    Fig. Remove the right front fender liner

  4.  
  5. Remove the right front fender liner.
  6.  
  7. Remove the right radiator air deflector retainers.
  8.  
  9. Remove the right radiator air deflector.
  10.  
  11. Remove the engine drive belt.

    Click image to see an enlarged view

    Fig. Remove the compressor hose nut from the compressor

  12.  
  13. Remove the compressor hose nut from the compressor.
  14.  
  15. Remove the compressor hose from the compressor.
  16.  
  17. Remove the compressor wire harness connector.
  18.  
  19. Remove the compressor mounting bolts.

    Click image to see an enlarged view

    Fig. Remove the compressor

  20.  
  21. Remove the compressor.
    NOTE
    Cap all A/C components immediately to prevent system contamination.

  22.  
  23. Remove and discard the sealing washers.
  24.  

To install:


NOTE
Use a low viscosity, poly-alkylene glycol (PAG) oil. Use of the incorrect oil can result in compressor failure.

  1. Uncap A/C components.
  2.  
  3. Install new sealing washers.
  4.  
  5. Install the compressor.
  6.  
  7. Install the compressor mounting bolts, and tighten the bolts to 37 ft. lbs. (50 Nm).
  8.  
  9. Install the compressor wire harness connector.
  10.  
  11. Install the compressor hose to the compressor.
  12.  
  13. Install the compressor hose nut to the compressor, and tighten the nut to 15 ft. lbs. (20 Nm).
  14.  
  15. Install the engine drive belt.
    NOTE
    Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur.

  16.  
  17. Install the right radiator air deflector.
  18.  
  19. Install the right radiator air deflector retainers.
  20.  
  21. Install the right front fender liner.
  22.  
  23. Lower the vehicle.
  24.  
  25. Evacuate and charge the refrigerant system.
  26.  
  27. Leak test the fittings using the special tool J39400-A.
  28.  

3.1L Engine




WARNING
Before beginning this procedure, refer to the precautions at the beginning of this section. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

  1. Recover the refrigerant.
  2.  
  3. Remove the drive belt.
  4.  
  5. Raise the vehicle.
  6.  
  7. Remove the right front fender liner.

    Click image to see an enlarged view

    Fig. Disconnect the electrical connection from the compressor

  8.  
  9. Disconnect the electrical connection from the compressor.

    Click image to see an enlarged view

    Fig. Remove the compressor hose assembly mounting bolt from the compressor

  10.  
  11. Remove the compressor hose assembly mounting bolt from the compressor.
  12.  
  13. Remove the compressor hose assembly from the compressor.
  14.  
  15. Remove and discard the sealing washers.
  16.  
  17. Remove the compressor mounting bolts.

    Click image to see an enlarged view

    Fig. Remove the compressor and the spacer

  18.  
  19. Remove the compressor and the spacer.
  20.  

To install:


NOTE
NEW A/C compressors are shipped WITHOUT poly-alkylene glycol (PAG) oil. Use of the incorrect PAG oil can result in compressor failure.

  1. If a NEW A/C compressor is being installed, add 2 oz (60 ml) of PAG oil to the compressor.
    NOTE
    Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.



    Click image to see an enlarged view

    Fig. Install the compressor crankcase oil drain bolt to the compressor

  2.  
  3. Install the compressor crankcase oil drain bolt to the compressor, and tighten the compressor crankcase oil drain bolt to 15 ft. lbs. (20 Nm).
  4.  
  5. Install the spacer and the compressor.
  6.  
  7. Install the compressor bolts to the engine.
  8.  
  9. Tighten the front upper bolts to 37 ft. lbs. (50 Nm).
  10.  
  11. Tighten the front lower bolt to 37 ft. lbs. (50 Nm).
  12.  
  13. Tighten the bottom bolt to 37 ft. lbs. (50 Nm).
  14.  
  15. Install new sealing washers to the compressor.
  16.  
  17. Install the compressor hose assembly to the compressor.
  18.  
  19. Install the compressor hose assembly bolt to the compressor, and tighten the compressor hose assembly bolt to 24 ft. lbs. (33 Nm).
  20.  
  21. Connect the electrical connection to the compressor.
  22.  
  23. Install the right front fender liner.
  24.  
  25. Lower the vehicle.
  26.  
  27. Install the drive belt.
  28.  
  29. Evacuate and charge the refrigerant system.
  30.  

3.5L (LZ4) & 3.9L (LZ9) Engines



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Recover the refrigerant.
  4.  
  5. Remove the drive belt.
  6.  
  7. Raise and support the vehicle.
  8.  
  9. Remove the right front fender liner.
  10.  
  11. Disconnect the A/C compressor electrical connector.
  12.  
  13. Remove the compressor hose nut from the compressor.
  14.  
  15. Remove the compressor hose from the compressor. Cap A/C components.
  16.  
  17. Remove and discard sealing washers.
  18.  
  19. Remove A/C compressor bolts.
  20.  
  21. Remove the A/C compressor.

    Click image to see an enlarged view

    Fig. A/C compressor mounting view and related parts

  22.  

To install:


NOTE
If replacing the compressor, refer to Compressor Oil Balancing.

  1. Install the A/C compressor.
  2.  
  3. Install A/C compressor mounting bolts and nut tighten to 37 ft. lbs. (50 Nm).
  4.  
  5. Uncap A/C components.
  6.  
  7. Install new sealing washers.
  8.  
  9. Install the compressor hose to the compressor. Tighten the hose mounting nut to 15 ft. (20 Nm).
  10.  
  11. Reconnect the A/C compressor electrical connector.
  12.  
  13. Install the right front fender liner.
  14.  
  15. Lower the vehicle.
  16.  
  17. Install the drive belt.
  18.  
  19. Evacuate and charge the A/C system.
  20.  
  21. Leak test the fittings.
  22.  

3.5L Engine




WARNING
Before beginning this procedure, refer to the precautions at the beginning of this section. Only a MVAC-trained, EPA-certified, automotive technician should service the A/C system or its components.

  1. Recover refrigerant.
  2.  
  3. Remove the engine drive belt.
  4.  
  5. Raise the vehicle.
  6.  
  7. Remove the right front fender liner.
  8.  
  9. Remove the right radiator air deflector retainers.
  10.  
  11. Remove the right radiator air deflector.
  12.  
  13. Remove the compressor hose nut from the compressor.

    Click image to see an enlarged view

    Fig. Remove the compressor hose from the compressor

  14.  
  15. Remove the compressor hose from the compressor.

    Click image to see an enlarged view

    Fig. Remove the compressor hose and liquid line bolt from the condenser

  16.  
  17. Remove the compressor hose and liquid line bolt from the condenser.
  18.  
  19. Remove the compressor hose from the condenser.
  20.  
  21. Remove the liquid line from the condenser.
  22.  
  23. Remove the compressor wire harness connector.
  24.  
  25. Remove the compressor mounting bolts.

    Click image to see an enlarged view

    Fig. Remove the compressor

  26.  
  27. Remove the compressor.
    NOTE
    Cap all A/C components immediately to prevent system contamination.

  28.  
  29. Remove and discard the sealing washers.
  30.  

To install:


NOTE
Use a low viscosity, poly-alkylene glycol (PAG) oil. Use of the incorrect oil can result in compressor failure.

  1. Uncap A/C components.
  2.  
  3. Install new sealing washers.
  4.  
  5. Install the compressor.
  6.  
  7. Install the compressor mounting bolts, and tighten the bolts to 37 ft. lbs. (50 Nm).
  8.  
  9. Install the compressor wire harness connector.
  10.  
  11. Install the liquid line to the condenser.
  12.  
  13. Install the compressor hose to the condenser.
  14.  
  15. Install the compressor hose and liquid line bolt to the condenser, and tighten the bolt to 15 ft. lbs. (20 Nm).
  16.  
  17. Install the compressor hose to the compressor
  18.  
  19. Install the compressor hose nut to the compressor, and tighten the nut to 15 ft. lbs. (20 Nm).
    NOTE
    Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur.

  20.  
  21. Install the right radiator air deflector.
  22.  
  23. Install the right radiator air deflector retainers.
  24.  
  25. Install the right front fender liner.
  26.  
  27. Lower the vehicle.
  28.  
  29. Install the engine drive belt.
  30.  
  31. Evacuate and charge the refrigerant system.
  32.  
  33. Leak test the fittings using the special tool J39400-A .
  34.  

 
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