Malibu 2001-2005

Charging the System

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CAUTION
Refer to the applicable precautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death.


NOTE
Always refer to the underhood HVAC Specification Label for the refrigerant fill specification of the vehicle being serviced.

After all refrigerant system leaks have been repaired and the refrigerant system has been evacuated, a refrigerant charge can be injected into the system. For the proper amount of the refrigerant charge, refer to the underhood HVAC Specification Label.


NOTE
A R-134a refrigerant recovery/recycling/charging station that meets SAE Standard J2210 must be used to charge the refrigerant system with R-134a refrigerant. Refer to the operating instructions supplied by the equipment manufacturer for proper care and use of this equipment.


WARNING
A small amount of refrigerant oil is removed from the A/C system each time the refrigerant system is recovered and evacuated. Before charging the A/C system, you MUST replenish any oil lost during the recovery process. Refer the equipment manufacturer instructions for more information.

  1. Evacuate the refrigerant system as outlined in this section.
  2.  
  3. A manifold gauge set and an R-134a refrigerant recovery/recycling/charging station that meets SAE standard J2210 should be connected to the refrigerant system.
  4.  
  5. Measure the proper amount of refrigerant and heat it to 125° F (52° C) with the charging station. See the operating instructions supplied by the equipment manufacturer for proper use of this equipment.
  6.  
  7. Open both the suction and discharge valves, then open the charge valve to allow the heated refrigerant to flow into the system.
  8.  
  9. When the transfer of refrigerant has stopped, close both the suction and discharge valves.
  10.  
  11. If all of the refrigerant charge did not transfer from the dispensing device, open all of the windows in the vehicle and set the heating-A/C system controls so that the A/C compressor is engaged and the blower motor is operating at its lowest speed setting. Run the engine at a steady high idle (about 1400 rpm). If the A/C compressor does not engage, test the compressor clutch control circuit and repair as required. Open the low-side valve to allow the remaining refrigerant to transfer to the refrigerant system.
    CAUTION
    Take care NOT to open the discharge (high pressure) valve at this time. Failure to follow this warning could result in possible personal injury or death.

  12.  
  13. Disconnect the charging station and manifold gauge set from the refrigerant system service ports.
  14.  
  15. Reinstall the caps onto the refrigerant system service ports.
  16.  


CAUTION
For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained.


WARNING
To avoid system damage use only R-134a dedicated tools when servicing the A/C system.

  1. A complete air conditioning service center for R-134a will be needed.
  2.  
  3. Remove A/C refrigerant system service caps.
  4.  
  5. Attach the high-side hose with the quick disconnect coupler to the high-side fitting of the vehicle's A/C system.
  6.  
  7. Attach the low-side hose with the quick disconnect coupler to the low-side fitting of the vehicle's A/C system.
  8.  
  9. Close the low-side valve on the control panel.
  10.  
  11. Open the high-side valve on the control panel.
  12.  
  13. Refer to the manufacturer's instructions for the charging station in use.
  14.  
  15. Enter the amount of refrigerant needed to charge the A/C system.
  16.  
  17. Install 1.10 lbs. of R-134a refrigerant.
  18.  
  19. Close the high-side valve on the unit's control panel. Both valves should be closed.
  20.  
  21. Start the vehicle and the A/C system.
  22.  
  23. Let the engine run until the readings on the high-side gauge and the low-side gauge stabilize.
  24.  
  25. Compare the readings to the system specifications.
  26.  
  27. Check the evaporator outlet temperature to ensure that the A/C system is operating within the system specifications.
  28.  
  29. Keep the A/C running.
  30.  
  31. Close the high-side coupler valve.
  32.  
  33. Disconnect the high-side hose from the vehicle.
  34.  
  35. Open the high-side and low-side valves on the control panel. The system will quickly draw in refrigerant from both hoses through the low-side hose.
  36.  
  37. Close the low-side coupler valve.
  38.  
  39. Disconnect the low-side hose from the vehicle.
  40.  
  41. Reinstall the caps onto the refrigerant system service ports.
    NOTE
    Any oil removed from the A/C system during the recovery process must be replenished

  42.  

 
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