Heating, Ventilation and Air Conditioning Chevrolet Malibu VI

Fastener Tightening Specifications

Fastener Tightening Specifications

Refrigerant System Capacities

Refrigerant System Capacities

The heating, ventilation and air conditioning (HVAC) system is divided into 3 sections. The first, Heating, Ventilation and Air Conditioning, has all procedures that pertain to an HVAC component or function that are not specifically associated with an automatic or manual control system. The 2nd, HVAC Systems-Manual, has all procedures specific to the manual control system. The third, HVAC Systems-Automatic, has all the procedures specific to the automatic control system.

For systems with DTCs, begin the system diagnosis with the following procedure

Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information.

The Diagnostic System Check will provide the following information

1. The identification of the control modules which command the system.
2. The ability of the control modules to communicate through the class 2 or GM LAN serial data circuit.

The use of the Diagnostic System Check will identify and lead the technician to the correct diagnostic procedure.

Review the Description and Operation information to help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. The HVAC Description and Operation information is divided into

1. «Air Delivery Description and Operation»(/chevrolet/malibu/vi-2003-2006/remont/manual-hvac-system/#hvac-systems-manual__air-delivery-description-and-operation) in HVAC Systems-Manual
2. «Air Temperature Description and Operation»(/chevrolet/malibu/vi-2003-2006/remont/manual-hvac-system/#hvac-systems-manual__air-temperature-description-and-operation) in HVAC Systems-Manual
3. «Air Delivery Description and Operation»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#hvac-systems-automatic__air-delivery-description-and-operation) in HVAC Systems-Automatic
4. «Air Temperature Description and Operation»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#hvac-systems-automatic__air-temperature-description-and-operation) in HVAC Systems-Automatic

The Air Delivery Description and Operation contains the following topics

1. HVAC Control Components
2. Air Speed
3. Air Distribution
4. Recirculation Operation
5. Automatic Operation

The Air Temperature Description and Operation contains the following topics

1. HVAC Control Components
2. Heating and A/C Operation
3. Automatic Operation
4. Engine Coolant
5. A/C Cycle

Leak Testing

Tools Required

1. J 39400-A Halogen Leak Detector
2. J 41447 Leak Detection Dye. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. J 42220 Leak Detection Lamp. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. J 43872 Fluorescent Dye Cleaner. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. J 46297 A/C Dye Injector Kit. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. J 46297-12 Replacement Dye Cartridges. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Refrigerant Leak Testing

The fluorescent dye mixes and flows with the polyalkylene glycol (PAG) oil throughout the refrigerant system.

Verifying some passive leaks may require using the J 39400-A , even though the A/C system contains fluorescent dye.

The only time that adding additional fluorescent dye is required is after flushing the A/C system.

Fluorescent Leak Detector

Fluorescent dye will assist in locating any leaks in the A/C system.

1. Condensation on the evaporator core or the refrigerant lines may wash the PAG oil and fluorescent dye away from the actual leak. Condensation may also carry dye through the HVAC module drain.
2. Leaks in the A/C system will be indicated in a light green or yellow color when using the leak detection lamp. Use the leak detection lamp in the following areas: All fittings or connections that use seal washers or O-rings All of the A/C components The A/C compressor shaft seal The A/C hoses and pressure switches The HVAC module drain tube, if the evaporator core is suspected of leaking The service port sealing caps The sealing cap is the primary seal for the service ports.
3. Follow the instructions supplied with the J 42220 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. To prevent false diagnosis in the future, thoroughly clean the residual dye from any area where leaks were found. Use a rag and the approved J 43872 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Fluorescent Dye Injection

1. Not all of the fluorescent dyes are compatible with PAG oil. Some types of dye decrease the oil viscosity or may chemically react with the oil.
2. R-134A leak detection dye requires time to work. Depending upon the leak rate, a leak may not become visible for between 15 minutes and 7 days.
3. To prevent false diagnosis, thoroughly clean any residual dye from the service port with a rag and the approved fluorescent dye cleaner J 43872 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Halogen Leak Detector

Ensure that the vehicle has at least 0.45 kg (1 lb) of refrigerant in the A/C refrigeration system in order to perform a leak test. Refer to Refrigerant Recovery and Recharging for recharging the A/C system.

Clean and dry all surfaces in order to prevent a false warning. Liquids will damage the detector.

Follow the instructions supplied with the J 39400-A .

Air Conditioning (A/C) System Performance Test

This test measures the operating efficiency of the A/C system under the following conditions

1. The current ambient air temperature
2. The current relative humidity
3. The high side pressure of the A/C system
4. The low side pressure of the A/C system
5. The temperature of the air being discharged into the passenger compartment

Test Description

The numbers below refer to the step numbers on the diagnostic table.

1. 1: This step determines if the A/C system has at least the minimum refrigerant charge required to operate the system without damage.
2. 2: This step measures the performance of the A/C system.
3. 3: This step is to allow for vehicle variations as well as high ambient temperatures.

Air Conditioning (A/C) System Performance Test

A/C Performance Table

Scheme 15

Air Conditioning (A/C) Diagnostics - Pressure Zone A

Air Conditioning (A/C) Diagnostics - Pressure Zone A

Air Conditioning (A/C) Diagnostics - Pressure Zone B

Air Conditioning (A/C) Diagnostics - Pressure Zone B

Air Conditioning (A/C) Diagnostics - Pressure Zone C

Air Conditioning (A/C) Diagnostics - Pressure Zone C

Air Conditioning (A/C) Diagnostics - Pressure Zone D

Air Conditioning (A/C) Diagnostics - Pressure Zone D

Heating Performance Diagnostic

Heating Performance Diagnostic

Defrosting Insufficient

Defrosting Insufficient

Noise Diagnosis - Blower Motor

Noise Diagnosis - Blower Motor

Noise Diagnosis - Air Conditioning (A/C) System

Noise Diagnosis - Air Conditioning (A/C) System

Noise Diagnosis - HVAC Module

Noise Diagnosis - HVAC Module

Odor Diagnosis

Odor Diagnosis

Eliminating Air Conditioning Odor

Odors may be emitted from the air conditioning system primarily at start up in hot, humid climates. The following conditions may cause the odor

1. Debris is present in the HVAC module.
2. Microbial growth on the evaporator core

When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. To remove odors of this type, the microbial growth must be eliminated. Perform the following procedure

Deodorize the evaporator core using Deodorizing Aerosol Kit.

Perform the following steps in order to deodorize the A/C system

1. Ensure that the plenum which draws outside air into the HVAC module is clear of debris.
2. Disable the A/C compressor clutch operation by disconnecting the clutch coil electrical connector.
3. Dry the evaporator core by performing the following steps: Start the engine. Select the warmest temperature setting. Select the recirculation mode. Run the blower motor on high for 10 minutes.
4. Locate an area in the air conditioning duct between the blower motor and the evaporator core downstream of the blower motor.
5. Drill a 3.175 mm (0.125 in) hole where the hole will not interfere with or damage the following components: The blower motor The evaporator core Any other operating part the of system
6. Wear safety goggles and latex gloves in order to perform the following actions: Select the maximum blower speed. Insert the deodorizer extension tube into the hole to the mark on the extension tube. Use short spray bursts and vary the direction of spray for a 2-3 minute period of time.
7. Shut the engine OFF. Allow the vehicle to sit for 3-5 minutes.
8. Seal the 3.175 mm (0.125 in) hole with body sealer or RTV gasket compound.
9. Start the engine.
10. Operate the blower motor on high for 15-20 minutes to dry.
11. Reconnect the A/C compressor clutch coil electrical connector.
12. Verify proper clutch operation.

Refrigerant Recovery and Recharging

Tools Required

1. J 43600 ACR 2000 Air Conditioning Service Center. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 45037 A/C Oil Injector. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Note. R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure.

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

Note. Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result.

Note. R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing.

The J 43600 is a complete air conditioning service center for R-134a. See Special Tools and Equipment . The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant.

The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system.

The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain.

Refer to the J 43600 ACR 2000 manual for operation and setup instruction. See Special Tools and Equipment . Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the correct amount.

A/C Refrigerant System Oil Charge Replenishing

If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037 . See Special Tools and Equipment . For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities .

Flushing

Tools Required

1. J 41447 R-134A A/C Tracer Dye Box of 24. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 42220 Universal 12V Leak Detection Lamp. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. J 43600 ACR 2000 Air Conditioning Service Center. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. J 45268 A/C Flush Adapter Kit. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Flushing is intended to remove the following

1. Contaminated polyalkylene glycol (PAG) oil
2. Desiccant, following a desiccant bag failure
3. Overcharge of PAG oil
4. Refrigerant contamination

Forward Flushing Setup

1. Install both J 45268-9 onto J 45268-10.
2. Install J 45268-7 onto suction side of J 45268-10.
3. Install J 45268-8 onto discharge side of J 45268-10.

Reverse Flushing Setup

1. Install both J 45268-9 onto J 45268-10.
2. Install J 45268-8 onto suction side of J 45268-10.
3. Install J 45268-7 onto discharge side of J 45268-10.

Flush Procedure

1. Recover refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove thermal expansion valve (TXV). Refer to «Thermal Expansion Valve Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install TXV stud onto J 45268-115.
4. Install new sealing washers onto evaporator core. Refer to «Sealing Washer Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Install J 45268-115 in place of TXV.
6. Install TXV mounting bolts. Tighten: Tighten bolts to 7 N.m (62 lb in).
7. Install new washers onto liquid line and suction hose. Refer to «Sealing Washer Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
8. Connect liquid line and suction hose to J 45268-115.
9. Install TXV block fitting nut. Tighten: Tighten nut to 27 N.m (20 lb ft).
10. Remove A/C compressor. Refer to «Compressor Replacement (L61)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Compressor Replacement (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
11. Remove A/C refrigerant filter. Refer to «Air Conditioning (A/C) Refrigerant Filter Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
12. Service filter with ACDelco P/N GF 470, before each flush.
13. Install J 45268-10 to compressor hose assembly.
14. Connect J 45268-1 flush filter to J 45268-7 flush adapter.
15. Connect blue hose from J 43600 to J 45268-1 flush filter adapter. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
16. Connect red hose from J 43600 to J 45268-8 flush adapter. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
17. Flush A/C system. Follow instructions supplied with J 43600 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
18. Disconnect red hose from J 43600 to J 45268-8 flush adapter. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
19. Disconnect blue hose from J 43600 to J 45268-1 flush filter adapter. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
20. Disconnect J 45268-1 flush filter from J 45268-10 flush adapter.
21. Remove J 45268-10 from compressor hose assembly.
22. If you will reinstall the removed A/C compressor, perform the following procedure: Remove A/C compressor drain plug. Drain PAG oil from A/C compressor. Rotate compressor input shaft to assist in draining the PAG oil from compressor. Add the total system capacity of PAG oil to A/C compressor. Refer to «Refrigerant System Capacities»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-capacities) . IMPORTANT: Flushing will remove fluorescent leak detection dye from A/C system. Add one bottle of J 41447 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . Install A/C compressor drain plug. Tighten: Tighten drain plug to 15 N.m (11 lb ft).
23. Install A/C compressor. Refer to «Compressor Replacement (L61)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Compressor Replacement (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
24. Install new A/C refrigerant filter. Refer to «Air Conditioning (A/C) Refrigerant Filter Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
25. Remove TXV block fitting nut.
26. Disconnect liquid line and suction line from J 45268-115.
27. Remove TXV bolts retaining J 45268-115.
28. Remove J 45268-115.
29. Inspect TXV for debris. Clean or replace as needed.
30. Install TXV. Refer to «Thermal Expansion Valve Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
31. Evacuate and recharge A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
32. Leak test fittings using J 42220 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Draining Procedure

1. Remove the compressor crankcase oil drain plug and drain the crankcase into a clean, graduated container.
2. Drain the oil from both the suction and discharge ports of the removed compressor into the same container. Rotate the compressor shaft to assist in draining the compressor.
3. Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor.
4. Properly discard the used refrigerant oil.

Balancing Procedure

1. The replacement compressor is shipped with the total system capacity of refrigerant oil.
2. Before installing the compressor, the refrigerant oil will have to be partially drained: Refer to the amount of refrigerant oil recorded during the compressor removal. Subtract the amount recorded from the total system capacity. Refer to «Refrigerant System Capacities»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-capacities) . The difference between the total system capacity and the recorded amount is the calculated amount to be drained from the replacement compressor.
3. Drain the calculated amount of refrigerant oil from the replacement compressor.

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
3. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) .
4. Remove the right radiator air deflector retainers.
5. Remove the right radiator air deflector.
6. Remove the engine drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__drive-belt-replacement) in Engine Mechanical - 2.2L (L61).
7. Remove the compressor hose nut from the compressor.
8. Remove the compressor hose from the compressor.
9. Remove the compressor wire harness connector.
10. Remove the compressor mounting bolts.
11. Remove the compressor.
12. Remove and discard the sealing washers.

Scheme 16

1. If replacing the compressor, refer to «Compressor Oil Balancing»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Uncap A/C components.
3. Install new sealing washers. Refer to «Sealing Washer Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Install the compressor.
5. Install the compressor mounting bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
6. Install the compressor wire harness connector.
7. Install the compressor hose to the compressor.
8. Install the compressor hose nut to the compressor. Tighten: Tighten the nut to 20 N.m (15 lb ft).
9. Install the engine drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__drive-belt-replacement) in Engine Mechanical - 2.2L (L61).
10. Install the right radiator air deflector.
11. Install the right radiator air deflector retainers.
12. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) .
13. Lower the vehicle.
14. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
15. Leak test the fittings using the J 39400-A .

J 39400-A Halogen Leak Detector

1. Recover refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the engine drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) in Engine Mechanical - 3.5L (LX9).
3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
4. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) .
5. Remove the right radiator air deflector retainers.
6. Remove the right radiator air deflector.
7. Remove the compressor hose nut from the compressor.
8. Remove the compressor hose from the compressor.
9. Remove the compressor hose and liquid line bolt from the condenser.
10. Remove the compressor hose from the condenser.
11. Remove the liquid line from the condenser.
12. Remove the compressor wire harness connector.
13. Remove the compressor mounting bolts.
14. Remove the compressor.
15. Remove and discard the sealing washers.

Scheme 17

1. If replacing the compressor, refer to «Compressor Oil Balancing»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Uncap A/C components.
3. Install new sealing washers. Refer to «Sealing Washer Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Install the compressor.
5. Install the compressor mounting bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
6. Install the compressor wire harness connector.
7. Install the liquid line to the condenser.
8. Install the compressor hose to the condenser.
9. Install the compressor hose and liquid line bolt to the condenser. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
10. Install the compressor hose to the compressor.
11. Install the compressor hose nut to the compressor. Tighten: Tighten the nut to 20 N.m (15 lb ft).
12. Install the right radiator air deflector.
13. Install the right radiator air deflector retainers.
14. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) .
15. Lower the vehicle.
16. Install the engine drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) in Engine Mechanical - 3.5L (LX9).
17. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
18. Leak test the fittings using the J 39400-A .

Compressor Clutch Assembly Replacement (L61)

Tools Required

1. J 37872 Universal Spanner Wrench. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 6083 Snap Ring Pliers. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
2. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
3. Remove the right radiator air deflector retainers.
4. Remove the right radiator air deflector.
5. Remove the engine drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__drive-belt-replacement) in Engine Mechanical - 2.2L (L61).
6. Remove the compressor mounting bolts.
7. Remove the compressor from the engine with compressor line attached.
8. Remove and discard the compressor clutch plate bolt. Use the J 37872 to hold the compressor clutch plate from turning. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
9. Remove the compressor clutch plate from the compressor.
10. Remove the compressor pulley snap ring using the J 6083 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
11. Remove the compressor pulley from the compressor.
12. Remove the compressor clutch coil snap ring using the J 6083 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
13. Remove the compressor clutch coil from the compressor.

Installation Procedure

1. Carefully clean the clutch plate bolt threads with a M6x1.0 tap. Carefully blow out debris with compressed air.
2. Install the compressor clutch coil to the compressor.
3. Install the compressor clutch coil snap ring using the J 6083 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Install the compressor pulley to the compressor.
5. Install the compressor pulley snap ring using the J 6083 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. Place a small amount of oil on the 0.4 mm (0.016 in) air gap shim and place inside the clutch drive plate.
7. Install the compressor clutch plate to the compressor.
8. Measure the air gap between the pulley and the drive plate. Adjust the shims to achieve a 0.3-0.6 mm (0.012-0.024 in) air gap.
9. Install the clutch drive plate bolt.
10. Tighten the compressor clutch drive plate bolt. Use the J 37872 to hold the compressor clutch plate from turning. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . Tighten: Tighten the bolt to 12 N.m (106 lb in).
11. Install the compressor to the engine.
12. Install the compressor mounting bolts. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
13. Install the engine drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__drive-belt-replacement) in Engine Mechanical - 2.2L (L61).
14. Install the right radiator air deflector.
15. Install the right radiator air deflector retainers.
16. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
17. Lower the vehicle.

Compressor Clutch Assembly Replacement (LX9)

Tools Required

1. J 37872 Universal Spanner Wrench. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 6083 Snap Ring Pliers. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Remove the engine drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) in Engine Mechanical - 3.5L (LX9).
2. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
3. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
4. Remove the right radiator air deflector retainers.
5. Remove the right radiator air deflector.
6. Remove the compressor mounting bolts.
7. Remove the compressor from the engine with compressor line attached.
8. Remove and discard the compressor clutch plate bolt. Use the J 37872 to hold the compressor clutch plate from turning. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
9. Remove the compressor clutch plate from the compressor.
10. Remove the compressor pulley snap ring using the J 6083 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
11. Remove the compressor pulley from the compressor.
12. Remove the compressor clutch coil snap ring using the J 6083 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
13. Remove the compressor clutch coil from the compressor.

1. Carefully clean the clutch plate bolt threads with a M6x1.0 tap. Carefully blow out debris with compressed air.
2. Install the compressor clutch coil to the compressor.
3. Install the compressor clutch coil snap ring using the J 6083 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Install the compressor pulley to the compressor.
5. Install the compressor pulley snap ring using the J 6083 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
6. Place a small amount of oil on the 0.4 mm (0.016 in) air gap shim and place inside the clutch drive plate.
7. Install the compressor clutch plate to the compressor.
8. Measure the air gap between the pulley and the drive plate. Adjust the shims to achieve a 0.3-0.6 mm (0.012-0.024 in) air gap.
9. Install the clutch drive plate bolt.
10. Tighten the compressor clutch drive plate bolt. Use the J 37872 to hold the compressor clutch plate from turning. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . Tighten: Tighten the bolt to 12 N.m (106 lb in).
11. Install the compressor to the engine.
12. Install the compressor mounting bolts. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
13. Install the right radiator air deflector.
14. Install the right radiator air deflector retainers.
15. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
16. Lower the vehicle.
17. Install the engine drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-35l-lx9) in Engine Mechanical - 3.5L (LX9).

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnect/Connect Procedure»(/chevrolet/malibu/vi-2003-2006/remont/charging-system/#battery-charging-system-and-starting-system) in Engine Electrical.
3. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
4. Remove the compressor pressure relief valve.

1. Install the compressor pressure relief valve. Tighten: Tighten to 8 N.m (70 lb in).
2. Lower the vehicle.
3. Connect the battery negative cable.
4. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
5. Leak test the fittings using the J 39400-A .

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the engine drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__drive-belt-replacement) in Engine Mechanical - 3.5L (LX9).
3. Remove the compressor wire harness connector.
4. Remove the compressor mounting bolts.
5. Remove the compressor from the engine with the compressor line attached.
6. Remove the compressor pressure relief valve.

1. Install the compressor pressure relief valve. Tighten: Tighten to 8 N.m (70 lb in).
2. Install the compressor to the engine.
3. Install the compressor mounting bolts. Tighten: Tighten to 50 N.m (37 lb ft).
4. Install the compressor wire harness connector.
5. Install the engine drive belt. Refer to «Drive Belt Replacement»(/chevrolet/malibu/vi-2003-2006/remont/mechanical/#engine-mechanical-22l-l61__drive-belt-replacement) in Engine Mechanical - 3.5L (LX9).
6. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
7. Leak test the fittings using the J 39400-A .

1. Remove the seal washer from the A/C refrigerant component.
2. Inspect the seal washer for signs of damage to help determine the root cause of the failure.
3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary.
4. Discard the sealing washer.

1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer.
2. Remove the cap or tape from the A/C refrigerant components.
3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components.
4. Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting.
5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure.

1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure.
2. Remove the O-ring seal from the A/C refrigerant component.
3. Inspect the O-ring seal for signs of damage to help determine the root cause of the failure.
4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary.
5. Cap or tape the A/C refrigerant components.
6. Discard the O-ring seal.

1. Inspect the new O-ring seal for any sign or cracks, cuts, or damage. Replace if necessary.
2. Remove the cap or tape from the A/C refrigerant components.
3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components.
4. Lightly coat the new O-ring seal with mineral base 525 viscosity refrigerant oil.
5. Carefully slide the new O-ring seal onto the A/C refrigerant component.
6. The O-ring seal must be fully seated.
7. Assemble the A/C components. Refer to the appropriate repair procedure.

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Insert 2 small screwdrivers into the 2 slots of the compressor hose and suction line connector and release locking tabs.
3. Remove the compressor hose and suction line connector.
4. Remove the compressor hose from the suction line.
5. Remove and discard the O-rings.
6. Remove the compressor hose bracket bolt.
7. Remove the air cleaner intake duct from the air cleaner assembly. Refer to «Air Cleaner Intake Duct Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls - 2.2L (L61).
8. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
9. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) .
10. Remove the right radiator air deflector retainers.
11. Remove the right radiator air deflector.
12. Remove the liquid line and compressor hose bolt from the condenser.
13. Remove the compressor hose from the condenser.
14. Remove the compressor hose nut from the compressor.
15. Remove the compressor hose from the compressor.
16. Remove the compressor hose from the rail clip.
17. Remove the compressor line.
18. Remove and discard the sealing washers.

Scheme 18

1. Uncap A/C components.
2. Install new sealing washers. Refer to «Sealing Washer Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the compressor line.
4. Install the compressor hose to the rail clip.
5. Install the compressor hose to the compressor.
6. Install the compressor hose nut to the compressor. Tighten: Tighten the nut to 20 N.m (15 lb ft).
7. Install the compressor hose to the condenser.
8. Install the liquid line and compressor hose bolt to the condenser. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
9. Install the right radiator air deflector.
10. Install the right radiator air deflector retainers.
11. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) .
12. Lower the vehicle.
13. Install the air cleaner intake duct to the air cleaner assembly. Refer to «Air Cleaner Intake Duct Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls - 2.2L (L61).
14. Install new O-rings. Refer to «O-Ring Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
15. Install the compressor hose to the suction line.
16. Install the compressor hose and suction line connector.
17. Install the compressor hose bracket bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
18. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
19. Leak test the fitting using the J 39400-A .

J 39400-A Halogen Leak Detector

Scheme 19

Scheme 20

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Insert 2 small screwdrivers into the 2 slots of the compressor hose and suction line connector and release locking tabs.
3. Remove the compressor hose and suction line connector.
4. Remove the compressor hose from the suction line.
5. Remove and discard the O-rings.
6. Remove the compressor hose bracket bolt.
7. Remove the air cleaner intake duct from the air cleaner assembly. Refer to «Air Cleaner Intake Duct Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L (LX9).
8. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
9. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) .
10. Remove the right radiator air deflector retainers.
11. Remove the right radiator air deflector.
12. Remove the liquid line and compressor hose bolt from the condenser.
13. Remove the compressor hose from the condenser.
14. Remove the right lower radiator mounting bracket bolt.
15. Remove the right lower radiator mounting bracket.
16. Remove the compressor hose nut from the compressor.
17. Remove the compressor hose from the compressor.
18. Remove the compressor hose from the rail clip.
19. Remove the compressor line.
20. Remove and discard the sealing washers.

1. Uncap A/C components.
2. Install new sealing washers. Refer to «Sealing Washer Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the compressor line.
4. Install the compressor hose to the rail clip.
5. Install the compressor hose to the compressor.
6. Install the compressor hose nut to the compressor. Tighten: Tighten the nut to 20 N.m (15 lb ft).
7. Install the right lower radiator mounting bracket.
8. Install the right lower radiator mounting bracket bolt. Tighten: Tighten the nut to 60 N.m (44 lb ft).
9. Install the compressor hose to the condenser.
10. Install the liquid line and compressor hose bolt to the condenser. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
11. Install the right radiator air deflector.
12. Install the right radiator air deflector retainers.
13. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) .
14. Lower the vehicle.
15. Install the air cleaner intake duct to the air cleaner assembly. Refer to «Air Cleaner Intake Duct Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-35l-lx9) in Engine Controls - 3.5L (LX9).
16. Install new O-rings. Refer to «O-Ring Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
17. Install the compressor hose to the suction line.
18. Install the compressor hose and suction line connector.
19. Install the compressor hose bracket bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
20. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
21. Leak test the fitting using the J 39400-A .

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Insert 2 small screwdrivers into the 2 slots of the compressor hose and suction line connector and release locking tabs.
3. Remove the compressor hose and liquid line connector.
4. Remove the suction hose from the compressor hose.
5. Remove and discard the O-rings.
6. Remove the surge tank from the surge tank bracket.
7. Remove the suction hose and liquid line nut from the thermal expansion valve (TXV).
8. Remove the suction hose and liquid line from the TXV.
9. Remove the suction hose from the dash clip.
10. Remove the line clip from the dash.
11. Remove the refrigerant pressure sensor wire harness connector.
12. Remove the liquid line bracket bolt.
13. Remove the suction hose.
14. Remove and discard the sealing washers.

1. Uncap A/C components.
2. Install new sealing washers. Refer to «Sealing Washer Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the suction hose.
4. Install the liquid line bracket bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
5. Install the refrigerant pressure sensor wire harness connector.
6. Install the line clip to the dash.
7. Install the suction hose to the dash clip.
8. Install the suction hose and liquid line to the TXV.
9. Install the suction hose and liquid line nut to the TXV. Tighten: Tighten the nut to 20 N.m (15 lb ft).
10. Install new O-rings. Refer to «O-Ring Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
11. Install the suction hose to the compressor hose.
12. Install the compressor hose and liquid line connector.
13. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
14. Leak test the fittings using the J 39400-A .
15. Install the surge tank to the surge tank bracket.

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the refrigerant pressure sensor wire harness connector.
3. Remove the refrigerant pressure sensor.
4. Remove the liquid line bracket bolt.
5. Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls - 2.2L (L61) or «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls - 3.5L (LX9).
6. Remove the surge tank from the surge tank bracket.
7. Remove the suction hose and liquid line nut from the thermal expansion valve (TXV).
8. Remove the suction hose and liquid line from the TXV.
9. Remove the suction hose from the dash clip.
10. Remove the liquid line from the dash clip.
11. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
12. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
13. Remove the right radiator air deflector retainers.
14. Remove the right radiator air deflector.
15. Remove the liquid line and compressor hose bolt from the condenser.
16. Remove the liquid line and compressor hose from the condenser.
17. Remove the liquid line from the rail clip.
18. Lower the vehicle.
19. Remove the liquid line.
20. Remove and discard the sealing washers.

1. Uncap A/C components.
2. Install new sealing washers. Refer to «Sealing Washer Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the liquid line.
4. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
5. Install the liquid line and compressor hose to the condenser.
6. Install the liquid line and compressor hose bolt to the condenser. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
7. Install the liquid line to the rail clip.
8. Install the right radiator air deflector.
9. Install the right radiator air deflector retainers.
10. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
11. Lower the vehicle.
12. Install the suction hose and liquid line to the TXV.
13. Install the suction hose and liquid line nut to the TXV. Tighten: Tighten the nut to 20 N.m (15 lb ft).
14. Install the liquid line to the dash clip.
15. Install the suction hose to the dash clip.
16. Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls - 2.2L (L61) or «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/testing-diagnostics/#engine-control-system-introduction-22l-l61) in Engine Controls - 3.5L (LX9).
17. Install the liquid line bracket bolt. Tighten: Tighten the bolt to 10 N.m (89 lb in).
18. Install the refrigerant pressure sensor. Tighten: Tighten the bolt to 5 N.m (44 lb in).
19. Install the refrigerant pressure sensor wire harness connector.
20. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
21. Leak test the fittings using the J 39400-A .
22. Install the surge tank to the surge tank bracket.

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the surge tank from the surge tank bracket.
3. Remove the suction hose and liquid line nut from the thermal expansion valve (TXV).
4. Remove the suction hose and liquid line from the TXV.
5. Remove the line clip from the dash.
6. Remove the refrigerant filter from the line.
7. Remove and discard the sealing washers.

Scheme 21

1. Uncap A/C components.
2. Install new sealing washers. Refer to «Sealing Washer Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the refrigerant filter into the line.
4. Install the line clip to the dash.
5. Install the suction hose and liquid line to the TXV.
6. Install the suction hose and liquid line nut to the TXV. Tighten: Tighten the nut to 20 N.m (15 lb ft).
7. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
8. Leak test the fittings using the J 39400-A .
9. Install the surge tank to the surge tank bracket.

Suction Screen Installation

Note. Tools Required

J 44551 Suction Screen Kit. See Special Tools and Equipment .

The suction screens are available in 3 different sizes.

1. Insert the J 44551-6 Sizing Tool (1) into the suction hose to select the correct size suction screen.
2. Insert the suction screen into the compressor end of the suction hose.
3. Install the correct mandrel (1) to the J 44551-5 Screen Installation Tool.
4. Install the J 44551-5 (3) over the end of the suction hose and the suction screen (2).
5. Tighten the forcing screw of the J 44551-5. The suction screen is fully installed when the screen is flush with the end of the suction hose fitting.
6. Remove the J 44551-5 from the suction hose.
7. Install the J 44551-1 Suction Screen Notification Label.

1. J 42220 Universal Leak Detection Lamp. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. J 44551 Suction Screen Kit. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Recover the refrigerant from the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the A/C compressor hose assembly bolt.
3. Separate the A/C compressor hose assembly from the A/C compressor.
4. Select the proper size removal tool (1) from the J 44551 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Remove the suction screen using the J 44551-31 Suction Screen Removal Tool. Thread the forcing screw into the suction screen. Tighten the nut on the forcing screw to remove the suction screen.

1. Insert the J 44551-6 Sizing Tool (1) into the suction hose to select the correct size suction screen.
2. Insert the suction screen into the suction hose.
3. Install the J 44551-3 Mandrel (1) to the J 44551-5 Screen Installation Tool.
4. Install the J 44551-5 (3) over the end of the suction hose and the suction screen (2).
5. Tighten the forcing screw of the J 44551-5. The suction screen is fully installed when the screen is flush with the end of the suction hose.
6. Remove the J 44551-5 from the suction hose.
7. Replace the seal washers. Refer to «Sealing Washer Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
8. Install the A/C compressor hose assembly to the A/C compressor.
9. Install the A/C compressor hose assembly bolt. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
10. Evacuate and recharge the A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
11. Leak test the fittings of the component using the J 42220 . See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Service Port Valve Core Replacement

Tools Required

1. J 39400-A Halogen Leak Detector
2. J 46246 Valve Core Removal Tool. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the service port valve core using J 46246 or equivalent. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Install the service port valve core using J 46246 or equivalent. See «Special Tools and Equipment»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . Tighten: Tighten the service port valve core to 2.5 N.m (22 lb in).
2. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
3. Leak test the fittings using the J 39400-A .

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the surge tank from the surge tank bracket.
3. Remove the suction line from the dash clip.
4. Remove the liquid line from the dash clip.
5. Remove the liquid line and suction line nut from the thermal expansion valve (TXV).
6. Remove the suction line from the TXV.
7. Remove the liquid line from the TXV.
8. Remove the TXV screws.
9. Remove the TXV.
10. Remove and discard the sealing washers.

1. Uncap A/C components.
2. Install new sealing washers. Refer to «Sealing Washer Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the TXV.
4. Install the TXV screws. Tighten: Tighten the TXV screws to 7 N.m (62 lb in).
5. Install the liquid line to the TXV.
6. Install the suction line to the TXV.
7. Install the liquid line and suction line nut to the TXV. Tighten: Tighten the nut to 20 N.m (15 lb ft).
8. Install the liquid line to the dash clip.
9. Install the suction line to the dash clip.
10. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
11. Leak test the fittings using the J 39400-A .
12. Install the surge tank to the surge tank bracket.

J 39400-A Halogen Leak Detector

1. Remove the refrigerant pressure sensor wire harness connector.
2. Remove the refrigerant pressure sensor.
3. Remove and discard the O-ring.

1. Install a new O-ring. Refer to «O-Ring Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Install the refrigerant pressure sensor. Tighten: Tighten to 5 N.m (44 lb in).
3. Install the refrigerant pressure sensor wire harness connector.
4. Leak test the fittings using the J 39400-A .

J 39400-A Halogen Leak Detector

Scheme 22

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
2. Remove the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
3. Remove the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
4. Loop a rope around each of the 2 upper tabs of the radiator and tie the rope around the upper tie bar.
5. Remove both upper radiator support bracket bolts.
6. Remove both upper radiator support brackets.
7. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vi-2003-2006/remont/hoistjack/#general-information__lifting-and-jacking-the-vehicle) in General Information.
8. Remove the lower radiator air deflector retainers.
9. Remove the lower radiator air deflector.
10. Remove the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
11. Remove the right radiator air deflector retainers.
12. Remove the right radiator air deflector.
13. Remove the left radiator air deflector retainers.
14. Remove the left radiator air deflector.
15. Remove the liquid line and compressor hose bolt from condenser.
16. Remove the compressor hose from the condenser.
17. Remove the liquid line from the condenser.
18. Remove both lower radiator mounting bracket bolts.
19. Remove both lower radiator mounting brackets.
20. Remove and discard the condenser mounting bolts.
21. Remove and discard the condenser mounting nuts.
22. Push upward on the radiator and downward on the condenser to unsnap the condenser mounting tabs from the radiator clip.
23. Remove the condenser.
24. Remove the upper seal.
25. Remove and discard the sealing washers.

1. Uncap A/C components.
2. Install new sealing washers. Refer to «Sealing Washer Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the upper seal.
4. If replacing the condenser, add the specific amount of PAG® oil directly to the condenser. Refer to «Refrigerant System Capacities»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-capacities) .
5. Install the radiator air side seals onto the condenser mounting tabs on the radiator.
6. Insert condenser mounting tabs into the radiator clips.
7. Install the condenser mounting nuts.
8. Install the condenser mounting bolts. Tighten: Tighten the mounting bolts to 6 N.m (53 lb in).
9. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.
10. The radiator air side seals must be in the proper position for proper airflow.
11. Install both lower radiator mounting brackets.
12. Install both lower radiator mounting brackets bolts. Tighten: Tighten the bolts to 60 N.m (44 lb ft).
13. Install the liquid line to the condenser.
14. Install the compressor hose to the condenser.
15. Install the liquid line and compressor hose bolt to the condenser. Tighten: Tighten the bolt to 20 N.m (15 lb ft).
16. Install the left radiator air deflector.
17. Install the left radiator air deflector retainers.
18. Install the right radiator air deflector.
19. Install the right radiator air deflector retainers.
20. Install the right front fender liner. Refer to «Front Fender Liner Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-body-panels/#body-front-end) in Body Front End.
21. Install the lower radiator air deflector.
22. Install the lower radiator air deflector retainers.
23. Lower the vehicle.
24. Remove the rope attached to the radiator and upper tie bar.
25. Install both upper radiator support brackets.
26. Install both upper radiator support bracket bolts. Tighten: Tighten the bolt to 10 N.m (89 lb in).
27. Install the right headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
28. Install the left headlamp. Refer to «Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement»(/chevrolet/malibu/vi-2003-2006/remont/exterior-lights/#lighting-systems) in Lighting Systems.
29. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-recovery-and-recharging) .
30. Leak test the fittings using the J 39400-A .

Scheme 23

1. Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel (I/P) Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
2. Remove the recirculation actuator wire harness connector.
3. Remove the air temperature actuator wire harness connector.
4. Remove the mode actuator wire harness connector.
5. Remove the blower motor wire harness connector.
6. Remove the blower motor resistor wire harness connector.
7. Remove the left hand side window defogger outlet duct.
8. Remove the lower floor duct push-in fastener.
9. Remove the HVAC module assembly mounting bolts.
10. Remove the HVAC module assembly.

Scheme 24

Scheme 25

1. Install the HVAC module assembly.
2. Install the HVAC module assembly mounting bolts. Tighten: Tighten the bolts to 5 N.m (44 lb in).
3. Install the lower floor duct push-in fastener.
4. Install the left hand side window defogger outlet duct.
5. Install the blower motor resistor wire harness connector.
6. Install the blower motor wire harness connector.
7. Install the mode actuator wire harness connector.
8. Install the air temperature actuator wire harness connector.
9. Install the recirculation actuator wire harness connector.
10. Install the I/P assembly. Refer to «Instrument Panel (I/P) Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.

Scheme 26

Scheme 27

Scheme 28

1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the lower center floor air outlet duct.
3. Remove the upper center floor air outlet duct screws.
4. Remove the upper center floor air outlet duct.
5. Remove the air inlet assembly screws.
6. Remove the air inlet assembly.
7. Remove the air temperature actuator screws.
8. Remove the air temperature actuator.
9. Remove the mode actuator screws.
10. Remove the mode actuator.
11. Drill out the mode valve assembly heat stakes.
12. Remove the mode valve assembly screws.
13. Remove the mode valve assembly.
14. Drill out the lower HVAC module case heat stakes.
15. Remove the lower HVAC module case screws.
16. Remove the lower HVAC module case.
17. Remove the thermal expansion valve screws.
18. Remove the thermal expansion valve.
19. Remove and discard the sealing washers.
20. Remove the evaporator.

Scheme 29

Scheme 30

1. If replacing the evaporator, add the specific amount of PAG® oil directly to the evaporator. Refer to «Refrigerant System Capacities»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-capacities) .
2. Install the evaporator.
3. Install new sealing washers. Refer to «Sealing Washer Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Install the thermal expansion valve.
5. Install the thermal expansion valve screws. Tighten: Tighten the screws to 7 N.m (62 lb in).
6. Install the lower HVAC module case.
7. Install the lower HVAC module case screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
8. Install the mode valve assembly. Install the mode valve assembly screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
9. Install the mode actuator.
10. Install the mode actuator screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
11. Install the air temperature actuator.
12. Install the air temperature actuator screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
13. Install the air inlet assembly.
14. Install the air inlet assembly screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
15. Install the upper center floor air outlet duct.
16. Install the upper center floor air outlet duct screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
17. Install the lower center floor air outlet duct.
18. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

J 38185 Hose Clamp Pliers

1. Drain the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
2. Remove the surge tank from the surge tank bracket.
3. Reposition the heater inlet hose clamp at the heater core using the J 38185 .
4. Reposition the heater inlet hose clamp at the engine using the J 38185 .
5. Remove the heater inlet hose from the heater core.
6. Remove the heater inlet hose from the engine.
7. Remove both heater inlet hose clamps from the heater inlet hose.

1. Install both heater inlet hose clamps to the heater inlet hose.
2. Install the heater inlet hose to the engine.
3. Install the heater inlet hose to the heater core.
4. Reposition the heater inlet hose clamp at the engine using the J 38185 .
5. Reposition the heater inlet hose clamp at the heater core using the J 38185 .
6. Install the surge tank to the surge tank bracket.
7. Fill the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.

J 38185 Hose Clamp Pliers

1. Drain the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
2. Remove the surge tank from the surge tank bracket.
3. Reposition the heater inlet hose clamp at the heater core using the J 38185 .
4. Reposition the heater inlet hose clamp at the engine using the J 38185 .
5. Remove the heater inlet hose from the heater core.
6. Remove the heater inlet hose from the engine.
7. Remove both heater inlet hose clamps from the heater inlet hose.

1. Install both heater inlet hose clamps to the heater inlet hose.
2. Install the heater inlet hose to the engine.
3. Install the heater inlet hose to the heater core.
4. Reposition the heater inlet hose clamp at the engine using the J 38185 .
5. Reposition the heater inlet hose clamp at the heater core using the J 38185 .
6. Install the surge tank to the surge tank bracket.
7. Fill the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.

J 38185 Hose Clamp Pliers

1. Drain the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
2. Remove the surge tank from the surge tank bracket.
3. Reposition the heater outlet hose clamp at the heater core using the J 38185 .
4. Reposition the heater outlet hose clamp at the engine using the J 38185 .
5. Remove the heater outlet hose from the heater core.
6. Remove the heater outlet hose from the engine.
7. Remove both heater outlet hose clamps from the heater outlet hose.

1. Install both heater outlet hose clamps to the heater outlet hose.
2. Install the heater outlet hose to the engine.
3. Install the heater outlet hose to the heater core.
4. Reposition the heater outlet hose clamp at the engine using the J 38185 .
5. Reposition the heater outlet hose clamp at the heater core using the J 38185 .
6. Install the surge tank to the surge tank bracket.
7. Fill the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.

J 38185 Hose Clamp Pliers

1. Drain the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.
2. Remove the surge tank from the surge tank bracket.
3. Reposition the heater outlet hose clamp at the heater core using the J 38185 .
4. Reposition the heater outlet hose clamp at the engine using the J 38185 .
5. Remove the heater outlet hose from the heater core.
6. Remove the heater outlet hose from the engine.
7. Remove both heater outlet hose clamps from the heater outlet hose.

1. Install both heater outlet hose clamps to the heater outlet hose.
2. Install the heater outlet hose to the engine.
3. Install the heater outlet hose to the heater core.
4. Reposition the heater outlet hose clamp at the engine using the J 38185 .
5. Reposition the heater outlet hose clamp at the heater core using the J 38185 .
6. Install the surge tank to the surge tank bracket.
7. Fill the coolant. Refer to «Draining and Filling Cooling System (L61)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) or «Draining and Filling Cooling System (LX9)»(/chevrolet/malibu/vi-2003-2006/remont/cooling-fan/#engine-cooling-system) in Engine Cooling.

Scheme 31

1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the recirculation actuator screws.
3. Remove the recirculation actuator.
4. Remove the air inlet assembly screws.
5. Remove the air inlet assembly.

1. Install the air inlet assembly.
2. Install the air inlet assembly screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
3. Install the recirculation actuator.
4. Install the recirculation actuator screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
5. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Remove the right closeout panel. Refer to «Closeout/Insulator Panel Replacement - Right»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
2. Remove the blower motor resistor wire harness connector.
3. Remove the blower motor resistor screws.
4. Remove the blower motor resistor.

1. Install the blower motor resistor.
2. Tighten the blower motor resistor screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
3. Install the blower motor resistor wire harness connector.
4. Install the right closeout panel. Refer to «Closeout/Insulator Panel Replacement - Right»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.

1. Remove the right closeout panel. Refer to «Closeout/Insulator Panel Replacement - Right»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
2. Remove the blower motor wire harness connector.
3. Cut out the blower motor using a utility knife in the narrow groove of the lower case.
4. Remove the blower motor.

1. Install the motor blower seal.
2. Install the blower motor.
3. Install the blower motor attachment ring if reusing the blower motor.
4. Tighten the blower motor screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
5. Install the blower motor wire harness connector.
6. Install the right closeout panel. Refer to «Closeout/Insulator Panel Replacement - Right»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.

1. Use a small screwdriver and release the 4 tabs.
2. Remove the instrument panel (I/P) air outlet deflector.

Scheme 32

Install the I/P outer deflector.

1. Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel (I/P) Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
2. Disconnect the wire harness clip at the left air outlet duct.
3. Remove the left air outlet duct screws.
4. Remove the left air outlet duct.

1. Install the left air outlet duct.
2. Install the left air outlet duct screws. Tighten: Tighten the left air outlet duct screws to 2.5 N.m (22 lb in).
3. Connect the wire harness clip at the left air outlet duct.
4. Install the I/P assembly. Refer to «Instrument Panel (I/P) Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.

Scheme 33

1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the right hand side window defogger duct screws.
3. Remove the right hand side window defogger duct.
4. Disconnect the wire harness clip at the right air outlet duct.
5. Remove the right air outlet duct screws.
6. Remove the right air outlet duct.

1. Install the right air outlet duct.
2. Install the right air outlet duct screws. Tighten: Tighten the right air outlet duct screws to 2.5 N.m (22 lb in).
3. Connect the wire harness clip at the right air outlet duct.
4. Install the right hand side window defogger duct.
5. Install the right hand side window defogger duct screws. Tighten: Tighten the screws to 2.5 N.m (22 lb in).
6. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the lower center floor air duct push-in fastener.
3. Remove the lower center floor air duct.
4. Remove the upper center floor air duct screws.
5. Remove the upper center floor air duct.

1. Install the upper center floor air duct.
2. Install the upper center floor air duct screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
3. Install the lower center floor air duct.
4. Install the lower center floor air duct push-in fastener.
5. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Remove the instrument panel (I/P) center trim panel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Center»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
2. Remove the center air outlet duct.

1. Install the center air outlet duct.
2. Install the I/P center trim panel. Refer to «Trim Panel Replacement - Instrument Panel (I/P) Center»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.

1. Remove the instrument panel (I/P) pad. Refer to «Trim Pad Replacement - Instrument Panel (I/P)»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
2. Press on the 2 tabs of the windshield defroster duct.
3. Remove the windshield defroster duct.

1. Install the windshield defroster duct.
2. Install the I/P pad. Refer to «Trim Pad Replacement - Instrument Panel (I/P)»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.

1. Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel (I/P) Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
2. Remove the left hand side window defogger duct screws.
3. Remove the left hand side window defogger duct.

1. Install the left hand side window defogger duct.
2. Install the left hand side window defogger duct screws. Tighten: Tighten the screws to 2.5 N.m (22 lb in).
3. Install the I/P assembly. Refer to «Instrument Panel (I/P) Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.

1. Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel (I/P) Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
2. Remove the right hand side window defogger duct screws.
3. Remove the right hand side window defogger duct.

1. Install the right hand side window defogger duct.
2. Install the right hand side window defogger duct screws. Tighten: Tighten the screws to 2.5 N.m (22 lb in).
3. Install the I/P assembly. Refer to «Instrument Panel (I/P) Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.

1. Remove the console. Refer to «Console Replacement»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
2. Remove the left front seat. Refer to «Seat Replacement - Front Bucket»(/chevrolet/malibu/vi-2003-2006/remont/seats/#seat-system) in Seats.
3. Remove the left front carpet retainer. Refer to «Carpet Retainer Replacement - Front»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
4. Remove the left center pillar lower garnish molding. Refer to «Garnish Molding Replacement - Center Pillar Lower»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
5. Remove the floor carpet enough to access the left rear floor duct. Refer to «Carpet Replacement - Front»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
6. Remove the left rear floor duct.

1. Install the left rear floor duct.
2. Install the floor carpet. Refer to «Carpet Replacement - Front»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
3. Install the left center pillar lower garnish molding. Refer to «Garnish Molding Replacement - Center Pillar Lower»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
4. Install the left front carpet retainer. Refer to «Carpet Retainer Replacement - Front»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
5. Install the left front seat. Refer to «Seat Replacement - Front Bucket»(/chevrolet/malibu/vi-2003-2006/remont/seats/#seat-system) in Seats.
6. Install the console. Refer to «Console Replacement»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.

1. Remove the console. Refer to «Console Replacement»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.
2. Remove the right front seat. Refer to «Seat Replacement - Front Bucket»(/chevrolet/malibu/vi-2003-2006/remont/seats/#seat-system) in Seats.
3. Remove the right front carpet retainer. Refer to «Carpet Retainer Replacement - Front»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
4. Remove the right center pillar lower garnish molding. Refer to «Garnish Molding Replacement - Center Pillar Lower»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
5. Remove the front floor carpet enough to access the right rear floor duct. Refer to «Carpet Replacement - Front»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
6. Remove the right rear floor duct.

1. Install the right rear floor duct.
2. Install the front floor carpet. Refer to «Carpet Replacement - Front»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
3. Install the right center pillar lower garnish molding. Refer to «Garnish Molding Replacement - Center Pillar Lower»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
4. Install the right front carpet retainer. Refer to «Carpet Retainer Replacement - Front»(/chevrolet/malibu/vi-2003-2006/remont/exteriorinterior-trim/#interior-trim) in Interior Trim.
5. Install the right front seat. Refer to «Seat Replacement - Front Bucket»(/chevrolet/malibu/vi-2003-2006/remont/seats/#seat-system) in Seats.
6. Install the console. Refer to «Console Replacement»(/chevrolet/malibu/vi-2003-2006/remont/gauges-instrument-panels/#instrument-panel-system-displays-gauges-and-console) in Instrument Panel, Gages and Console.

1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the lower center floor air outlet duct.
3. Remove the upper center floor air outlet duct screws.
4. Remove the upper center floor air outlet duct.
5. Remove the air inlet assembly screws.
6. Remove the air inlet assembly.
7. Remove the air temperature actuator.
8. Remove the air temperature actuator screws.
9. Remove the mode actuator screws.
10. Remove the mode actuator.
11. Drill out the mode valve assembly heat stakes.
12. Remove the mode valve assembly screws.
13. Remove the mode valve assembly.
14. Drill out the lower HVAC module case heat stakes.
15. Remove the lower HVAC module case screws.
16. Remove the lower HVAC module case.
17. Remove the air temperature door.

1. Install the air temperature door.
2. Install the lower HVAC module case.
3. Install the lower HVAC module case screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
4. Install the mode valve assembly. Install the mode valve assembly screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
5. Install the mode actuator.
6. Install the mode actuator screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
7. Install the air temperature actuator.
8. Install the air temperature actuator screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
9. Install the air inlet assembly.
10. Install the air inlet assembly screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
11. Install the upper center floor air outlet duct.
12. Install the upper center floor air outlet duct screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
13. Install the lower center floor air outlet duct.
14. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the lower center floor air outlet duct.
3. Remove the upper center floor air outlet duct screws.
4. Remove the upper center floor air outlet duct.
5. Remove the mode actuator screws.
6. Remove the mode actuator.
7. Drill out the mode valve assembly heat stakes.
8. Remove the valve assembly screws.
9. Remove the valve assembly.

1. Install the valve assembly.
2. Install the valve assembly screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
3. Install the mode actuator.
4. Install the mode actuator screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
5. Install the upper center floor air outlet duct.
6. Install the upper center floor air outlet duct screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
7. Install the lower center floor air outlet duct.
8. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the lower center floor air outlet duct.
3. Remove the upper center floor air outlet duct screws.
4. Remove the upper center floor air outlet duct.
5. Drill out the heater core cover heat stakes.
6. Remove the heater core cover screws.
7. Remove the heater core cover.

1. Install the heater core cover.
2. Install the heater core cover screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
3. Install the upper center floor air outlet duct.
4. Install the upper center floor air outlet duct screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
5. Install the lower center floor air outlet duct.
6. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 34

1. Remove the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the lower center floor air outlet duct.
3. Remove the upper center floor air outlet duct screws.
4. Remove the upper center floor air outlet duct.
5. Drill out the heater core cover heat stakes.
6. Remove the heater core cover screws.
7. Remove the heater core cover.
8. Remove the heater core.

1. Install the heater core.
2. Install the heater core cover.
3. Install the heater core cover screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
4. Install the upper center floor air outlet duct.
5. Install the upper center floor air outlet duct screws. Tighten: Tighten the screws to 1.5 N.m (13 lb in).
6. Install the lower center floor air outlet duct.
7. Install the HVAC module assembly. Refer to «HVAC Module Assembly Replacement»(/chevrolet/malibu/vi-2003-2006/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Special Tools

Special Tools Illustration Tool Number/Description J 6083 Snap Ring Pliers J 37872 Universal Spanner Wrench J 38185 Hose Clamp Pliers J 39400-A Halogen Leak Detector J 41447 R-134A A/C Tracer Dye - Box of 24 J 42220 Universal 12V Leak Detection Lamp J 43600 ACR 2000 Air Conditioning Service Center J 43872 Fluorescent Dye Cleaner J 44551 Suction Screen Kit J 45037 A/C Oil Injector J 45268 A/C Flushing Adapter Kit J 46246 Valve Core Tool J 46297 A/C Dye Injector Kit J 46297-12 Replacement Dye Cartridges

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

See also:
• Diagnostic System Check - Vehicle
• Air Delivery Description and Operation
• Air Temperature Description and Operation
• Air Delivery Description and Operation
• Air Temperature Description and Operation
• Symptoms - HVAC Systems - Manual
• Symptoms - HVAC Systems - Automatic
• Moving Parts and Hot Surfaces Caution
• Too Hot in Vehicle
• Cooling System Description and Operation
• Cooling Fan Inoperative (LX9)
• Cooling Fan Inoperative (L61)
• Engine Fails To Reach Normal Operating Temperature
• HVAC Compressor Clutch Does Not Disengage
• Drive Belt Excessive Wear Diagnosis
• Drive Belt Tensioner Diagnosis
• Drive Belt Tensioner Diagnosis
• Drive Belt Replacement
• Drive Belt Replacement
• Drive Belt Tensioner Replacement
• Vibration Analysis - Engine
• Loss of Coolant
• Oil Leak Diagnosis
• Fluid Leak Diagnosis
• Fastener Notice
• Lifting and Jacking the Vehicle
• Front Fender Liner Replacement
• Battery Negative Cable Disconnect/Connect Procedure
• Air Cleaner Intake Duct Replacement
• Air Cleaner Intake Duct Replacement
• Headlamp Assembly or Headlamp Bulb and/or Cornering, Sidemarker, Park, Turn Signal Bulb Replacement
• Instrument Panel (I/P) Assembly Replacement
• Seat Replacement - Front Bucket
• Carpet Retainer Replacement - Front
• Special Tools and Equipment
• Refrigerant Recovery and Recharging
• Leak Testing
• Air Conditioning (A/C) Diagnostics - Pressure Zone A
• Air Conditioning (A/C) System Performance Test
• Flushing
• Refrigerant System Capacities
• Suction Screen Installation
• Heating Performance Diagnostic
• Compressor Clutch Assembly Replacement (L61)
• Compressor Clutch Assembly Replacement (LX9)