Heating, Ventilation, and Air Conditioning — Chevrolet Malibu VII (2008-2012)

Fastener Tightening Specifications

Application	Specification
Application	Metric	English
Air Inlet Assembly Screw	1.5 N.m	13 lb in
Air Outlet Duct Screw	2.5 N.m	22 lb in
Blower Motor Resistor Screw	1.5 N.m	13 lb in
Blower Motor Screw	1.5 N.m	13 lb in
Center Floor Air Duct Screw	1.5 N.m	13 lb in
Compressor Clutch Drive Plate Bolt	12 N.m	106 lb in
Compressor Drain Plug	16 N.m	12 lb ft
Compressor Hose Bracket Bolt	10 N.m	89 lb in
Compressor Hose to Compressor Nut	20 N.m	15 lb ft
Compressor Hose to Compressor Stud	10 N.m	89 lb in
Compressor Mounting Bolt LE5, LAT	22 N.m	16 lb ft
Compressor Mounting Bolt LZ4, LZE, LY7	50 N.m	37 lb ft
Compressor Mounting Nut LZ4, LZE, LY7	50 N.m	37 lb ft
Compressor Pressure Relief Valve	8 N.m	70 lb in
Condenser Mounting Bolt	6 N.m	53 lb in
Heater Core Cover Screw	1.5 N.m	13 lb in
HVAC Module Assembly Mounting Bolt	5 N.m	44 lb in
HVAC Module Case Screw	1.5 N.m	13 lb in
Liquid Line and Compressor Hose to Condenser Bolt	20 N.m	15 lb ft
Liquid Line and Suction Hose to TXV Nut	20 N.m	15 lb ft
Liquid Line Bracket Bolt	10 N.m	89 lb in
Mode Valve Assembly Screw	1.5 N.m	13 lb in
Refrigerant Pressure Sensor	5 N.m	44 lb in
Service Port Valve Core	2.5 N.m	22 lb in
Side Window Defogger Duct Screw	2.5 N.m	22 lb in
TXV Screw	7 N.m	62 lb in

Refrigerant System Capacities

Application	Specification
Application	Metric	English
PAG Oil GM P/N 12378526 for United States PAG Oil GM P/N 88900060 for Canada
Abrupt Refrigerant Loss	60 ml 1	2.0 oz 1
Compressor Replacement
The service compressor for the LY7 engine is precharged with 150 ml (5 oz) of PAG oil. The service compressor for the LAT, LE5, LZ4 and LZE engines are precharged with 74 ml (2.5 oz) of PAG oil.
Condenser Replacement	30 ml 2	1.0 oz 2
Evaporator Replacement	45 ml 2	1.5 oz 2
Total System PAG Oil Capacity	150 ml	5.0 oz
R-134a
Refrigerant Charge	0.5 kg	1.1 lb
1 Abrupt refrigerant loss due to large leak, hose rupture, collision, or pressure relief valve opening. Conditions that allow the refrigerant to seep or bleed off over time do not cause this oil loss. Upon replacement of a component that caused a large refrigerant loss, also add the required amount of oil for the particular component. 2 If more than the specified amount of PAG oil was drained from a component, add the equal amount of oil drained.

Refrigerant System Capacities

Special Tools

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-43872: Fluorescent Dye Cleaner
J-46297: A/C Dye Injector Kit
J-46297-12: Replacement Dye Cartridges

Refrigerant Leak Testing

Note. General Motors vehicles are now manufactured with fluorescent dye installed directly into the air conditioning (A/C) system.

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: detector, 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.

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.
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.
Follow the instructions supplied with the J-42220: lamp.
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: cleaner.

Fluorescent Dye Injection

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.
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.
To prevent false diagnosis, thoroughly clean any residual dye from the service port with a rag and the approved fluorescent dye cleaner J-43872: dye cleaner.

Halogen Leak Detector

WARNING

Do not operate the detector in a combustible atmosphere since its sensor operates at high temperatures or personal injury and/or damage to the equipment may result.

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.

Note. Halogen leak detectors are sensitive to the following items: Windshield washing solutions Many solvents and cleaners Some adhesives used in the vehicle

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

Note. Follow a continuous path in order to ensure that you will not miss any possible leaks. Test all areas of the system for leaks.

Follow the instructions supplied with the J-39400-A: detector.

Air Conditioning (A/C) System Performance Test

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

The current ambient air temperature
The current relative humidity
The high side pressure of the A/C system
The low side pressure of the A/C system
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: This step determines if the A/C system has at least the minimum refrigerant charge required to operate the system without damage.
2: This step measures the performance of the A/C system.
3: This step is to allow for vehicle variations as well as high ambient temperatures.

Step	Action	Values	Yes	No
IMPORTANT: The ambient air temperature must be at least 16°C (60°F). Do not induce additional air flow across the front of the vehicle during the test. If you were sent here from a DTC diagnostic table, clear the DTC upon completion of this test.
1	Park the vehicle inside or in the shade. Open the windows in order to ventilate the interior of the vehicle. If the A/C system was operating, allow the A/C system to equalize for about 2 minutes. Turn OFF the ignition. Install the J 43600 ACR 2000 Air Conditioning Service Center. See Special Tools . Record the ambient air temperature displayed on the J 43600 . See Special Tools . Record the low and high side STATIC pressure readings. Are both the low side and high side pressures within the specified value?	More than 16°C (60°F) - 345 kPa (50 psi) More than 24°C (75°F) - 483 kPa (70 psi) More than 33°C (90°F) - 690 kPa (100 psi)	Go to Step 2	Go to Leak Testing
2	IMPORTANT: Record the relative humidity and the ambient air temperature at the time of the test. Close the vehicle doors and windows. Open the drivers door window 12.7-15.2 cm (5-6 in). Select the following HVAC control settings: The A/C is ON. The coldest temperature setting The maximum blower speed Recirculation mode The instrument panel (I/P) outlet mode All I/P outlets are OPEN. Install the temperature probes of the J 43600 in the left and right center panel air outlets. See Special Tools . Apply the parking brake. Place the transaxle/transmission in one of the following positions: PARK (Automatic) NEUTRAL (Manual) Start the engine and warm to operating temperature. Operate the A/C system for 5 minutes. Inspect A/C components for the following conditions: Abnormal frost areas Unusual noises IMPORTANT: Press the RESET button, before using the print function of the J 43600 . See Special Tools . Print the following information: The panel outlet air temperatures The low-side pressure The high-side pressure Compare the low and high side pressures and the panel output temperatures to the A/C Performance Table below. Does all the data recorded fall within the specified ranges of the A/C Performance Table below?		Go to Step 8	Go to Step 3
3	If the pressures and temperatures recorded do not fall within the specified ranges: Continue to operate the A/C system for an additional 5 minutes. RESET the J 43600 and record the pressures and temperatures again. See Special Tools . Compare the low and high side pressures and the panel output temperature to the table below. Does all the data recorded fall within the specified ranges of the table below?		Go to Step 8	Go to Step 4
4	Do the high and low side pressures fall within the specified ranges, but the panel outlet temperatures do not?		Go to Air Conditioning (A/C) Diagnostics - Pressure Zone A	Go to Step 5
5	Is the low side pressure greater than the specified range, but the high side pressure within or less than the specified range?		Go to Air Conditioning (A/C) Diagnostics - Pressure Zone B	Go to Step 6
6	Are the low and high side pressures both greater than the specified ranges?		Go to Air Conditioning (A/C) Diagnostics - Pressure Zone C	Go to Step 7
7	Is the high side pressure greater than the specified range, but the low side pressure is within or less than the specified range?		Go to Air Conditioning (A/C) Diagnostics - Pressure Zone D	Go to Step 8
8	Operate the system in order to verify the test results. Did you find the same results?		System OK	Go to Symptoms - HVAC Systems - Manual or Go to Symptoms - HVAC Systems - Automatic

IMPORTANT
The ambient air temperature must be at least 16°C (60°F). Do not induce additional air flow across the front of the vehicle during the test. If you were sent here from a DTC diagnostic table, clear the DTC upon completion of this test.

IMPORTANT
Record the relative humidity and the ambient air temperature at the time of the test.

IMPORTANT
Press the RESET button, before using the print function of the J 43600 . See Special Tools .

Ambient Temperature	Relative Humidity	Low Side Service Port Pressure	High Side Service Port Pressure	Maximum Left Center Discharge Air Temperature
13-18°C (55-65°F)	0-100%	175-200 kPa (25-30 psi)	500-850 kPa (70-125 psi)	5°C (40°F)
19-24°C (66-75°F)	Less than 40%	175-240 kPa (25-35 psi)	690-1100 kP (100-160 psi)	5°C (40°F)
19-24°C (66-75°F)	Greater than 40%	175-240 kPa (25-35 psi)	690-1100 kP (100-160 psi)	7°C (45°F)
25-29°C (76-85°F)	Less than 35%	175-240 kPa (25-35 psi)	1000-1300 kPa (145-190 psi)	10°C (50°F)
	35-60%	175-240 kPa (25-35 psi)	1000-1340 kPa (145-195 psi)	10°C (50°F)
	Greater than 60%	175-280 kPa (25-40 psi)	1000-1370 kPa (145-200 psi)	10°C (50°F)
30-35°C (86-95°F)	Less than 30%	175-280 kPa (25-40 psi)	1240-1590 kPa (180-230 psi)	13°C (55°F)
	30-50%	175-280 kPa (25-40 psi)	1240-1620 kPa (180-235 psi)	13°C (55°F)
	Greater than 50%	175-280 kPa (25-40 psi)	1240-1650 kPa (180-240 psi)	13°C (55°F)
36-41°C (96-105°F)	Less than 20%	240-320 kPa (35-45 psi)	1500-1860 kPa (215-270 psi)	15°C (60°F)
	20-40%	240-320 kPa (35-45 psi)	1500-1900 kPa (215-275 psi)	15°C (60°F)
	Greater than 40%	240-320 kPa (35-45 psi)	1500-1900 kPa (215-275 psi)	15°C (60°F)
42-46°C (106-115°F)	Less than 20%	280-350 kPa (40-50 psi)	1765-2100 kPa (255-305 psi)	18°C (65°F)
42-46°C (106-115°F)	Greater than 20%	280-350 kPa (40-50 psi)	1765-2100 kPa (255-305 psi)	18°C (65°F)
47-49°C (116-120°F)	Below 30%	320-380 kPa (45-55 psi)	2000-2240 kPa (290-325 psi)	20°C (70°F)

A/C Performance Table

Scheme 1

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

Step	Action	Value	Yes	No
DEFINITION: The high and low side pressures may be normal or slightly less than normal. Air Delivery Concern Slight Refrigerant Under Charge Refrigerant Contamination
1	Were you sent here from the A/C System Performance Test?		Go to Step 2	Go to Air Conditioning (A/C) System Performance Test
2	Refer to the instrument panel outlet air temperatures recorded during the A/C system performance test. Does the discharge air temperature between the right and left center instrument panel outlets vary by more than 1-2°C (2-3°F)?		Go to Step 7	Go to Step 3
3	Did the customer mention that the A/C system output temperatures are good at first, but then turn warm during extended drives?		Go to Step 4	Go to Step 5
4	Increase engine speed to 2000 RPM. During extended operation of the A/C system, does the low side pressure decrease, possibly accompanied by heavy frost on the liquid line between the expansion device and the evaporator?		Go to Air Conditioning (A/C) Diagnostics - Pressure Zone D	Go to Step 5
5	Refer to the pressures recorded during the A/C system performance test. WARNING: Refer to Moving Parts and Hot Surfaces Warning . Inspect for the following conditions: The high side pressure is slightly greater than the specified pressure ranges but still within Zone A on the A/C Pressure-Zone Classification Chart in the A/C System Performance Test. Refer to Air Conditioning (A/C) System Performance Test . The discharge line is hot. The suction line is cool. Do the listed conditions exist?		Go to Step 7	Go to Step 6
6	Refer to the pressures recorded during the A/C system performance test. Inspect for the following conditions: The low side pressure is slightly lower than the specified pressure ranges but still within Zone A on the A/C Pressure-Zone Classification Chart in the A/C System Performance Test. Refer to Air Conditioning (A/C) System Performance Test . The discharge line is warm-to-hot. The suction line is cool-to-warm. Do the listed conditions exist?		Go to Step 8	Go to Air Temperature Malfunction for the manual system or Air Temperature Malfunction for the automatic system
7	The A/C system may be undercharged. Leak test A/C system. Refer to Leak Testing . Recharge the A/C system to specifications. Refer to Refrigerant Recovery and Recharging . Is the action complete?		Go to Step 13
8	The A/C system may be contaminated. View the information screen on the J 43600 for detection of foreign gases in the A/C system. See Special Tools . Do foreign gases exist?		Go to Step 9	Go to Step 10
9	Evacuate the A/C system to a scavenging tank. Refer to Refrigerant Recovery and Recharging . Recharge the A/C system to specifications. Is the action complete?		Go to Step 13
10	The A/C system may contain too much moisture or air. Evacuate and recharge the A/C system to specifications. Refer to Refrigerant Recovery and Recharging . Operate the A/C system and inspect the instrument panel outlet air temperatures. Refer to Air Conditioning (A/C) System Performance Test . Are the instrument panel outlet air temperatures within the specified ranges of the A/C Performance Test Table?		Go to Step 14	Go to Step 11
11	The A/C system may contain too much refrigerant oil. NOTE: Review the vehicles A/C repair history. If the vehicle history shows multiple A/C repairs and is suspected of improper PAG oil balancing in the previous repairs, perform the following procedure: Drain all of the PAG oil drain bottle on the ACR 2000. Flush the A/C system. Refer to Flushing . Was more than the total system capacity of refrigerant oil recovered from the ACR 2000 oil drain bottle?	148 ml (5 oz)	Go to Step 12	Go to Step 13
12	Add the specified amount of refrigerant oil. Refer to Refrigerant System Capacities . Recharge the A/C system. Refer to Refrigerant Recovery and Recharging . Are the actions complete?		Go to Step 13
13	Record the low and high side pressures and the instrument panel outlet air temperature. Compare the instrument panel outlet air temperatures to those listed in the A/C System Performance Chart. Refer to Air Conditioning (A/C) System Performance Test . Are the high and low side pressures and the instrument panel outlet air temperatures within specifications?		Go to Step 14
14	Operate the system in order to verify the repair. Did you find and correct the condition?		System OK	Go to Symptoms - HVAC Systems - Manual or Go to Symptoms - HVAC Systems - Automatic

WARNING
Refer to Moving Parts and Hot Surfaces Warning .

NOTE
Review the vehicles A/C repair history.

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

Step	Action	Yes	No
DEFINITION: The low side pressure is higher than normal and the high side pressure is lower than normal. Malfunctioning A/C Compressor Refrigerant Under Charge
1	Were you sent here from the A/C System Performance Test?	Go to Step 2	Go to Air Conditioning (A/C) System Performance Test
2	After continued operation of the A/C system, do the low and the high side pressures equalize or become static?	Go to Step 5	Go to Step 3
3	Refer to the pressures recorded during the A/C System Performance Test. WARNING: Refer to Moving Parts and Hot Surfaces Warning . Inspect for the following conditions: The low side pressure is equal to or greater than the specified pressure range of the A/C Performance Table. Refer to Air Conditioning (A/C) System Performance Test . The high side pressure is less than the specified pressure range of the A/C Performance Table. Refer to Air Conditioning (A/C) System Performance Test . The low side refrigerant line at the compressor feels cool-to-warm. The high side refrigerant line at the compressor feels warm-to-hot. Do the listed conditions exist?	Go to Step 5	Go to Step 4
4	Refer to the pressures recorded during the A/C System Performance Test. WARNING: Refer to Moving Parts and Hot Surfaces Warning . Inspect for the following conditions: The low side pressure is greater than the specified pressure range of the A/C Performance Table. Refer to Air Conditioning (A/C) System Performance Test . The high side pressure is less than the specified pressure range of the A/C Performance Table. Refer to Air Conditioning (A/C) System Performance Test . The low side refrigerant line at the compressor feels warm. The high side refrigerant line at the compressor feels warm-to-hot. Do the listed conditions exist?	Go to Step 5	Go to Air Conditioning (A/C) System Performance Test
5	The A/C system has a low refrigerant charge. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging . Is the action complete?	Go to Step 6
6	After you perform the repairs, record the following: The low and the high side pressures The instrument panel outlet air temperature Compare the pressures and the temperature to those listed in the A/C Performance Chart. Refer to Air Conditioning (A/C) System Performance Test . Are the readings within the specified ranges found on the A/C Performance Chart?	Go to Step 13	Go to Step 7
7	The A/C compressor is malfunctioning. Remove the expansion device and inspect for contamination. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement . Did you find metal flakes on the expansion device?	Go to Step 9	Go to Step 8
8	Inspect the expansion device for a brown, powdery residue indicating desiccant in the A/C system. Is a brown, powdery residue present?	Go to Step 11	Go to Step 12
9	Remove the compressor hose from the compressor. Refer to Air Conditioning Compressor and Condenser Hose Replacement (LAT) or Air Conditioning Compressor and Condenser Hose Replacement (LZ4, LZE) or Air Conditioning Compressor and Condenser Hose Replacement (LY7) . Inspect for metal flake contamination at the line connections and the compressor ports. Is metal flake contamination present?	Go to Step 10	Go to Step 12
10	Replace the A/C compressor. Refer to Air Conditioning Compressor Replacement (LZ4, LZE) or Air Conditioning Compressor Replacement (LY7) or Air Conditioning Compressor Replacement (LAT) . Replace the A/C refrigerant filter. Refer to Air Conditioning (AC) Refrigerant Filter Replacement . Replace the thermal expansion valve. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement . Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging . Install a suction screen. Refer to Suction Screen Replacement . Is the action complete?	Go to Step 13
11	Flush the A/C system. Refer to Flushing . Replace the thermal expansion valve. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement . Replace the A/C compressor. Refer to Air Conditioning Compressor Replacement (LZ4, LZE) or Air Conditioning Compressor Replacement (LY7) or Air Conditioning Compressor Replacement (LAT) . Replace the A/C refrigerant filter. Refer to Air Conditioning (AC) Refrigerant Filter Replacement . Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging . Is the action complete?	Go to Step 13
12	Replace the A/C compressor. Refer to Air Conditioning Compressor Replacement (LZ4, LZE) or Air Conditioning Compressor Replacement (LY7) or Air Conditioning Compressor Replacement (LAT) . Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging . Is the action complete?	Go to Step 13
13	Operate the system in order to verify the repair Did you find and correct the condition?	System OK	Go to Symptoms - HVAC Systems - Manual or Go to Symptoms - HVAC Systems - Automatic

WARNING
Refer to Moving Parts and Hot Surfaces Warning .

WARNING
Refer to Moving Parts and Hot Surfaces Warning .

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

Step	Action	Yes	No
DEFINITION: The low and the high side pressures are both higher than normal. Restricted Condenser Air Flow Cooling Fan Malfunction Expansion Device Malfunction
1	Were you sent here from the A/C System Performance Test?	Go to Step 2	Go to Air Conditioning (A/C) System Performance Test
2	Start the engine. Turn ON the A/C. Inspect for proper cooling fan operation. Refer to Cooling System Description and Operation . Are the cooling fans ON and operating properly?	Go to Step 3	Go to Step 5
3	Visually inspect for the following conditions: Damaged condenser cooling fins Missing or misaligned air baffles Restricted air flow Do any of these conditions exist?	Go to Step 4	Go to Step 6
4	Repair the air flow restriction. Is the action complete?	Go to Step 9
5	Repair the fault to the cooling fan operation. Refer to Cooling Fan Inoperative . Is the repair complete?	Go to Step 9
6	WARNING: Refer to Moving Parts and Hot Surfaces Warning . Feel the liquid line on both sides of the expansion device.Are the temperatures on both sides of the expansion device similar?	Go to Step 7	Go to Step 8
7	Replace the damaged or faulty thermal expansion valve. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement . Is the action complete?	Go to Step 9
8	Air is in the refrigerant system, or the system is overcharged. Refer to the view screen on J 43600 for foreign gas content in the refrigerant. See Special Tools . Recover and recharge the A/C system. Refer to Refrigerant Recovery and Recharging . Is the action complete?	Go to Step 9
9	Record the low and high side pressures and the instrument panel outlet air temperature after you have performed the repairs. Compare the pressures and the instrument panel outlet air temperature to those listed in the A/C Performance Chart. Refer to Air Conditioning (A/C) System Performance Test . Are the readings within the specified ranges listed in the A/C Performance Chart?	Go to Step 10	Go to Air Conditioning (A/C) System Performance Test
10	Operate the system in order to verify the repair. Did you find and correct the condition?	System OK	Go to Symptoms - HVAC Systems - Manual or Symptoms - HVAC Systems - Automatic

WARNING
Refer to Moving Parts and Hot Surfaces Warning .

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

Step	Action	Yes	No
DEFINITION: The low side pressure is lower than normal and the high side pressure is higher than normal. A restriction in the A/C system Debris in the system
1	Were you sent here from the A/C System Performance Test?	Go to Step 2	Go to Air Conditioning (A/C) System Performance Test
2	WARNING: Refer to Moving Parts and Hot Surfaces Warning . Feel the liquid line before the expansion device.Is the liquid line cold before the expansion device?	Go to Step 3	Go to Step 8
3	Feel along the surfaces of the following high side components: The compressor discharge hose The condenser The liquid line between the condenser and the expansion device Did you detect an abrupt drop in temperature along the surfaces of any of the listed components?	Go to Step 7	Go to Step 4
4	Feel the liquid line at the expansion device location for extreme cold, possibly accompanied by heavy frost. Feel along the liquid line beyond the expansion device location for warm temperature. Is the liquid line extremely cold at the expansion device location and warm beyond the expansion device location?	Go to Step 11	Go to Step 5
5	Feel along the surfaces of the following low side components: The suction hose between the evaporator core and the compressor suction hose The compressor suction hose Did you feel an abrupt temperature change along the surfaces of any of the listed components?	Go to Step 7	Go to Step 6
6	Feel along the surfaces of the low and the high side components: The suction hose between the evaporator core and the compressor The compressor discharge hose The condenser The liquid line between the condenser and the expansion device Are all the temperatures of these components only mildly warm?	Go to Step 14	Go to Step 8
7	Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the restriction from the component, or replace the component which produced an abrupt temperature drop. Is the repair complete?	Go to Step 9
8	Recover the refrigerant and evacuate the system. Refer to Refrigerant Recovery and Recharging . Record the weight of the recovered refrigerant. Compare the weight of the recovered refrigerant with the system capacity. Refer to Refrigerant System Capacities . Is the weight of the recovered refrigerant charge greater than 75 percent of the total system capacity?	Go to Step 9	Go to Step 10
9	Recharge the A/C system. Refer to Refrigerant Recovery and Recharging . Is the cooling performance improved?	Go to Step 18	Go to Step 10
10	Leak test the system. Refer to Leak Testing . Repair any leaks. Is the repair complete?	Go to Step 9
11	Replace the A/C refrigerant filter. Refer to Air Conditioning (AC) Refrigerant Filter Replacement . Replace the expansion device. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement . Are metal flakes present?	Go to Step 12	Go to Step 13
12	Remove the compressor hose assembly from the vehicle. Refer to Air Conditioning Compressor and Condenser Hose Replacement (LAT) or Air Conditioning Compressor and Condenser Hose Replacement (LZ4, LZE) or Air Conditioning Compressor and Condenser Hose Replacement (LY7) . Inspect the hose for debris by blowing shop air through one end of the hose while covering the other end with a shop towel. Observe the amount of debris collected in the shop towel. Did a large amount of debris collect in the shop towel?	Go to Step 16	Go to Step 17
13	If the expansion device was restricted with a brown or black residue, perform the following procedure: Replace the condenser. Refer to Air Conditioning Condenser Replacement . Flush the A/C system. Refer to Flushing . Are the repairs complete?	Go to Step 18
14	Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Disconnect the compressor hose from the compressor. Refer to Air Conditioning Compressor and Condenser Hose Replacement (LAT) or Air Conditioning Compressor and Condenser Hose Replacement (LZ4, LZE) or Air Conditioning Compressor and Condenser Hose Replacement (LY7) . Inspect for the presence of debris in the compressor suction port. Is debris present in the compressor suction port?	Go to Step 15	Go to Step 17
15	Remove the debris from the suction port. Inspect the A/C refrigerant filter for damage or debris. Refer to Air Conditioning (AC) Refrigerant Filter Replacement . Inspect the expansion device for damage or debris. Refer to Air Conditioning Evaporator Thermal Expansion Valve Replacement . Did you find evidence of damage or debris?	Go to Step 11	Go to Step 12
16	Replace the condenser. Refer to Air Conditioning Condenser Replacement . Install a suction screen. Refer to Suction Screen Replacement . Is the repair complete?	Go to Step 17
17	Install the compressor hose assembly. Refer to Air Conditioning Compressor and Condenser Hose Replacement (LAT) or Air Conditioning Compressor and Condenser Hose Replacement (LZ4, LZE) or Air Conditioning Compressor and Condenser Hose Replacement (LY7) . Recharge the A/C system. Refer to Refrigerant Recovery and Recharging . Are the repairs complete?	Go to Step 18
18	Record the low and the high side pressures and the panel outlet air temperature after you perform the repairs. Compare the pressures and the panel outlet temperature to those listed in the A/C Performance Chart. Refer to Air Conditioning (A/C) System Performance Test . Are the readings within the specified ranges as shown on the A/C Performance Chart?	Go to Step 19	Go to Air Conditioning (A/C) System Performance Test
19	Operate the system in order to verify the repair. Did you find and correct the condition?	System OK	Go to Symptoms - HVAC Systems - Manual or Go to Symptoms - HVAC Systems - Automatic

WARNING
Refer to Moving Parts and Hot Surfaces Warning .

Heating Performance Diagnostic

Step	Action	Yes	No
DEFINITION: Heating system performance.
1	Were you sent here from Symptoms or another diagnostic table?	Go to Step 2	Go to Symptoms - HVAC Systems - Manual or Go to Symptoms - HVAC Systems - Automatic
2	Start the engine. Allow the engine to idle. Does the engine reach a normal operating temperature?	Go to Step 3	Go to Step 9
3	WARNING: Refer to Moving Parts and Hot Surfaces Warning . Allow the engine to idle. Select the FLOOR mode. Select the minimum blower speed. Select the warmest temperature setting. Feel the temperature of the inlet and outlet heater hoses at the heater core. Does the inlet heater hose feel warmer than the outlet heater hose?	Go to Step 7	Go to Step 4
4	Install a thermometer into the center I/P PANEL air outlet. Secure a thermometer to the heater core outlet hose. Select the PANEL mode. Select the maximum blower speed. Select the warmest temperature setting. Record the temperature at the following locations: The center I/P PANEL air outlet The heater core outlet hose Compare the recorded temperatures. Are the 2 temperature readings about equal?	Go to Step 5	Go to Step 6
5	Inspect and repair the following areas of the vehicle for air leaks: Center floor air outlet duct-Refer to Instrument Panel Center Air Outlet Duct Replacement . LH rear floor air outlet duct-Refer to Floor Rear Air Outlet Duct Replacement - Left Side . RH rear floor air outlet duct-Refer to Floor Rear Air Outlet Duct Replacement - Right Side . Perform the necessary repairs. Are the repairs complete?	Go to Step 10
6	Inspect the temperature door operation. Refer to Diagnostic System Check - Vehicle . Perform any necessary repairs. Are the repairs complete?	Go to Step 10
7	Turn OFF the engine. Backflush the heater core. Start the engine. Select the FLOOR mode. Select the minimum blower speed. Select the warmest temperature setting. Feel the temperature of the inlet and outlet heater hoses at the heater core. Does the inlet heater hose feel warmer than the outlet heater hose?	Go to Step 8	Go to Step 10
8	Replace the heater core. Refer to Heater Core Replacement . Is the repair complete?	Go to Step 10
9	Repair the low engine temperature concern. Refer to Engine Fails To Reach Normal Operating Temperature . Is the repair complete?	Go to Step 10
10	Operate the system in order to verify the repair. Did you find and correct the condition?	System OK	Go to Step 2

WARNING
Refer to Moving Parts and Hot Surfaces Warning .

Defrosting Insufficient

Step	Action	Yes	No
DEFINITION: Time required to defrost the windshield is longer than normal.
1	Were you sent here from Symptoms or another diagnostic table?	Go to Step 2	Go to Symptoms - HVAC Systems - Manual or Symptoms - HVAC Systems - Automatic
2	Start the engine. Select the DEFROST mode. Select the maximum blower speed. Does sufficient air flow from the defroster outlets?	Go to Step 3	Go to Step 10
3	Measure the engine operating temperature. Does engine reach a normal operating temperature?	Go to Step 4	Go to Step 8
4	Select the minimum blower speed. Select the maximum temperature setting. WARNING: Refer to Moving Parts and Hot Surfaces Warning . Feel the temperature of the inlet and outlet hoses at the heater core. Does the inlet hose feel warmer than the outlet hose?	Go to Step 11	Go to Step 5
5	Test the operation of the A/C compressor clutch. Does the A/C compressor clutch engage?	Go to Step 7	Go to Step 6
6	Repair the A/C compressor clutch. Refer to Air Conditioning Compressor Malfunction . Is the repair complete?	Go to Step 14
7	Perform the A/C system performance test. Refer to Air Conditioning (A/C) System Performance Test . Is the A/C system operating within the specifications?	Go to Step 9	Go to Step 12
8	Repair the low engine temperature concern. Refer to Engine Fails To Reach Normal Operating Temperature . Is the repair complete?	Go to Step 14
9	Inspect for correct operation of the recirculation door. Is the recirculation door operating correctly?	Go to Step 14	Go to Step 13
10	Repair the air delivery concern. Refer to Air Delivery Improper . Is the repair complete?	Go to Step 14
11	Repair the heating concern. Refer to Heating Performance Diagnostic . Is the repair complete?	Go to Step 14
12	Repair the A/C performance concern. Refer to Symptoms - HVAC Systems - Manual or Symptoms - HVAC Systems - Automatic . Is the repair complete?	Go to Step 14
13	Repair the recirculation door concern. Refer to Air Recirculation Malfunction . Is the repair complete?	Go to Step 14
14	Operate the system in order to verify the repair. Did you find and correct the problem?	System OK	Go to Step 2

WARNING
Refer to Moving Parts and Hot Surfaces Warning .

Noise Diagnosis - Blower Motor

Step	Action	Yes	No
DEFINITION: Noise originating from the blower motor.
1	Were you sent here from Symptoms or another diagnostic table?	Go to Step 2	Go to Symptoms - HVAC Systems - Manual or Symptoms - HVAC Systems - Automatic
2	Inspect the air inlet grille for debris. Is debris present?	Go to Step 8	Go to Step 3
3	Sit inside the vehicle. Close the vehicle doors and windows. Turn ON the ignition, with the engine OFF. Cycle the blower motor through all of the speeds and modes in order to determine where and when the noise occurs. Is a noise evident during the blower operation?	Go to Step 4	Go to Step 11
4	Inspect for excessive vibration at each blower motor speed by feeling the blower case. Is excess vibration present?	Go to Step 6	Go to Step 5
5	Listen to the blower motor at each speed. Is the blower motor making a squeaking or chirping noise?	Go to Step 9	Go to Step 11
6	Remove the blower motor. Refer to Blower Motor Replacement . Inspect the blower motor impeller for deposits of foreign material. Inspect the blower motor for deposits of foreign material. Did you find any foreign material on the blower motor or blower motor impeller?	Go to Step 8	Go to Step 7
7	Inspect the blower motor for the following conditions: Cracked blades A loose impeller retainer Improper impeller alignment Did you find any of these conditions?	Go to Step 9	Go to Step 10
8	Remove the foreign material. Is the action complete?	Go to Step 10
9	Replace the blower motor. Refer to Blower Motor Replacement . Is the repair complete?	Go to Step 11
10	Install the blower motor. Refer to Blower Motor Replacement . Is the action complete?	Go to Step 11
11	Operate the system in order to verify the repair. Did you find and correct the condition?	System OK	Go to Step 2

Air Conditioning Compressor Oil Diagnosis

Condition	Corrective Action
NOTE: This procedure is not used in Brazil. To avoid repeat compressor failure, always inspect the condition of the refrigerant oil and take the appropriate corrective action before installing the replacement compressor.
Clean Oil no debris present	No corrective action necessary.
Clean Oil with debris present	Inspect the suction port of the replacement compressor for presence of a suction screen. If the replacement compressor does NOT contain a suction screen, install suction screen in the line. Replace desiccant or component containing the desiccant. Replace desiccant filter if applicable. Remove and inspect high pressure side filter (if applicable). Remove, inspect, clean, or replace orifice tube. If the system has a front orifice tube and is equipped with a filter in the rear auxiliary line, remove, inspect, clean, or replace the filter. If the system has a front orifice tube and is not equipped with a filter in the rear auxiliary line, remove the filter in the auxiliary TXV and Install a universal inline A/C Filter P/N 89016656 (AC Delco P/N 15-10413) as close to the rear TXV as possible.
Dark brown/black and/or pungent/unusual odor with no debris present	Replace desiccant or component containing the desiccant. Replace desiccant filter if applicable. Flush refrigerant system.
Dark brown/black and/or pungent/unusual odor with debris present	Replace desiccant or component containing the desiccant. Replace desiccant filter if applicable. Flush refrigerant system. Inspect the suction port of the replacement compressor for presence of a suction screen. If the replacement compressor does NOT contain a suction screen, install suction screen. Remove and inspect high pressure side filter (if applicable). Remove, inspect, clean, or replace orifice tube. If the system has a front orifice tube and is equipped with a filter in the rear auxiliary line, remove, inspect, clean, or replace the filter. If the system has a front orifice tube and is not equipped with a filter in the rear auxiliary line, remove the filter in the auxiliary TXV and install a universal inline A/C Filter P/N 89016656 (AC Delco P/N 15-10413) as close to the rear TXV as possible.
Oil Overcharge	Flush refrigerant system.
Refrigerant Contamination	Flush refrigerant system.
Hybrid Polyester Refrigerant Oil (POE) Contamination	Flush refrigerant system. Replace desiccant or component containing the desiccant. Replace desiccant filter if applicable.

NOTE
This procedure is not used in Brazil. To avoid repeat compressor failure, always inspect the condition of the refrigerant oil and take the appropriate corrective action before installing the replacement compressor.

Noise Diagnosis - Air Conditioning (A/C) System

Step	Action	Yes	No
DEFINITION: Noise originating from the A/C compressor, drive belt, or the A/C lines.
1	Were you sent here from Symptoms or another diagnostic table?	Go to Step 2	Go to Symptoms - HVAC Systems - Manual or Go to Symptoms - HVAC Systems - Automatic
2	A/C system noises can be generally categorized into 3 areas: Screeching, squealing, chirping noises Moaning noises Vibration/rattle noises Start the engine. Ensure that the A/C is ON. Is a screeching, squealing noise heard when the A/C is engaged?	Go to Step 3	Go to Step 9
3	With the engine OFF, inspect the drive belt for excessive wear. Refer to the appropriate procedure: Drive Belt Falls Off and Excessive Wear Diagnosis for the 2.4L engine Drive Belt Falls Off and Excessive Wear Diagnosis for the 3.5L engine Drive Belt Falls Off and Excessive Wear Diagnosis for the 3.6L engine Is the drive belt excessively worn?	Go to Step 18	Go to Step 4
4	Inspect the drive belt tension. Refer to the appropriate procedure: Drive Belt Tensioner Diagnosis for the 2.4L engine Drive Belt Tensioner Diagnosis for the 3.5L engine Drive Belt Tensioner Diagnosis for the 3.6L engine Is the drive belt tension correct?	Go to Step 5	Go to Step 19
5	Inspect the drive belt for excessive oil coverage. Is the drive belt covered with oil?	Go to Step 17	Go to Step 6
6	Start the engine. Ensure that the A/C is ON. Inspect the compressor and the clutch. Is the A/C compressor locked up?	Go to Step 24	Go to Step 7
7	Is the A/C compressor clutch slipping?	Go to Step 23	Go to Step 8
8	WARNING: Refer to Moving Parts and Hot Surfaces Warning . Using a stethoscope, listen to the A/C compressor for any abnormal noises.Is the compressor causing an abnormal noise?	Go to Step 15	Go to Step 10
9	Does a moaning noise exist when the A/C clutch is engaged?	Go to Step 10	Go to Step 12
10	Listen to the A/C compressor components and mounting for noise concerns using a stethoscope. Are any of these components loose, damaged, or excessively worn?	Go to Step 20	Go to Step 11
11	Idle the engine. Engage the A/C compressor clutch. Using a stethoscope, move around the entire refrigerant plumbing system. Listening for any abnormal noises caused by a component of the A/C system touching another component. Are any of the A/C components grounding out and causing a vibration noise?	Go to Step 22	Go to Step 13
12	Does a vibration or rattle noise exist when the A/C clutch is engaged?	Go to Step 13	Go to Step 14
13	Does the noise stop when the A/C clutch is disengaged?	Go to Step 15	Go to Step 25
14	Idle the engine in PARK with the A/C compressor clutch engaged. Using a stethoscope, move around the entire A/C system testing for any abnormal noises caused by a component. Do any of the A/C components cause an abnormal noise?	Go to Step 21	Go to Step 25
15	Verify that the A/C system is properly charged. Refer to Refrigerant System Capacities . Is the A/C system properly charged?	Go to Step 26	Go to Step 16
16	Recharge the A/C system to specification. Refer to Refrigerant Recovery and Recharging . Is the abnormal compressor noise still present?	Go to Step 24	Go to Step 26
17	Repair the oil leak. Refer to the appropriate procedure: Oil Leak Diagnosis for the 2.4L engine Oil Leak Diagnosis for the 3.5L engine Oil Leak Diagnosis for the 3.6L engine Is the repair complete?	Go to Step 18
18	Replace the drive belt. Refer to the appropriate procedure: Drive Belt Replacement (LE5) or Drive Belt Replacement (LAT) for the 2.4L engine Drive Belt Replacement for the 3.5L engine Drive Belt Replacement for the 3.6L engine Is the replacement complete?	Go to Step 26
19	Replace the drive belt tensioner. Refer to the appropriate procedure: Drive Belt Tensioner Replacement (LE5) or Drive Belt Tensioner Replacement (LAT) for the 2.4L engine Drive Belt Tensioner Replacement for the 3.5L engine Drive Belt Tensioner Replacement for the 3.6L engine Is the replacement complete?	Go to Step 26
20	Repair or replace the A/C compressor mounting component. Is the repair complete?	Go to Step 26
21	Repair or replace the component which is causing the moaning concern as needed. Is the repair complete?	Go to Step 26
22	Correctly route or insulate the A/C component. Is the repair complete?	Go to Step 26
23	Replace the A/C compressor clutch. Refer to Air Conditioning Clutch Assembly Replacement . Is the repair complete?	Go to Step 26
24	Replace the A/C compressor. Refer to Air Conditioning Compressor Replacement (LZ4, LZE) or Air Conditioning Compressor Replacement (LY7) or Air Conditioning Compressor Replacement (LAT) . Is the repair complete?	Go to Step 26
25	The concern may be caused by an engine related component. Refer to Vibration Analysis - Engine . Did you find and correct the condition?	Go to Step 26
26	Operate the system in order to verify the repair. Did you find and correct the condition?	System OK	Go to Step 2

WARNING
Refer to Moving Parts and Hot Surfaces Warning .

Noise Diagnosis - HVAC Module

Step	Action	Yes	No
DEFINITION: Noise originating from the HVAC module.
1	Were you sent here from Symptoms or another diagnostic table?	Go to Step 2	Go to Symptoms - HVAC Systems - Manual or Symptoms - HVAC Systems - Automatic
2	Start the engine. Cycle through all of the following: Blower motor speeds HVAC modes Temperature control settings Determine the location of noise: Recirculation door Temperature door Mode valve Is noise evident when selecting recirculation?	Go to Step 6	Go to Step 3
3	Is noise evident when selecting temperature?	Go to Step 6	Go to Step 4
4	Is noise evident when selecting mode ?	Go to Step 5	Go to Step 2
5	Remove HVAC module. Refer to Air Conditioning and Heater Module Assembly Removal and Installation . Inspect mode valve for dust, dirt or debris. Is dust, dirt or debris present?	Go to Step 11	Go to Step 12
6	Remove the HVAC module. Refer to Air Conditioning and Heater Module Assembly Removal and Installation . Is action complete?	Go to Step 7
7	Inspect the air flow door for proper operation. Inspect the ducts for obstructions or foreign materials. Were any of these conditions found?	Go to Step 10	Go to Step 8
8	Inspect air flow door for warping or cracking. Is air flow door in normal condition?	Go to Step 13	Go to Step 9
9	Replace air flow door. Is repair complete?	Go to Step 13
10	Remove any obstructions or foreign material found. Is action complete?	Go to Step 13
11	Vacuum and remove dust, dirt and debris. Is action complete?	Go to Step 14
12	Replace the upper evaporator case. Refer to Air Conditioning Evaporator Core Replacement . Is action complete?	Go to Step 14
13	Install HVAC Module. Refer to Air Conditioning and Heater Module Assembly Removal and Installation . Is action complete?	Go to Step 14
14	Operate the system to verify the repair. Did you find and correct the condition?	System OK	Go to Step 2

Odor Diagnosis

Step	Action	Yes	No
DEFINITION: Odor originating or noticed through the HVAC system.
1	Were you sent here from Symptoms or another diagnostic table?	Go to Step 2	Go to Symptoms - HVAC Systems - Manual
2	Sit inside the vehicle. Close all of the doors and windows. Start the engine. Allow the engine idle at normal operating temperature. Select the maximum blower speed. Select the PANEL air outlet mode. Select the coldest temperature setting. Cycle through all of the blower speeds, modes and temperatures to define what type of odor is present. Musty smell Coolant smell Oil smell Does the odor have a musty smell?	Go to Step 3	Go to Step 8
3	Inspect the HVAC filter and the air inlet grille for debris. Is debris present?	Go to Step 4	Go to Step 5
4	Remove any debris. Is the action complete?	Go to Step 15
5	Inspect for wet carpeting. Is the carpet wet?	Go to Step 6	Go to Step 14
6	Inspect for the following conditions: Water leaks around the windshield Blockage of the HVAC module drain Leaks around the door seals Is a leak present?	Go to Step 7	Go to Step 14
7	Repair the leak as necessary. Is the repair complete?	Go to Step 15
8	Does the odor have a coolant smell?	Go to Step 9	Go to Step 12
9	Inspect the cooling system for leaks. Refer to Loss of Coolant . Is a leak present?	Go to Step 10	Go to Step 12
10	Inspect for coolant leaking inside the vehicle or for a film build-up on the windshield. Is the condition present?	Go to Step 11	Go to Step 15
11	Replace the heater core. Refer to Heater Core Replacement . Is the repair complete?	Go to Step 15
12	Does the odor have an oily smell?	Go to Step 13	Go to Step 15
13	Inspect the engine compartment for any leaks. Refer to the following procedures: Oil Leak Diagnosis for the 2.4L engine Oil Leak Diagnosis for the 3.5L engine Oil Leak Diagnosis for the 3.6L engine Fluid Leak Diagnosis for the 4T45E transaxle Fluid Leak Diagnosis for the 6T40/4T45 transmission Fluid Leak Diagnosis for the 6T70/6T75 transmission Repair any oil leaks. Is the repair complete?	Go to Step 15
14	A musty odor can be caused by mold or mildew build-up on the evaporator or the heater core or inside of the HVAC module. Refer to Odor Correction . Is the action complete?	Go to Step 15
15	Operate the system in order to verify the repair. Did you find and correct the condition?	System OK	Go to Step 2

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

Debris is present in the HVAC module.
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

Ensure that the plenum which draws outside air into the HVAC module is clear of debris.
Disable the A/C compressor clutch operation by disconnecting the clutch coil electrical connector.
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.
Locate an area in the air conditioning duct between the blower motor and the evaporator core downstream of the blower motor.
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
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.
Shut the engine OFF. Allow the vehicle to sit for 3-5 minutes.
Seal the 3.175 mm (0.125 in) hole with body sealer or RTV gasket compound.
Start the engine.
Operate the blower motor on high for 15-20 minutes to dry.
Reconnect the A/C compressor clutch coil electrical connector.
Verify proper clutch operation.

J 43600 ACR 2000 Air Conditioning Service Center. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
J 45037 A/C Oil Injector. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

WARNING

To prevent personal injury, avoid breathing A/C Refrigerant and lubricant vapor or mist. Work in a well ventilated area. To remove refrigerant from the A/C System, use service equipment designed for recovery that is certified to meet the requirements of the appropriate SAE Standards. If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant, refrigerant recovery, and lubricant manufacturers.

WARNING

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

CAUTION

You must replace the desiccant if the A/C refrigerant system has been open to atmosphere for more than four hours, or if the A/C refrigerant oil has been contaminated. Failure to replace the desiccant will result in damage to the A/C refrigerant system.

CAUTION

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.

CAUTION

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

CAUTION

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.

CAUTION

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 . 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 . 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 . For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities .

J 41447 R-134A A/C Tracer Dye Box of 24. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
J 42220 Universal 12V Leak Detection Lamp
J 43600 ACR 2000 Air Conditioning Service Center. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
J 45268 A/C Flush Adapter Kit. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Note. Flushing with the ACR 2000 is not intended to remove metal from the A/C system.

Flushing is intended to remove the following

Contaminated polyalkylene glycol (PAG) oil
Desiccant, following a desiccant bag failure
Overcharge of PAG oil
Refrigerant contamination

Forward Flushing Setup

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

Reverse Flushing Setup

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

Flush Procedure

Recover refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Remove thermal expansion valve (TXV). Refer to «Air Conditioning Evaporator Thermal Expansion Valve Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Install TXV stud onto J 45268-115.
Install new sealing washers onto evaporator core. Refer to «Air Conditioning System Seal Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Install J 45268-115 in place of TXV.
Install TXV mounting bolts and tighten to 7 N.m (62 lb in).
Install new washers onto liquid line and suction hose. Refer to «Air Conditioning System Seal Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Connect liquid line and suction hose to J 45268-115.
Install TXV block fitting nut and tighten to 27 N.m (20 lb ft).
Remove A/C compressor. Refer to «Air Conditioning Compressor Replacement (LZ4, LZE)»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Air Conditioning Compressor Replacement (LY7)»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Air Conditioning Compressor Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Remove A/C refrigerant filter. Refer to «Air Conditioning (AC) Refrigerant Filter Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Service filter with ACDelco P/N GF 470, before each flush.
Install J 45268-10 to compressor hose assembly.
Connect J 45268-1 flush filter to J 45268-7 flush adapter.
Connect blue hose from J 43600 to J 45268-1 flush filter adapter. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Connect red hose from J 43600 to J 45268-8 flush adapter. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Flush A/C system. Follow instructions supplied with J 43600 . See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Disconnect red hose from J 43600 to J 45268-8 flush adapter. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Disconnect blue hose from J 43600 to J 45268-1 flush filter adapter. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Disconnect J 45268-1 flush filter from J 45268-10 flush adapter.
Remove J 45268-10 from compressor hose assembly.
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/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-capacities) . NOTE: Flushing will remove fluorescent leak detection dye from A/C system. Add one bottle of J 41447 . See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . Install A/C compressor drain plug and tighten to 15 N.m (11 lb ft).
Install A/C compressor. Refer to «Air Conditioning Compressor Replacement (LZ4, LZE)»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Air Conditioning Compressor Replacement (LY7)»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Air Conditioning Compressor Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Install new A/C refrigerant filter. Refer to «Air Conditioning (AC) Refrigerant Filter Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Remove TXV block fitting nut.
Disconnect liquid line and suction line from J 45268-115.
Remove TXV bolts retaining J 45268-115.
Remove J 45268-115.
Inspect TXV for debris. Clean or replace as needed.
Install TXV. Refer to «Air Conditioning Evaporator Thermal Expansion Valve Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Evacuate and recharge A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Leak test fittings using J 42220 .

Draining Procedure

Remove the compressor crankcase oil drain plug and drain the crankcase into a clean, graduated container.
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.
Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor.
Inspect oil drained from removed compressor. Refer to «Air Conditioning Compressor Oil Diagnosis»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__air-conditioning-compressor-oil-diagnosis)
Properly discard the used refrigerant oil.

Balancing Procedure

The replacement compressor is shipped with the total system capacity of refrigerant oil.
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/vii-2008-2012/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.
Drain the calculated amount of refrigerant oil from the replacement compressor.

Scheme 2

Scheme 2: Air Conditioning Compressor Replacement (LZ4, LZE)

Callout	Component Name
Preliminary Procedure Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the drive belt. Refer to Drive Belt Replacement . Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the right front fender liner. Refer to Front Wheelhouse Panel Splash Shield Replacement . Disconnect the electrical connector.
1	A/C Compressor Hose Nut CAUTION: Refer to Fastener Caution . Tip: Remove the A/C compressor hose from the A/C compressor and cap hose. Tighten: 20 N.m (15 lb ft)
2	Sealing Washer Tip: Remove and discard sealing washers. Refer to Air Conditioning System Seal Replacement .
3	A/C Compressor Nut Tip: Tighten in sequence with A/C compressor mounting bolts. Tighten: 50 N.m (37 lb ft)
4	A/C Compressor Bolt Tip: Tighten the A/C compressor mounting bolts and nut in sequence. Tighten: 50 N.m (37 lb ft)
5	A/C Compressor Assembly Procedure Removal of oil filter and repositioning of the front exhaust pipe may be necessary to ease in compressor replacement. Use a low viscosity, poly-alkylene glycol (PAG) oil. Use of the incorrect oil can result in compressor failure. When replacing the A/C compressor, balance the compressor. Refer to Air Conditioning Compressor Oil Balancing . Using J 39400 , leak test A/C compressor fittings. See Special Tools .

CAUTION
Refer to Fastener Caution .

Scheme 3

Scheme 3: Air Conditioning Compressor Replacement (LY7)

Callout	Component Name
Preliminary Procedure Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the drive belt. Refer to Drive Belt Replacement . Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the right front fender liner. Refer to Front Wheelhouse Panel Splash Shield Replacement . Remove the right side engine splash shield. Refer to Engine Splash Shield Replacement - Right Side Disconnect the A/C compressor electrical connector.
1	A/C Compressor Hose Nut CAUTION: Refer to Fastener Caution . Tip: Remove the A/C compressor hose from the A/C compressor and cap hose. Tighten: 20 N.m (15 lb ft)
2	Sealing Washer (Qty: 2) Tip: Remove and discard sealing washers. Refer to Air Conditioning System Seal Replacement .
3	A/C Compressor Nut Tip: Tighten the A/C compressor mounting bolts and nut in sequence. Tighten: 50 N.m (37 lb ft)
4	A/C Compressor Bolt (Qty: 2) Tighten: 50 N.m (37 lb ft)
5	A/C Compressor Assembly Procedure Use a low viscosity, poly-alkylene glycol (PAG) oil. Use of the incorrect oil can result in compressor failure. When replacing the A/C compressor, balance the compressor. Refer to Air Conditioning Compressor Oil Balancing . Using J 39400 leak test A/C compressor fittings. See Special Tools . Special Tools: J-39400: Electronic Halogen Leak Detector

CAUTION
Refer to Fastener Caution .

Scheme 4

Scheme 4: Air Conditioning Compressor Replacement (LAT)

Callout	Component Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the drive belt. Refer to Drive Belt Replacement (LAT) . Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the right engine splash shield. Refer to Engine Splash Shield Replacement - Right Side . Remove drive belt tensioner. Refer to Drive Belt Tensioner Replacement (LE5) or Drive Belt Tensioner Replacement (LAT) . Disconnect the A/C compressor electrical connector. Remove compressor hose assembly. Refer to Air Conditioning Compressor and Condenser Hose Replacement (LAT) .
1	A/C Compressor Bolt (Qty: 3) CAUTION: Refer to Fastener Caution . Tip: Tighten the A/C compressor mounting bolts in sequence shown in graphic. Tighten: 50 N.m (37 lb ft)
2	A/C Compressor Assembly Procedure Use a low viscosity, poly-alkylene glycol (PAG) oil. Use of the incorrect oil can result in compressor failure. When replacing the A/C compressor, balance the compressor oil. Refer to Air Conditioning Compressor Oil Balancing . Using J 39400 leak test A/C compressor fittings. See Special Tools . Special Tools: J-39400: Electronic Halogen Leak Detector

CAUTION
Refer to Fastener Caution .

J 37872 Universal Spanner Wrench. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
J 6083 Snap Ring Pliers. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
J 39400-A Halogen Leak Detector. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Removal Procedure

Remove the drive belt from the A/C compressor. Refer to «Drive Belt Replacement (LE5)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) or «Drive Belt Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) for the 2.4L engine or «Drive Belt Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) for the 3.5L engine or «Drive Belt Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) for the 3.6L engine.
Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
Remove the lower air deflector. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(/chevrolet/malibu/vii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
Remove and discard the compressor clutch plate bolt. Use the J 37872 to hold the compressor clutch plate from turning. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Remove the compressor clutch plate from the compressor.
Remove the compressor pulley snap ring using the J 6083 . See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Remove the compressor pulley from the compressor.
Remove the compressor clutch coil snap ring using the J 6083 . See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Remove the compressor clutch coil from the compressor.

Installation Procedure

Carefully clean the clutch plate bolt threads with a M6x1.0 tap. Carefully blow out debris with compressed air.
Install the compressor clutch coil to the compressor.
Install the compressor clutch coil snap ring using the J 6083 . See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Install the compressor pulley to the compressor.
Install the compressor pulley snap ring using the J 6083 . See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Place a small amount of oil on the 0.4 mm (0.016 in) air gap shim and place inside the clutch drive plate.
Install the compressor clutch plate to the compressor.
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.
Install the clutch drive plate bolt.
Tighten the compressor clutch drive plate bolt. Use the J 37872 to hold the compressor clutch plate from turning. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . Tighten: Tighten the bolt to 12 N.m (106 lb in).
Install the lower air deflector. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(/chevrolet/malibu/vii-2008-2012/remont/cooling-system-mechanical/#engine-cooling-system) .
Lower the vehicle.
Install the drive belt to the A/C compressor. Refer to «Drive Belt Replacement (LE5)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) or «Drive Belt Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-24l-repair-instructions-on-vehicle) for the 2.4L engine or «Drive Belt Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-35l-repair-instructions-on-vehicle) for the 3.5L engine or «Drive Belt Replacement»(/chevrolet/malibu/vii-2008-2012/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle-1-of-2) for the 3.6L engine.
Leak test the fittings using the J 39400-A . See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 5

Scheme 5: Compressor Pressure Relief Valve Replacement (LY7)

Callout	Component Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement (LY7) .
1	Compressor Pressure Relief Valve CAUTION: Refer to Fastener Caution . Tighten: 8 N.m (70 lb in)

CAUTION
Refer to Fastener Caution .

Scheme 6

Scheme 6: Compressor Pressure Relief Valve Replacement (LZ4, LZE)

Callout	Component Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement (LZ4, LZE) .
1	Compressor Pressure Relief Valve CAUTION: Refer to Fastener Caution . Tighten: 8 N.m (70 lb in)

CAUTION
Refer to Fastener Caution .

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

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

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

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

Scheme 7

Scheme 7: Air Conditioning Compressor and Condenser Hose Replacement (LAT)

Callout	Component Name
Preliminary Procedure Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the air cleaner intake duct fro the air cleaner assembly. Refer to Air Cleaner Assembly Replacement . Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the right front fender liner. Refer to Front Wheelhouse Panel Splash Shield Replacement .
1	A/C Compressor and Condenser Connector Tip: Insert 2 small screwdrivers into the 2 slots of the compressor hose and suction line connector and release locking tabs. Remove the A/C compressor hose from the evaporator hose assembly and discard O-rings. Refer to Air Conditioning O-Ring Seal Replacement .
2	A/C Compressor Hose Nut CAUTION: Refer to Fastener Caution . Tip: Remove the A/C compressor hose from the A/C compressor and cap hose. Tighten: 20 N.m (15 lb ft)
3	Sealing Washer Tip: Remove and discard sealing washers. Refer to Air Conditioning System Seal Replacement .
4	A/C Compressor Hose Bolt Tighten: 20 N.m (15 lb ft)
5	Sealing Washer Tip: Remove and discard sealing washers. Refer to Air Conditioning System Seal Replacement .
6	A/C Compressor Hose Assembly Procedure Note routing of the A/C compressor hose to ensure proper routing. Using J 39400 leak test A/C compressor hose connections. See Special Tools . Special Tools: J 39400 Electronic Halogen Leak Detector. See Special Tools .

CAUTION
Refer to Fastener Caution .

Scheme 8

Scheme 8: Air Conditioning Compressor and Condenser Hose Replacement (LZ4, LZE)

Callout	Component Name
Preliminary Procedure Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the air cleaner intake duct from the air cleaner assembly. Refer to Air Cleaner Assembly Replacement . Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the right front fender liner. Refer to Front Wheelhouse Panel Splash Shield Replacement .
1	A/C Compressor and Condenser Connector Procedure Insert 2 small screwdrivers into the 2 slots of the compressor hose and suction line connector and release locking tabs. Remove the A/C compressor hose from the evaporator hose assembly and discard O-rings. Refer to Air Conditioning O-Ring Seal Replacement .
2	A/C Compressor Hose Nut CAUTION: Refer to Fastener Caution . Tip: Remove the A/C compressor hose from the A/C compressor and cap hose. Tighten: 20 N.m (15 lb ft)
3	Sealing Washer Tip: Remove and discard sealing washers. Refer to Air Conditioning System Seal Replacement .
4	A/C Compressor Hose Bolt Tighten: 20 N.m (15 lb ft)
5	Sealing Washer Tip: Remove and discard sealing washers. Refer to Air Conditioning System Seal Replacement .
6	A/C Compressor Hose Assembly Procedure Note routing of the A/C compressor hose to ensure proper routing. Using J 39400 leak test A/C compressor hose connections. See Special Tools . Special Tools: J 39400 Electronic Halogen Leak Detector. See Special Tools .

CAUTION
Refer to Fastener Caution .

Scheme 9

Scheme 9: Air Conditioning Compressor and Condenser Hose Replacement (LY7)

Callout	Component Name
Preliminary Procedures Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the air cleaner intake duct from the air cleaner assembly. Refer to Air Cleaner Inlet Duct Replacement . Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the right front fender liner. Refer to Front Wheelhouse Panel Splash Shield Replacement .
1	A/C Compressor and Condenser Connector Procedure Insert 2 small screwdrivers into the 2 slots of the compressor hose and suction line connector and release locking tabs. Remove the A/C compressor hose from the evaporator hose assembly and discard O-rings. Refer to Air Conditioning O-Ring Seal Replacement .
2	A/C Compressor Hose Clip Bracket Bolt CAUTION: Refer to Fastener Caution . Tighten: 10 N.m (89 lb in)
3	A/C Compressor Hose Nut Tip: Remove the A/C compressor hose from the A/C compressor and cap hose. Tighten: 20 N.m (15 lb ft)
4	Sealing Washer Tip: Remove and discard sealing washers. Refer to Air Conditioning System Seal Replacement .
5	A/C Compressor Hose Bolt Tighten: 20 N.m (15 lb ft)
6	Sealing Washer Tip: Remove and discard sealing washers. Refer to Air Conditioning System Seal Replacement .
7	A/C Compressor Hose Assembly Procedure Note routing of the A/C compressor hose to ensure proper routing. Using J 39400 leak test A/C compressor hose connections. See Special Tools . Special Tools: J 39400 Electronic Halogen Leak Detector. See Special Tools .

CAUTION
Refer to Fastener Caution .

J 39400-A Halogen Leak Detector. See Special Tools .

Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Insert 2 small screwdrivers into the 2 slots of the compressor hose and suction line connector and release locking tabs.
Remove the compressor hose and liquid line connector.
Remove the suction hose from the compressor hose.
Remove and discard the O-rings.
Remove the surge tank from the surge tank bracket.
Remove the suction hose and liquid line nut from the thermal expansion valve (TXV).
Remove the suction hose and liquid line from the TXV.
Remove the suction hose from the dash clip.
Remove the line clip from the dash.
Remove the refrigerant pressure sensor wire harness connector.
Remove the liquid line bracket bolt.
Remove the suction hose.
Remove and discard the sealing washers.

Uncap A/C components.
Install new sealing washers. Refer to «Air Conditioning System Seal Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Install the suction hose.
Install the liquid line bracket bolt and tighten to 10 N.m (89 lb in).
Install the refrigerant pressure sensor wire harness connector.
Install the line clip to the dash.
Install the suction hose to the dash clip.
Install the suction hose and liquid line to the TXV.
Install the suction hose and liquid line nut to the TXV and tighten the nut to 20 N.m (15 lb ft).
Install new O-rings. Refer to «Air Conditioning O-Ring Seal Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Install the suction hose to the compressor hose.
Install the compressor hose and liquid line connector.
Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Leak test the fittings using the J 39400-A . See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Install the surge tank to the surge tank bracket.

J 39400-A Halogen Leak Detector. See Special Tools .

Scheme 10

Scheme 10: Removal Procedure

Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Remove the refrigerant pressure sensor wire harness connector.
Remove the refrigerant pressure sensor.
Remove the liquid line bracket bolt.
Remove the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
Remove the surge tank from the surge tank bracket.
Remove the suction hose and liquid line nut from the thermal expansion valve (TXV).
Remove the suction hose and liquid line from the TXV.
Remove the suction hose from the dash clip.
Remove the liquid line from the dash clip.
Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
Remove the right front fender liner. Refer to «Front Wheelhouse Panel Splash Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
Remove the right radiator air deflector retainers.
Remove the right radiator air deflector.
Remove the liquid line and compressor hose bolt from the condenser.
Remove the liquid line and compressor hose from the condenser.
Remove the liquid line from the rail clip.
Lower the vehicle.
Remove the liquid line.
Remove and discard the sealing washers.

Uncap A/C components.
Install new sealing washers. Refer to «Air Conditioning System Seal Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Install the liquid line.
Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
Install the liquid line and compressor hose to the condenser.
Install the liquid line and compressor hose bolt to the condenser and tighten to 20 N.m (15 lb ft).
Install the liquid line to the rail clip.
Install the right radiator air deflector.
Install the right radiator air deflector retainers.
Install the right front fender liner. Refer to «Front Wheelhouse Panel Splash Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
Lower the vehicle.
Install the suction hose and liquid line to the TXV.
Install the suction hose and liquid line nut to the TXV and tighten to 20 N.m (15 lb ft).
Install the liquid line to the dash clip.
Install the suction hose to the dash clip.
Install the air cleaner assembly. Refer to «Air Cleaner Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/testing-diagnostics/#engine-controls-and-fuel-35l-repair-instructions) .
Install the liquid line bracket bolt and tighten to 10 N.m (89 lb in).
Install the refrigerant pressure sensor and tighten to 5 N.m (44 lb in).
Install the refrigerant pressure sensor wire harness connector.
Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Leak test the fittings using the J 39400-A . See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Install the surge tank to the surge tank bracket.

Scheme 11

Scheme 11: Air Conditioning Evaporator Thermal Expansion Valve Hose Replacement

Callout	Component Name
Preliminary Procedure Recover the refrigerant. Refer to Refrigerant Recovery and Recharging . Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
1	A/C Evaporator TXV Hose Nut CAUTION: Refer to Fastener Caution . Tip: Remove the A/C evaporator TXV hose from the evaporator hose assembly and discard O-rings. Refer to Air Conditioning O-Ring Seal Replacement . Tighten: 10 N.m (89 lb in)
2	A/C Evaporator TXV Hose Clips
3	A/C Evaporator TXV Hose Tip: Cap all hose/pipe fittings.

CAUTION
Refer to Fastener Caution .

J 39400-A Halogen Leak Detector. See Special Tools .

Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Remove the surge tank from the surge tank bracket.
Remove the suction hose and liquid line nut from the thermal expansion valve (TXV).
Remove the suction hose and liquid line from the TXV.
Remove the line clip from the dash.
Remove the refrigerant filter from the line.
Remove and discard the sealing washers.

Scheme 12

Scheme 12: Installation Procedure

Uncap A/C components.
Install new sealing washers. Refer to «Air Conditioning System Seal Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Install the refrigerant filter into the line.
Install the line clip to the dash.
Install the suction hose and liquid line to the TXV.
Install the suction hose and liquid line nut to the TXV and tighten the nut to 20 N.m (15 lb ft).
Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Leak test the fittings using the J 39400-A . See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Install the surge tank to the surge tank bracket.

Scheme 13

Scheme 13: Suction Screen Replacement

Callout	Component Name
Preliminary Procedure: Remove the A/C compressor. Refer to Air Conditioning Compressor Replacement (LZ4, LZE) or Air Conditioning Compressor Replacement (LY7) or Air Conditioning Compressor Replacement (LAT) .
1	Suction Screen Tip: Remove the suction screen from the A/C compressor suction port using a flat bladed tool or pick.

J 39400-A Halogen Leak Detector. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
J 46246 Valve Core Removal Tool. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Remove the service port valve core using J 46246 or equivalent. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Install the service port valve core using J 46246 or equivalent. See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) . Tighten the service port valve core to 2.5 N.m (22 lb in).
Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Leak test the fittings using the J 39400-A . See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

J 39400-A Halogen Leak Detector. See Special Tools .

Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Remove the surge tank from the surge tank bracket.
Remove the suction line from the dash clip.
Remove the liquid line from the dash clip.
Remove the liquid line and suction line nut from the thermal expansion valve (TXV).
Remove the suction line from the TXV.
Remove the liquid line from the TXV.
Remove the TXV screws.
Remove the TXV.
Remove and discard the sealing washers.

Uncap A/C components.
Install new sealing washers. Refer to «Air Conditioning System Seal Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Install the TXV.
Install the TXV screws and tighten to 7 N.m (62 lb in).
Install the liquid line to the TXV.
Install the suction line to the TXV.
Install the liquid line and suction line nut to the TXV and tighten to 20 N.m (15 lb ft).
Install the liquid line to the dash clip.
Install the suction line to the dash clip.
Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Leak test the fittings using the J 39400-A . See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Install the surge tank to the surge tank bracket.

J 39400-A Halogen Leak Detector. See Special Tools .

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

Install a new O-ring. Refer to «Air Conditioning O-Ring Seal Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Install the refrigerant pressure sensor and tighten to 5 N.m (44 lb in).
Install the refrigerant pressure sensor wire harness connector.
Leak test the fittings using the J 39400-A . See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

J 39400-A Halogen Leak Detector. See Special Tools .

Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Remove the left and right headlamp assemblies. Refer to «Headlamp Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exterior-lights/#lighting-system) .
Loop a rope around each of the 2 upper tabs of the radiator and tie the rope around the upper tie bar.
Remove both upper radiator support bracket bolts.
Remove both upper radiator support brackets.
Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/vii-2008-2012/remont/ignition-switchsteering-lock/#general-information) .
Remove the lower radiator air deflector retainers.
Remove the lower radiator air deflector.
Remove the right front fender liner. Refer to «Front Wheelhouse Panel Splash Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
Remove the right radiator air deflector retainers.
Remove the right radiator air deflector.
Remove the left radiator air deflector retainers.
Remove the left radiator air deflector.
Remove the liquid line and compressor hose bolt from condenser.
Remove the compressor hose from the condenser.
Remove the liquid line from the condenser.
Remove both lower radiator mounting bracket bolts.
Remove both lower radiator mounting brackets.
Remove and discard the condenser mounting bolts.
Remove and discard the condenser mounting nuts.
Push upward on the radiator and downward on the condenser to unsnap the condenser mounting tabs from the radiator clip.
Remove the condenser.
Remove the upper seal.
Remove and discard the sealing washers.

Scheme 14

Scheme 14: Installation Procedure

Uncap A/C components.
Install new sealing washers. Refer to «Air Conditioning System Seal Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Install the upper seal.
If replacing the condenser, add the specific amount of PAG® oil directly to the condenser. Refer to «Refrigerant System Capacities»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-capacities) .
Install the radiator air side seals onto the condenser mounting tabs on the radiator.
Insert condenser mounting tabs into the radiator clips.
Install the condenser mounting nuts.
Install the condenser mounting bolts and tighten to 6 N.m (53 lb in).
Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.
The radiator air side seals must be in the proper position for proper airflow.
Install both lower radiator mounting brackets.
Install both lower radiator mounting brackets bolts and tighten to 60 N.m (44 lb ft).
Install the liquid line to the condenser.
Install the compressor hose to the condenser.
Install the liquid line and compressor hose bolt to the condenser and tighten to 20 N.m (15 lb ft).
Install the left radiator air deflector.
Install the left radiator air deflector retainers.
Install the right radiator air deflector.
Install the right radiator air deflector retainers.
Install the right front fender liner. Refer to «Front Wheelhouse Panel Splash Shield Replacement»(/chevrolet/malibu/vii-2008-2012/remont/frames-subframes-crossmembers/#frame-and-underbody) .
Install the lower radiator air deflector.
Install the lower radiator air deflector retainers.
Lower the vehicle.
Remove the rope attached to the radiator and upper tie bar.
Install both upper radiator support brackets.
Install both upper radiator support bracket bolts and tighten to 10 N.m (89 lb in).
Install the left and right headlamp assemblies. Refer to «Headlamp Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exterior-lights/#lighting-system) .
Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Leak test the fittings using the J 39400-A . See «Special Tools»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Remove the air conditioner (A/C) lines from the thermal expansion valve. Refer to «Air Conditioning Evaporator Thermal Expansion Valve Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Remove the heater hose from the heater core. Refer to «Heater Inlet Hose Replacement (LAT Pump to Heater Core)»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Heater Inlet Hose Replacement (LY7)»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Heater Inlet Hose Replacement (LAT Pump to Engine)»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Heater Inlet Hose Replacement (LZ4, LZE)»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) and «Heater Outlet Hose Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Heater Outlet Hose Replacement (LY7)»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel Reinforcement Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
Remove the recirculation actuator wire harness connector.
Remove the air temperature actuator wire harness connector.
Remove the mode actuator wire harness connector.
Remove the blower motor wire harness connector.
Remove the blower motor resistor wire harness connector.
Remove the left hand side window defogger outlet duct.
Remove the HVAC module assembly mounting bolts from the instrument panel reinforcement.
Remove the HVAC module assembly to dash panel bolts (1).
Remove the HVAC module assembly (1).

Scheme 15

Scheme 15: Installation Procedure

Install the HVAC module assembly (1).
Install the HVAC module assembly to dash panel bolts (1) and tighten to 10 N.m (88 lb in).
Install the HVAC module assembly mounting bolts to the instrument panel reinforcement and tighten the bolts to 5 N.m (44 lb in).
Install the left hand side window defogger outlet duct.
Install the blower motor resistor wire harness connector.
Install the blower motor wire harness connector.
Install the mode actuator wire harness connector.
Install the air temperature actuator wire harness connector.
Install the recirculation actuator wire harness connector.
Install the I/P assembly. Refer to «Instrument Panel Reinforcement Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
Install the heater hoses to the heater core. Refer to «Heater Inlet Hose Replacement (LAT Pump to Heater Core)»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Heater Inlet Hose Replacement (LY7)»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Heater Inlet Hose Replacement (LAT Pump to Engine)»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Heater Inlet Hose Replacement (LZ4, LZE)»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) and «Heater Outlet Hose Replacement (LAT)»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) or «Heater Outlet Hose Replacement (LY7)»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Install the A/C lines to the thermal expansion valve. Refer to «Air Conditioning Evaporator Thermal Expansion Valve Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Remove the HVAC module assembly. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Remove the center floor air outlet duct screws.
Remove the center floor air outlet duct.
Drill out the lower HVAC module case heat stakes.
Remove the lower HVAC module case screws.
Remove the lower HVAC module case.
Remove the thermal expansion valve screws.
Remove the thermal expansion valve.
Remove and discard the sealing washers.
Remove the evaporator.

If replacing the evaporator, add the specific amount of PAG® oil directly to the evaporator. Refer to «Refrigerant System Capacities»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-capacities) .
Install the evaporator.
Install new sealing washers. Refer to «Air Conditioning System Seal Replacement»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Install the thermal expansion valve.
Install the thermal expansion valve screws and tighten to 7 N.m (62 lb in).
Install the lower HVAC module case.
Install the lower HVAC module case screws and tighten to 1.5 N.m (13 lb in).
Install the center floor air outlet duct.
Install the center floor air outlet duct screws and tighten to 1.5 N.m (13 lb in).
Install the HVAC module assembly. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 16

Scheme 16: Heater Inlet Hose Replacement (LAT Pump to Heater Core)

Callout	Component Name
Preliminary Procedures: Partially drain the cooling system. Refer to Cooling System Draining and Filling (GE 47716) .
1	Heater Inlet Hose Clamp (Qty: 2)
2	Heater Inlet Hose

Scheme 17

Scheme 17: Heater Inlet Hose Replacement (LY7)

Callout	Component Name
Preliminary Procedure: Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill-LY7, LZE, LZ4) or Cooling System Draining and Filling (GE 47716) .
1	Heater Inlet Hose Assembly Tip: Using J 38185 to reposition of the heater inlet hose clamps. Remove the heater inlet hose from the heater core and engine. Special Tools: J 38185 Hose Clamp Pliers

Scheme 18

Scheme 18: Heater Inlet Hose Replacement (LAT Pump to Engine)

Callout	Component Name
Preliminary Procedures: Partially drain the cooling system. Refer to Cooling System Draining and Filling (GE 47716) .
1	Heater Inlet Hose Clamp (Qty: 2)
2	Heater Inlet Hose

Scheme 19

Scheme 19: Heater Inlet Hose Replacement (LZ4, LZE)

Callout	Component Name
Preliminary Procedure Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill-LY7, LZE, LZ4) or Cooling System Draining and Filling (GE 47716) . Remove the radiator surge tank. Refer to Radiator Surge Tank Replacement .
1	Heater Inlet Hose Assembly Tip: Using J 38185 to reposition of the heater inlet hose clamps. Remove the heater inlet hose from the heater core and engine. Special Tools: J 38185 Hose Clamp Pliers

Scheme 20

Scheme 20: Heater Outlet Hose Replacement (LAT)

Callout	Component Name
Preliminary Procedures: Partially drain the cooling system. Refer to Cooling System Draining and Filling (GE 47716) .
1	Heater Outlet Hose Clamp (Qty: 2)
2	Heater Outlet Hose

Scheme 21

Scheme 21: Heater Outlet Hose Replacement (LY7)

Callout	Component Name
Preliminary Procedure: Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill-LY7, LZE, LZ4) or Cooling System Draining and Filling (GE 47716) .
1	Heater Outlet Hose Assembly Tip: Using J 38185 to reposition of the heater outlet hose clamps. Remove the heater outlet hose from the heater core and engine. Special Tools: J 38185 Hose Clamp Pliers

Scheme 22

Scheme 22: Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement

Callout	Component Name
Preliminary Procedure Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill-LY7, LZE, LZ4) or Cooling System Draining and Filling (GE 47716) . Remove the heater inlet hose from the heater pipe assembly. Refer to Heater Inlet Hose Replacement (LAT Pump to Heater Core) or Heater Inlet Hose Replacement (LY7) or Heater Inlet Hose Replacement (LAT Pump to Engine) or Heater Inlet Hose Replacement (LZ4, LZE) . Remove the heater outlet hose from the heater pipe assembly. Refer to Heater Outlet Hose Replacement (LAT) or Heater Outlet Hose Replacement (LY7) . Remove the air cleaner duct. Refer to Air Cleaner Outlet Duct Replacement .
1	Pipe Assembly - Heater Inlet and Outlet Pipe - Left - Nut CAUTION: Refer to Fastener Caution . Tighten: 10 N.m (89 lb in)
2	Heater Inlet and Outlet Pipe - Left Pipe Assembly Tip: Using J 38185 , disconnect the left heater pipe assembly from the front heater pipe assembly.
3	Pipe Assembly - Heater Inlet and Outlet Pipe - Front - Bolt Tighten: 25 N.m (18 lb in)
4	Pipe Assembly - Heater Inlet and Outlet Pipe - Front - Stud Tighten: 10 N.m (89 lb in)
5	Heater Inlet and Outlet Pipe - Front Pipe Assembly

CAUTION
Refer to Fastener Caution .

Scheme 23

Scheme 23: Heater Outlet Hose Replacement - Connector to Engine (LZ4, LZE)

Callout	Component Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill-LY7, LZE, LZ4) or Cooling System Draining and Filling (GE 47716) . Remove the air cleaner outlet duct. Refer to Air Cleaner Inlet Duct Replacement . Remove the radiator surge tank. Refer to Radiator Surge Tank Replacement .
1	Heater Outlet Hose Tip: Using SA9111E to reposition of the heater outlet hose clamps. Remove the heater outlet hose from the connector and the engine.

Scheme 24

Scheme 24: Heater Outlet Hose Replacement - Heater Core to Connector (LZ4, LZE)

Callout	Component Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill-LY7, LZE, LZ4) or Cooling System Draining and Filling (GE 47716) . Remove the air cleaner outlet duct. Refer to Air Cleaner Inlet Duct Replacement . Remove the radiator surge tank. Refer to Radiator Surge Tank Replacement .
1	Heater Outlet Hose Tip: Using SA9111E to reposition of the heater outlet hose clamps. Remove the heater outlet hose from the connector and the heater core.

Scheme 25

Scheme 25: Heater Coolant Pump Replacement

Callout	Component Name
Preliminary Procedures Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill-LY7, LZE, LZ4) or Cooling System Draining and Filling (GE 47716) . Remove the heater inlet hose pump to engine. Refer to Heater Inlet Hose Replacement (LAT Pump to Heater Core) or Heater Inlet Hose Replacement (LY7) or Heater Inlet Hose Replacement (LAT Pump to Engine) or Heater Inlet Hose Replacement (LZ4, LZE) . Remove the heater inlet hose pump to heater core. Refer to Heater Inlet Hose Replacement (LAT Pump to Heater Core) or Heater Inlet Hose Replacement (LY7) or Heater Inlet Hose Replacement (LAT Pump to Engine) or Heater Inlet Hose Replacement (LZ4, LZE) .
1	Auxiliary Heater Coolant Pump Screw CAUTION: Refer to Fastener Caution . Tighten: 9 N.m (80 lb in)
2	Auxiliary Heater Coolant Pump Tip: Disconnect the electrical connection.

CAUTION
Refer to Fastener Caution .

Scheme 26

Scheme 26: Blower Motor Resistor Replacement

Callout	Component Name
Preliminary Procedures Remove the right close out panel. Refer to Instrument Panel Insulator Replacement - Right Side . Disconnect the blower motor resistor electrical connector.
1	Blower Motor Resistor Screw (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten: 1.5 N.m (13 lb in)
2	Blower Motor Resistor

CAUTION
Refer to Fastener Caution .

Remove the right closeout panel. Refer to «Instrument Panel Insulator Replacement - Right Side»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
Remove the blower motor wire harness connector.
Cut out the blower motor using a utility knife in the narrow groove of the lower case.
Remove the blower motor.
Remove the blower motor nuts.
Remove the blower motor from the blower motor cup.

Install the new blower motor to the blower motor cup.
Install the blower motor nuts and tighten to 2.4 N.m (21 lb in).
Install the motor blower seal to the blower motor service ring.
Install the blower motor.
Install the blower motor attachment ring.
Install the blower motor screws and tighten to 1.5 N.m (13 lb in).
Install the blower motor wire harness connector.
Install the right closeout panel. Refer to «Instrument Panel Insulator Replacement - Right Side»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .

Scheme 27

Scheme 27: Instrument Panel Outer Air Outlet Replacement - Left Side

Callout	Component Name
Preliminary Procedure Remove the left instrument panel outer trim cover. Refer to Instrument Panel Outer Trim Cover Replacement . Remove the drivers knee bolster panel. Refer to Driver Knee Bolster Panel Replacement .
1	Instrument Panel Outer Air Outlet Assembly Procedure Reach through the indicated opening and release the lower tabs securing the air outlet to the instrument panel. Grasp the air outlet and pull downward and outward removing it from the instrument panel.

Scheme 28

Scheme 28: Instrument Panel Center Air Outlet Replacement

Callout	Component Name
Preliminary Procedure: Remove the instrument panel accessory upper trim plate. Refer to Instrument Panel Accessory Upper Trim Plate Replacement .
1	Instrument Panel Center Air Outlet Screw (Qty: 4) CAUTION: Refer to Fastener Caution . Tighten: 2.5 N.m (22 lb in)
2	Instrument Panel Center Air Outlet Assembly

CAUTION
Refer to Fastener Caution .

Scheme 29

Scheme 29: Instrument Panel Outer Air Outlet Replacement - Right Side

Callout	Component Name
Preliminary Procedure: Remove the instrument panel compartment assembly. Refer to Instrument Panel Compartment Replacement .
1	Instrument Panel Outer Air Outlet Assembly Procedure Reach through the indicated opening and release the lower tabs securing the air outlet to the instrument panel. Grasp the air outlet and pull downward and outward removing it from the instrument panel.

Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
Disconnect the wire harness clip at the left air outlet duct.
Remove the left air outlet duct screws.
Remove the left air outlet duct.

Install the left air outlet duct.
Install the left air outlet duct screws and tighten to 2.5 N.m (22 lb in).
Connect the wire harness clip at the left air outlet duct.
Install the I/P assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .

Scheme 30

Scheme 30: Removal Procedure

Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
Remove the right hand side window defogger duct screws.
Remove the right hand side window defogger duct.
Disconnect the wire harness clip at the right air outlet duct.
Remove the right air outlet duct screws.
Remove the right air outlet duct.

Install the right air outlet duct.
Install the right air outlet duct screws and tighten to 2.5 N.m (22 lb in).
Connect the wire harness clip at the right air outlet duct.
Install the right hand side window defogger duct.
Install the right hand side window defogger duct screws and tighten to 2.5 N.m (22 lb in).
Install the I/P assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .

Scheme 31

Scheme 31: Instrument Panel Center Air Outlet Duct Replacement

Callout	Component Name
Preliminary Procedures Remove the center air outlet. Refer to Instrument Panel Center Air Outlet Replacement . Disconnect the upper air temperature sensor electrical connector.
1	Air Temperature Sensor - Upper
2	Air Distribution Duct - Center

Remove the instrument panel (I/P) pad. Refer to «Instrument Panel Upper Trim Panel Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
Press on the 2 tabs of the windshield defroster duct.
Remove the windshield defroster duct.

Install the windshield defroster duct.
Install the I/P pad. Refer to «Instrument Panel Upper Trim Panel Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .

Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
Remove the left hand side window defogger duct screws.
Remove the left hand side window defogger duct.

Install the left hand side window defogger duct.
Install the left hand side window defogger duct screws and tighten to 2.5 N.m (22 lb in).
Install the I/P assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .

Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
Remove the right hand side window defogger duct screws.
Remove the right hand side window defogger duct.

Install the right hand side window defogger duct.
Install the right hand side window defogger duct screws and tighten to 2.5 N.m (22 lb in).
Install the I/P assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .

Remove the console. Refer to «Front Floor Console Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
Remove the Instrument panel lower bracket. Refer to «Instrument Panel Lower Bracket Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
Remove the center floor air duct screws.
Remove the center floor air duct.

Install the center floor air duct.
Install the Instrument panel lower bracket. Refer to «Instrument Panel Lower Bracket Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
Install the center floor air duct screws and tighten to 1.5 N.m (13 lb in).
Install the console. Refer to «Front Floor Console Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .

Remove the console. Refer to «Front Floor Console Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
Remove the left front seat. Refer to «Front Seat Replacement - Bucket»(/chevrolet/malibu/vii-2008-2012/remont/seats/#seat-hardware-seat-trim-and-upholstery) .
Remove the left front carpet retainer. Refer to «Front Side Door Opening Floor Carpet Retainer Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#floor-coverings-and-headlinings) .
Remove the left center pillar lower garnish molding. Refer to «Center Pillar Lower Garnish Molding Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#interior-trim-system-and-paneling) .
Remove the floor carpet enough to access the left rear floor duct. Refer to «Front Floor Panel Carpet Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#floor-coverings-and-headlinings) .
Remove the left rear floor duct.

Install the left rear floor duct.
Install the floor carpet. Refer to «Front Floor Panel Carpet Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#floor-coverings-and-headlinings) .
Install the left center pillar lower garnish molding. Refer to «Center Pillar Lower Garnish Molding Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#interior-trim-system-and-paneling) .
Install the left front carpet retainer. Refer to «Front Side Door Opening Floor Carpet Retainer Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#floor-coverings-and-headlinings) .
Install the left front seat. Refer to «Front Seat Replacement - Bucket»(/chevrolet/malibu/vii-2008-2012/remont/seats/#seat-hardware-seat-trim-and-upholstery) .
Install the console. Refer to «Front Floor Console Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .

Remove the console. Refer to «Front Floor Console Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
Remove the left front seat. Refer to «Front Seat Replacement - Bucket»(/chevrolet/malibu/vii-2008-2012/remont/seats/#seat-hardware-seat-trim-and-upholstery) .
Remove the left front carpet retainer. Refer to «Front Side Door Opening Floor Carpet Retainer Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#floor-coverings-and-headlinings) .
Remove the left center pillar lower garnish molding. Refer to «Center Pillar Lower Garnish Molding Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#interior-trim-system-and-paneling) .
Remove the floor carpet enough to access the left rear floor duct. Refer to «Front Floor Panel Carpet Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#floor-coverings-and-headlinings) .
Remove the left rear floor duct.

Install the left rear floor duct.
Install the floor carpet. Refer to «Front Floor Panel Carpet Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#floor-coverings-and-headlinings) .
Install the left center pillar lower garnish molding. Refer to «Center Pillar Lower Garnish Molding Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#interior-trim-system-and-paneling) .
Install the left front carpet retainer. Refer to «Front Side Door Opening Floor Carpet Retainer Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#floor-coverings-and-headlinings) .
Install the left front seat. Refer to «Front Seat Replacement - Bucket»(/chevrolet/malibu/vii-2008-2012/remont/seats/#seat-hardware-seat-trim-and-upholstery) .
Install the console. Refer to «Front Floor Console Replacement»(/chevrolet/malibu/vii-2008-2012/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .

Remove the HVAC module assembly. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Remove the center floor air outlet duct screws.
Remove the center floor air outlet duct.
Drill out the heater core cover heat stakes.
Remove the heater core cover screws.
Remove the heater core cover.

Install the heater core cover.
Install the heater core cover screws and tighten to 1.5 N.m (13 lb in).
Install the center floor air outlet duct.
Install the center floor air outlet duct screws and tighten to 1.5 N.m (13 lb in).
Install the HVAC module assembly. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Remove the HVAC module assembly. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
Remove the center floor air outlet duct screws.
Remove the center floor air outlet duct.
Drill out the heater core cover heat stakes.
Remove the heater core cover screws.
Remove the heater core cover.
Remove the heater core.

Install the heater core.
Install the heater core cover.
Install the heater core cover screws and tighten to 1.5 N.m (13 lb in).
Install the center floor air outlet duct.
Install the upper floor air outlet duct screws and tighten to 1.5 N.m (13 lb in).
Install the HVAC module assembly. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation»(/chevrolet/malibu/vii-2008-2012/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Auxiliary Air Conditioning Blower Motor Resistor Replacement

Callout	Component Name
Preliminary Procedures Remove the right close out panel. Refer to Instrument Panel Insulator Replacement - Right Side . Disconnect the auxiliary air conditioning blower motor resistor electrical connector.
1	Auxiliary air conditioning blower motor resistor Screw (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten: 1.5 N.m (13 lb in)
2	Auxiliary air conditioning blower motor resistor

CAUTION
Refer to Fastener Caution .

Note. This procedure is not used in Brazil.

Illustration Tool Number/ Description J-6083 External Snap Ring Pliers J-37872 Universal Spanner Wrench J-38185 Hose Clamp Pliers J-39400 Electronic Halogen Leak Detector 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 Florescent Dye Cleaner J-44551 Suction Screen Installation/Remover 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

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Scheme 32: Special Tools

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Heating, Ventilation, and Air Conditioning Chevrolet Malibu VII

Fastener Tightening Specifications

Refrigerant System Capacities

Special Tools

Refrigerant Leak Testing

Fluorescent Leak Detector

Fluorescent Dye Injection

Halogen Leak Detector

Air Conditioning (A/C) System Performance Test

Test Description

Scheme 1

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

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

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

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

Heating Performance Diagnostic

Defrosting Insufficient

Noise Diagnosis - Blower Motor

Air Conditioning Compressor Oil Diagnosis

Noise Diagnosis - Air Conditioning (A/C) System

Noise Diagnosis - HVAC Module

Odor Diagnosis

Eliminating Air Conditioning Odor

A/C Refrigerant System Oil Charge Replenishing

Forward Flushing Setup

Reverse Flushing Setup

Flush Procedure

Draining Procedure

Balancing Procedure

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Removal Procedure

Installation Procedure

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Auxiliary Air Conditioning Blower Motor Resistor Replacement

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