Heating, Ventilation, and Air Conditioning Chevrolet Malibu VIII

Fastener Tightening Specifications

Fastener Tightening Specifications

Refrigerant System Specifications

Refrigerant System Capacities

Special Tools

1. J-39400-A Halogen Leak Detector
2. J-41447 R-134A A/C Tracer Dye-Box of 24
3. J-42220 Universal 12V Leak Detection Lamp
4. J-43872 Fluorescent Dye Cleaner
5. J-46297 A/C Dye Injector Kit
6. 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.

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

Fluorescent Dye Injection

1. Not all of the fluorescent dyes are compatible with PAG oil. Some types of dye decrease the oil viscosity or may chemically react with the oil.
2. R-134A leak detection dye requires time to work. Depending upon the leak rate, a leak may not become visible for between 15 minutes and 7 days.
3. To prevent false diagnosis, thoroughly clean any residual dye from the service port with a rag and the approved fluorescent dye cleaner J-43872 dye cleaner.

Halogen Leak Detector

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

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

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

Test Description

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

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

Air Conditioning (A/C) System Performance Test

A/C Performance Table

A/C Diagnostics Chart

A/C Diagnostics Chart

Heating Performance Diagnostic

Heating Performance Diagnostic

Defrosting Insufficient

Defrosting Insufficient

Noise Diagnosis - Blower Motor

Noise Diagnosis - Blower Motor

Air Conditioning Compressor Oil Diagnosis

Air Conditioning Compressor Oil Diagnosis

Noise Diagnosis - Air Conditioning (A/C) System

Noise Diagnosis - Air Conditioning (A/C) System

Noise Diagnosis - HVAC Module

Noise Diagnosis - HVAC Module

Odor Diagnosis

Odor Diagnosis

Eliminating Air Conditioning Odor

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

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

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

Deodorize the evaporator core using Deodorizing Aerosol Kit.

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

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

1. J 43600 ACR 2000 Air Conditioning Service Center
2. J 45037 A/C Oil Injector

The J 43600 ACR 2000 air conditioning service center is a complete air conditioning service center for R-134a. 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 air conditioning service center ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Specifications 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 A/C oil injector. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Specifications .

1. J 41447 R-134A A/C Tracer Dye Box of 24
2. J 42220 Universal 12V Leak Detection Lamp
3. J 43600 ACR 2000 Air Conditioning Service Center
4. J 45268 A/C Flush Adapter Kit

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

Flushing is intended to remove the following

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

Forward Flushing Setup

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

Reverse Flushing Setup

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

Flush Procedure

1. Recover refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove thermal expansion valve (TXV). Refer to «Air Conditioning Evaporator Thermal Expansion Valve Replacement»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install TXV stud onto J 45268-115.
4. Install new sealing washers onto evaporator core. Refer to «Air Conditioning System Seal Replacement»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
5. Install J 45268-115 in place of TXV.
6. Install TXV mounting bolts and tighten to 7 N.m (62 lb in).
7. Install new washers onto liquid line and suction hose. Refer to «Air Conditioning System Seal Replacement»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
8. Connect liquid line and suction hose to J 45268-115.
9. Install TXV block fitting nut and tighten to 27 N.m (20 lb ft).
10. Remove A/C compressor. Refer to «Air Conditioning Compressor Replacement (LE5)»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) , «Air Conditioning Compressor Replacement (LY7)»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
11. Remove A/C refrigerant filter. Refer to «Air Conditioning (AC) Refrigerant Filter Replacement»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
12. Service filter with ACDelco P/N GF 470, before each flush.
13. Install J 45268-10 to compressor hose assembly.
14. Connect J 45268-1 flush filter to J 45268-7 flush adapter.
15. Connect blue hose from J 43600 ACR 2000 air conditioning service center to J 45268-1 flush filter adapter.
16. Connect red hose from J 43600 ACR 2000 air conditioning service center to J 45268-8 flush adapter.
17. Flush A/C system. Follow instructions supplied with J 43600 ACR 2000 air conditioning service center.
18. Disconnect red hose from J 43600 ACR 2000 air conditioning service center to J 45268-8 flush adapter.
19. Disconnect blue hose from J 43600 ACR 2000 air conditioning service center to J 45268-1 flush filter adapter.
20. Disconnect J 45268-1 flush filter from J 45268-10 flush adapter.
21. Remove J 45268-10 from compressor hose assembly.
22. If you will reinstall the removed A/C compressor, perform the following procedure: Remove A/C compressor drain plug. Drain PAG oil from A/C compressor. Rotate compressor input shaft to assist in draining the PAG oil from compressor. Add the total system capacity of PAG oil to A/C compressor. Refer to «Refrigerant System Specifications»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-specifications) . NOTE: Flushing will remove fluorescent leak detection dye from A/C system. Add one bottle of J 41447 R-134A A/C tracer dye box of 24. Install A/C compressor drain plug and tighten to 15 N.m (11 lb ft).
23. Install A/C compressor. Refer to «Air Conditioning Compressor Replacement (LE5)»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) , «Air Conditioning Compressor Replacement (LY7)»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
24. Install new A/C refrigerant filter. Refer to «Air Conditioning (AC) Refrigerant Filter Replacement»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
25. Remove TXV block fitting nut.
26. Disconnect liquid line and suction line from J 45268-115.
27. Remove TXV bolts retaining J 45268-115.
28. Remove J 45268-115.
29. Inspect TXV for debris. Clean or replace as needed.
30. Install TXV. Refer to «Air Conditioning Evaporator Thermal Expansion Valve Replacement»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
31. Evacuate and recharge A/C system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
32. Leak test fittings using J 42220 Universal 12V leak detection lamp.

Draining Procedure

1. Remove the compressor crankcase oil drain plug and drain the crankcase into a clean, graduated container.
2. Drain the oil from both the suction and discharge ports of the removed compressor into the same container. Rotate the compressor shaft to assist in draining the compressor.
3. Measure and record the amount of oil drained from the removed compressor. This measurement will be used during installation of the replacement compressor.
4. Inspect oil drained from removed compressor. Refer to «Air Conditioning Compressor Oil Diagnosis»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__air-conditioning-compressor-oil-diagnosis)
5. Properly discard the used refrigerant oil.

Balancing Procedure

1. The replacement compressor is shipped with the total system capacity of refrigerant oil.
2. Before installing the compressor, the refrigerant oil will have to be partially drained: Refer to the amount of refrigerant oil recorded during the compressor removal. Subtract the amount recorded from the total system capacity. Refer to «Refrigerant System Specifications»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-specifications) . The difference between the total system capacity and the recorded amount is the calculated amount to be drained from the replacement compressor.
3. Drain the calculated amount of refrigerant oil from the replacement compressor.

Scheme 1

Air Conditioning Compressor Replacement (LE5)

Scheme 2

Air Conditioning Compressor Replacement (LY7)

1. J 6083 Snap Ring Pliers
2. J 37872 Universal Spanner Wrench
3. J 39400-A Halogen Leak Detector

Removal Procedure

1. Remove the drive belt from the A/C compressor. Refer to «Drive Belt Replacement (LE5)»(/chevrolet/malibu/viii-2011-2014/remont/mechanical/#engine-mechanical-24l__drive-belt-replacement-le5) , for the 2.4L engine or «Drive Belt Replacement»(/chevrolet/malibu/viii-2011-2014/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle) for the 3.6L engine.
2. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
3. Remove the lower air deflector. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
4. Remove and discard the compressor clutch plate bolt. Use the J 37872 universal spanner wrench to hold the compressor clutch plate from turning.
5. Remove the compressor clutch plate from the compressor.
6. Remove the compressor pulley snap ring using the J 6083 snap ring pliers.
7. Remove the compressor pulley from the compressor.
8. Remove the compressor clutch coil snap ring using the J 6083 snap ring pliers.
9. Remove the compressor clutch coil from the compressor.

Installation Procedure

1. Carefully clean the clutch plate bolt threads with a M6x1.0 tap. Carefully blow out debris with compressed air.
2. Install the compressor clutch coil to the compressor.
3. Install the compressor clutch coil snap ring using the J 6083 snap ring pliers.
4. Install the compressor pulley to the compressor.
5. Install the compressor pulley snap ring using the J 6083 snap ring pliers.
6. Place a small amount of oil on the 0.4 mm (0.016 in) air gap shim and place inside the clutch drive plate.
7. Install the compressor clutch plate to the compressor.
8. Measure the air gap between the pulley and the drive plate. Adjust the shims to achieve a 0.3-0.6 mm (0.012-0.024 in) air gap.
9. Install the clutch drive plate bolt.
10. Tighten the compressor clutch drive plate bolt. Use the J 37872 universal spanner wrench to hold the compressor clutch plate from turning. Tighten Tighten the bolt to 12 N.m (106 lb in).
11. Install the lower air deflector. Refer to «Radiator Air Lower Baffle and Deflector Replacement»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
12. Lower the vehicle.
13. Install the drive belt to the A/C compressor. Refer to «Drive Belt Replacement (LE5)»(/chevrolet/malibu/viii-2011-2014/remont/mechanical/#engine-mechanical-24l__drive-belt-replacement-le5) , for the 2.4L engine or «Drive Belt Replacement»(/chevrolet/malibu/viii-2011-2014/remont/mechanical/#engine-mechanical-36l-repair-instructions-on-vehicle) for the 3.6L engine.
14. Leak test the fittings using the J 39400-A halogen leak detector.

Scheme 3

Compressor Pressure Relief Valve Replacement (LY7)

Scheme 4

Compressor Pressure Relief Valve Replacement (LE5)

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

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

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

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

Scheme 5

Air Conditioning Compressor and Condenser Hose Replacement (LE5)

Scheme 6

Air Conditioning Compressor and Condenser Hose Replacement (LY7)

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Insert 2 small screwdrivers into the 2 slots of the compressor hose and suction line connector and release locking tabs.
3. Remove the compressor hose and liquid line connector.
4. Remove the suction hose from the compressor hose.
5. Remove and discard the O-rings.
6. Remove the surge tank from the surge tank bracket.
7. Remove the suction hose and liquid line nut from the thermal expansion valve (TXV).
8. Remove the suction hose and liquid line from the TXV.
9. Remove the suction hose from the dash clip.
10. Remove the line clip from the dash.
11. Remove the refrigerant pressure sensor wire harness connector.
12. Remove the liquid line bracket bolt.
13. Remove the suction hose.
14. Remove and discard the sealing washers.

1. Uncap A/C components.
2. Install new sealing washers. Refer to «Air Conditioning System Seal Replacement»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the suction hose.
4. Install the liquid line bracket bolt and tighten to 10 N.m (89 lb in).
5. Install the refrigerant pressure sensor wire harness connector.
6. Install the line clip to the dash.
7. Install the suction hose to the dash clip.
8. Install the suction hose and liquid line to the TXV.
9. Install the suction hose and liquid line nut to the TXV and tighten the nut to 20 N.m (15 lb ft).
10. Install new O-rings. Refer to «Air Conditioning O-Ring Seal Replacement»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
11. Install the suction hose to the compressor hose.
12. Install the compressor hose and liquid line connector.
13. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
14. Leak test the fittings using the J 39400-A halogen leak detector.
15. Install the surge tank to the surge tank bracket.

J 39400-A Halogen Leak Detector

Scheme 7

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the refrigerant pressure sensor wire harness connector.
3. Remove the refrigerant pressure sensor.
4. Remove the liquid line bracket bolt.
5. Remove the air cleaner assembly.
6. Remove the surge tank from the surge tank bracket.
7. Remove the suction hose and liquid line nut from the thermal expansion valve (TXV).
8. Remove the suction hose and liquid line from the TXV.
9. Remove the suction hose from the dash clip.
10. Remove the liquid line from the dash clip.
11. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
12. Remove the right front fender liner. Refer to «Front Wheelhouse Panel Splash Shield Replacement»(/chevrolet/malibu/viii-2011-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
13. Remove the right radiator air deflector retainers.
14. Remove the right radiator air deflector.
15. Remove the liquid line and compressor hose bolt from the condenser.
16. Remove the liquid line and compressor hose from the condenser.
17. Remove the liquid line from the rail clip.
18. Lower the vehicle.
19. Remove the liquid line.
20. Remove and discard the sealing washers.

1. Uncap A/C components.
2. Install new sealing washers. Refer to «Air Conditioning System Seal Replacement»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the liquid line.
4. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
5. Install the liquid line and compressor hose to the condenser.
6. Install the liquid line and compressor hose bolt to the condenser and tighten to 20 N.m (15 lb ft).
7. Install the liquid line to the rail clip.
8. Install the right radiator air deflector.
9. Install the right radiator air deflector retainers.
10. Install the right front fender liner. Refer to «Front Wheelhouse Panel Splash Shield Replacement»(/chevrolet/malibu/viii-2011-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
11. Lower the vehicle.
12. Install the suction hose and liquid line to the TXV.
13. Install the suction hose and liquid line nut to the TXV and tighten to 20 N.m (15 lb ft).
14. Install the liquid line to the dash clip.
15. Install the suction hose to the dash clip.
16. Install the air cleaner assembly.
17. Install the liquid line bracket bolt and tighten to 10 N.m (89 lb in).
18. Install the refrigerant pressure sensor and tighten to 5 N.m (44 lb in).
19. Install the refrigerant pressure sensor wire harness connector.
20. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
21. Leak test the fittings using the J 39400-A halogen leak detector.
22. Install the surge tank to the surge tank bracket.

Scheme 8

Air Conditioning Evaporator Thermal Expansion Valve Hose Replacement

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the surge tank from the surge tank bracket.
3. Remove the suction hose and liquid line nut from the thermal expansion valve (TXV).
4. Remove the suction hose and liquid line from the TXV.
5. Remove the line clip from the dash.
6. Remove the refrigerant filter from the line.
7. Remove and discard the sealing washers.

Scheme 9

1. Uncap A/C components.
2. Install new sealing washers. Refer to «Air Conditioning System Seal Replacement»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the refrigerant filter into the line.
4. Install the line clip to the dash.
5. Install the suction hose and liquid line to the TXV.
6. Install the suction hose and liquid line nut to the TXV and tighten the nut to 20 N.m (15 lb ft).
7. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
8. Leak test the fittings using the J 39400-A halogen leak detector.
9. Install the surge tank to the surge tank bracket.

Scheme 10

Air Conditioning Compressor Suction Screen Replacement

1. J 39400-A Halogen Leak Detector
2. J 46246 Valve Core Removal Tool

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the service port valve core using J 46246 valve core removal tool or equivalent.

1. Install the service port valve core using J 46246 valve core removal tool or equivalent. Tighten the service port valve core to 2.5 N.m (22 lb in).
2. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Leak test the fittings using the J 39400-A halogen leak detector.

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the surge tank from the surge tank bracket.
3. Remove the suction line from the dash clip.
4. Remove the liquid line from the dash clip.
5. Remove the liquid line and suction line nut from the thermal expansion valve (TXV).
6. Remove the suction line from the TXV.
7. Remove the liquid line from the TXV.
8. Remove the TXV screws.
9. Remove the TXV.
10. Remove and discard the sealing washers.

1. Uncap A/C components.
2. Install new sealing washers. Refer to «Air Conditioning System Seal Replacement»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the TXV.
4. Install the TXV screws and tighten to 7 N.m (62 lb in).
5. Install the liquid line to the TXV.
6. Install the suction line to the TXV.
7. Install the liquid line and suction line nut to the TXV and tighten to 20 N.m (15 lb ft).
8. Install the liquid line to the dash clip.
9. Install the suction line to the dash clip.
10. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
11. Leak test the fittings using the J 39400-A halogen leak detector.
12. Install the surge tank to the surge tank bracket.

J 39400-A Halogen Leak Detector

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

1. Install a new O-ring. Refer to «Air Conditioning O-Ring Seal Replacement»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Install the refrigerant pressure sensor and tighten to 5 N.m (44 lb in).
3. Install the refrigerant pressure sensor wire harness connector.
4. Leak test the fittings using the J 39400-A halogen leak detector.

J 39400-A Halogen Leak Detector

1. Recover the refrigerant. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the left and right headlamp assemblies. Refer to «Headlamp Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exterior-lights/#lighting-system) .
3. Loop a rope around each of the 2 upper tabs of the radiator and tie the rope around the upper tie bar.
4. Remove both upper radiator support bracket bolts.
5. Remove both upper radiator support brackets.
6. Raise the vehicle. Refer to «Lifting and Jacking the Vehicle»(/chevrolet/malibu/viii-2011-2014/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
7. Remove the lower radiator air deflector retainers.
8. Remove the lower radiator air deflector.
9. Remove the right front fender liner. Refer to «Front Wheelhouse Panel Splash Shield Replacement»(/chevrolet/malibu/viii-2011-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
10. Remove the right radiator air deflector retainers.
11. Remove the right radiator air deflector.
12. Remove the left radiator air deflector retainers.
13. Remove the left radiator air deflector.
14. Remove the liquid line and compressor hose bolt from condenser.
15. Remove the compressor hose from the condenser.
16. Remove the liquid line from the condenser.
17. Remove both lower radiator mounting bracket bolts.
18. Remove both lower radiator mounting brackets.
19. Remove and discard the condenser mounting bolts.
20. Remove and discard the condenser mounting nuts.
21. Push upward on the radiator and downward on the condenser to unsnap the condenser mounting tabs from the radiator clip.
22. Remove the condenser.
23. Remove the upper seal.
24. Remove and discard the sealing washers.

Scheme 11

1. Uncap A/C components.
2. Install new sealing washers. Refer to «Air Conditioning System Seal Replacement»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Install the upper seal.
4. If replacing the condenser, add the specific amount of PAG® oil directly to the condenser. Refer to «Refrigerant System Specifications»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-specifications) .
5. Install the radiator air side seals onto the condenser mounting tabs on the radiator.
6. Insert condenser mounting tabs into the radiator clips.
7. Install the condenser mounting nuts.
8. Install the condenser mounting bolts and tighten to 6 N.m (53 lb in).
9. Bend the radiator air side seals and insert the seals into the channel of the intake air splash shields.
10. The radiator air side seals must be in the proper position for proper airflow.
11. Install both lower radiator mounting brackets.
12. Install both lower radiator mounting brackets bolts and tighten to 60 N.m (44 lb ft).
13. Install the liquid line to the condenser.
14. Install the compressor hose to the condenser.
15. Install the liquid line and compressor hose bolt to the condenser and tighten to 20 N.m (15 lb ft).
16. Install the left radiator air deflector.
17. Install the left radiator air deflector retainers.
18. Install the right radiator air deflector.
19. Install the right radiator air deflector retainers.
20. Install the right front fender liner. Refer to «Front Wheelhouse Panel Splash Shield Replacement»(/chevrolet/malibu/viii-2011-2014/remont/frames-subframes-crossmembers/#frame-and-underbody) .
21. Install the lower radiator air deflector.
22. Install the lower radiator air deflector retainers.
23. Lower the vehicle.
24. Remove the rope attached to the radiator and upper tie bar.
25. Install both upper radiator support brackets.
26. Install both upper radiator support bracket bolts and tighten to 10 N.m (89 lb in).
27. Install the left and right headlamp assemblies. Refer to «Headlamp Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exterior-lights/#lighting-system) .
28. Evacuate and charge the refrigerant system. Refer to «Refrigerant Recovery and Recharging»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
29. Leak test the fittings using the J 39400-A halogen leak detector.

1. Remove the air conditioner (A/C) lines from the thermal expansion valve. Refer to «Air Conditioning Evaporator Thermal Expansion Valve Replacement»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the heater hose from the heater core. Refer to «Heater Inlet Hose Replacement (LE5)»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) , «Heater Inlet Hose Replacement (LY7)»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) , and «Heater Outlet Hose Replacement (LY7)»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) , «Heater Outlet Hose Replacement (LE5)»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
3. Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel Reinforcement Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
4. Remove the recirculation actuator wire harness connector.
5. Remove the air temperature actuator wire harness connector.
6. Remove the mode actuator wire harness connector.
7. Remove the blower motor wire harness connector.
8. Remove the blower motor resistor wire harness connector.
9. Remove the left hand side window defogger outlet duct.
10. Remove the HVAC module assembly mounting bolts from the instrument panel reinforcement.
11. Remove the HVAC module assembly to dash panel bolts (1).
12. Remove the HVAC module assembly (1).

Scheme 12

1. Install the HVAC module assembly (1).
2. Install the HVAC module assembly to dash panel bolts (1) and tighten to 10 N.m (88 lb in).
3. Install the HVAC module assembly mounting bolts to the instrument panel reinforcement and tighten the bolts to 5 N.m (44 lb in).
4. Install the left hand side window defogger outlet duct.
5. Install the blower motor resistor wire harness connector.
6. Install the blower motor wire harness connector.
7. Install the mode actuator wire harness connector.
8. Install the air temperature actuator wire harness connector.
9. Install the recirculation actuator wire harness connector.
10. Install the I/P assembly. Refer to «Instrument Panel Reinforcement Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
11. Install the heater hoses to the heater core. Refer to «Heater Inlet Hose Replacement (LE5)»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) , «Heater Inlet Hose Replacement (LY7)»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) , and «Heater Outlet Hose Replacement (LY7)»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) , «Heater Outlet Hose Replacement (LE5)»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
12. Install the A/C lines to the thermal expansion valve. Refer to «Air Conditioning Evaporator Thermal Expansion Valve Replacement»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Remove the HVAC module assembly. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the center floor air outlet duct screws.
3. Remove the center floor air outlet duct.
4. Drill out the lower HVAC module case heat stakes.
5. Remove the lower HVAC module case screws.
6. Remove the lower HVAC module case.
7. Remove the thermal expansion valve screws.
8. Remove the thermal expansion valve.
9. Remove and discard the sealing washers.
10. Remove the evaporator.

1. If replacing the evaporator, add the specific amount of PAG® oil directly to the evaporator. Refer to «Refrigerant System Specifications»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning__refrigerant-system-specifications) .
2. Install the evaporator.
3. Install new sealing washers. Refer to «Air Conditioning System Seal Replacement»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
4. Install the thermal expansion valve.
5. Install the thermal expansion valve screws and tighten to 7 N.m (62 lb in).
6. Install the lower HVAC module case.
7. Install the lower HVAC module case screws and tighten to 1.5 N.m (13 lb in).
8. Install the center floor air outlet duct.
9. Install the center floor air outlet duct screws and tighten to 1.5 N.m (13 lb in).
10. Install the HVAC module assembly. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

Scheme 13

Heater Inlet Hose Replacement (LY7)

J 38185 Hose Clamp Pliers

1. Partially drain the coolant. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the surge tank from the surge tank bracket.
3. Reposition the heater inlet hose clamp at the heater core using the J 38185 hose clamp pliers.
4. Remove the heater inlet hose from the heater core.
5. Reposition the heater inlet hose clamp at the engine using the J 38185 hose clamp pliers.
6. Remove the heater inlet hose from the engine.

1. Install the heater inlet hose to the engine.
2. Reposition the heater inlet hose clamp at the engine using the J 38185 hose clamp pliers.
3. Install the heater inlet hose to the heater core.
4. Reposition the heater inlet hose clamp at the heater core using the J 38185 hose clamp pliers.
5. Install the surge tank to the surge tank bracket.
6. Fill the coolant. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .

Scheme 14

Heater Outlet Hose Replacement (LY7)

J 38185 Hose Clamp Pliers

1. Partially drain the coolant. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .
2. Remove the surge tank from the surge tank bracket.
3. Reposition the heater outlet hose clamp at the heater core using the J 38185 hose clamp pliers.
4. Remove the heater outlet hose from the heater core.
5. Reposition the heater outlet hose clamp at the engine using the J 38185 hose clamp pliers.
6. Remove the heater outlet hose from the engine.

1. Install the heater outlet hose to the engine.
2. Reposition the heater outlet hose clamp at the engine using the J 38185 hose clamp pliers.
3. Install the heater outlet hose to the heater core.
4. Reposition the heater outlet hose clamp at the heater core using the J 38185 hose clamp pliers.
5. Install the surge tank to the surge tank bracket.
6. Fill the coolant. Refer to «Cooling System Draining and Filling (GE 47716)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) , «Cooling System Draining and Filling (Static Fill)»(/chevrolet/malibu/viii-2011-2014/remont/cooling-system-mechanical/#engine-cooling-system) .

Scheme 15

Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement

Scheme 16

Blower Motor Resistor Replacement

1. Remove the right closeout panel. Refer to «Instrument Panel Insulator Replacement - Right Side»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
2. Remove the blower motor wire harness connector.
3. Cut out the blower motor using a utility knife in the narrow groove of the lower case.
4. Remove the blower motor.
5. Remove the blower motor nuts.
6. Remove the blower motor from the blower motor cup.

1. Install the new blower motor to the blower motor cup.
2. Install the blower motor nuts and tighten to 2.4 N.m (21 lb in).
3. Install the motor blower seal to the blower motor service ring.
4. Install the blower motor.
5. Install the blower motor attachment ring.
6. Install the blower motor screws and tighten to 1.5 N.m (13 lb in).
7. Install the blower motor wire harness connector.
8. Install the right closeout panel. Refer to «Instrument Panel Insulator Replacement - Right Side»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .

Scheme 17

Instrument Panel Outer Air Outlet Replacement - Left Side

Scheme 18

Instrument Panel Center Air Outlet Replacement

Scheme 19

Instrument Panel Outer Air Outlet Replacement - Right Side

1. Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
2. Disconnect the wire harness clip at the left air outlet duct.
3. Remove the left air outlet duct screws.
4. Remove the left air outlet duct.

1. Install the left air outlet duct.
2. Install the left air outlet duct screws and tighten to 2.5 N.m (22 lb in).
3. Connect the wire harness clip at the left air outlet duct.
4. Install the I/P assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .

Scheme 20

1. Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
2. Remove the right hand side window defogger duct screws.
3. Remove the right hand side window defogger duct.
4. Disconnect the wire harness clip at the right air outlet duct.
5. Remove the right air outlet duct screws.
6. Remove the right air outlet duct.

1. Install the right air outlet duct.
2. Install the right air outlet duct screws and tighten to 2.5 N.m (22 lb in).
3. Connect the wire harness clip at the right air outlet duct.
4. Install the right hand side window defogger duct.
5. Install the right hand side window defogger duct screws and tighten to 2.5 N.m (22 lb in).
6. Install the I/P assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .

Scheme 21

Instrument Panel Center Air Outlet Duct Replacement

1. Remove the instrument panel (I/P) pad. Refer to «Instrument Panel Upper Trim Panel Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
2. Press on the 2 tabs of the windshield defroster duct.
3. Remove the windshield defroster duct.

1. Install the windshield defroster duct.
2. Install the I/P pad. Refer to «Instrument Panel Upper Trim Panel Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .

1. Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
2. Remove the left hand side window defogger duct screws.
3. Remove the left hand side window defogger duct.

1. Install the left hand side window defogger duct.
2. Install the left hand side window defogger duct screws and tighten to 2.5 N.m (22 lb in).
3. Install the I/P assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .

1. Remove the instrument panel (I/P) assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
2. Remove the right hand side window defogger duct screws.
3. Remove the right hand side window defogger duct.

1. Install the right hand side window defogger duct.
2. Install the right hand side window defogger duct screws and tighten to 2.5 N.m (22 lb in).
3. Install the I/P assembly. Refer to «Instrument Panel Assembly Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .

1. Remove the console. Refer to «Front Floor Console Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
2. Remove the Instrument panel lower bracket. Refer to «Instrument Panel Lower Bracket Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
3. Remove the center floor air duct screws.
4. Remove the center floor air duct.

1. Install the center floor air duct.
2. Install the Instrument panel lower bracket. Refer to «Instrument Panel Lower Bracket Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
3. Install the center floor air duct screws and tighten to 1.5 N.m (13 lb in).
4. Install the console. Refer to «Front Floor Console Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .

1. Remove the console. Refer to «Front Floor Console Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
2. Remove the left front seat. Refer to «Front Seat Replacement - Bucket»(/chevrolet/malibu/viii-2011-2014/remont/seats/#seat-hardware-seat-trim-and-upholstery) .
3. Remove the left front carpet retainer. Refer to «Front Side Door Opening Floor Carpet Retainer Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#floor-coverings-and-headlinings) .
4. Remove the left center pillar lower garnish molding. Refer to «Center Pillar Lower Garnish Molding Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
5. Remove the floor carpet enough to access the left rear floor duct. Refer to «Front Floor Panel Carpet Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#floor-coverings-and-headlinings) .
6. Remove the left rear floor duct.

1. Install the left rear floor duct.
2. Install the floor carpet. Refer to «Front Floor Panel Carpet Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#floor-coverings-and-headlinings) .
3. Install the left center pillar lower garnish molding. Refer to «Center Pillar Lower Garnish Molding Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
4. Install the left front carpet retainer. Refer to «Front Side Door Opening Floor Carpet Retainer Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#floor-coverings-and-headlinings) .
5. Install the left front seat. Refer to «Front Seat Replacement - Bucket»(/chevrolet/malibu/viii-2011-2014/remont/seats/#seat-hardware-seat-trim-and-upholstery) .
6. Install the console. Refer to «Front Floor Console Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .

1. Remove the console. Refer to «Front Floor Console Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .
2. Remove the right front seat. Refer to «Front Seat Replacement - Bucket»(/chevrolet/malibu/viii-2011-2014/remont/seats/#seat-hardware-seat-trim-and-upholstery) .
3. Remove the right front carpet retainer. Refer to «Front Side Door Opening Floor Carpet Retainer Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#floor-coverings-and-headlinings) .
4. Remove the right center pillar lower garnish molding. Refer to «Center Pillar Lower Garnish Molding Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
5. Remove the floor carpet enough to access the right rear floor duct. Refer to «Front Floor Panel Carpet Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#floor-coverings-and-headlinings) .
6. Remove the left rear floor duct.

1. Install the right rear floor duct.
2. Install the floor carpet. Refer to «Front Floor Panel Carpet Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#floor-coverings-and-headlinings) .
3. Install the right center pillar lower garnish molding. Refer to «Center Pillar Lower Garnish Molding Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#interior-trim-and-interior-paneling) .
4. Install the right front carpet retainer. Refer to «Front Side Door Opening Floor Carpet Retainer Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#floor-coverings-and-headlinings) .
5. Install the right front seat. Refer to «Front Seat Replacement - Bucket»(/chevrolet/malibu/viii-2011-2014/remont/seats/#seat-hardware-seat-trim-and-upholstery) .
6. Install the console. Refer to «Front Floor Console Replacement»(/chevrolet/malibu/viii-2011-2014/remont/exteriorinterior-trim/#instrument-panel-trim-and-console-trim) .

1. Remove the HVAC module assembly. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the center floor air outlet duct screws.
3. Remove the center floor air outlet duct.
4. Drill out the heater core cover heat stakes.
5. Remove the heater core cover screws.
6. Remove the heater core cover.

1. Install the heater core cover.
2. Install the heater core cover screws and tighten to 1.5 N.m (13 lb in).
3. Install the center floor air outlet duct.
4. Install the center floor air outlet duct screws and tighten to 1.5 N.m (13 lb in).
5. Install the HVAC module assembly. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

1. Remove the HVAC module assembly. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .
2. Remove the center floor air outlet duct screws.
3. Remove the center floor air outlet duct.
4. Drill out the heater core cover heat stakes.
5. Remove the heater core cover screws.
6. Remove the heater core cover.
7. Remove the heater core.

1. Install the heater core.
2. Install the heater core cover.
3. Install the heater core cover screws and tighten to 1.5 N.m (13 lb in).
4. Install the center floor air outlet duct.
5. Install the upper floor air outlet duct screws and tighten to to 1.5 N.m (13 lb in).
6. Install the HVAC module assembly. Refer to «Air Conditioning and Heater Module Assembly Removal and Installation»(/chevrolet/malibu/viii-2011-2014/remont/automatic-hvac-system/#heating-ventilation-and-air-conditioning) .

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

Scheme 22

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

See also:
• Symptoms - HVAC Systems - Manual
• Symptoms - HVAC Systems - Automatic
• Moving Parts and Hot Surfaces Warning
• Diagnostic System Check - Vehicle
• Engine Fails To Reach Normal Operating Temperature
• Air Conditioning Compressor Malfunction
• Air Delivery Improper
• Drive Belt Falls Off and Excessive Wear Diagnosis
• Drive Belt Falls Off and Excessive Wear Diagnosis
• Drive Belt Tensioner Diagnosis
• Drive Belt Tensioner Diagnosis
• Oil Leak Diagnosis
• Oil Leak Diagnosis
• Drive Belt Replacement (LE5)
• Drive Belt Replacement
• Vibration Analysis - Engine
• Loss of Coolant
• Fluid Leak Diagnosis (Non Hybrid)
• Fluid Leak Diagnosis
• Fastener Caution
• Lifting and Jacking the Vehicle
• Front Wheelhouse Panel Splash Shield Replacement
• Radiator Air Lower Baffle and Deflector Replacement
• Air Cleaner Assembly Replacement
• Air Cleaner Inlet Duct Replacement
• Headlamp Replacement
• Instrument Panel Reinforcement Replacement
• Front Seat Replacement - Bucket
• Front Side Door Opening Floor Carpet Retainer Replacement
• Center Pillar Lower Garnish Molding Replacement
• Refrigerant Recovery and Recharging
• A/C Diagnostics Chart
• Air Conditioning (A/C) System Performance Test
• Heating Performance Diagnostic
• Refrigerant System Specifications
• Air Conditioning Compressor Oil Diagnosis