GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Malibu 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Compressor Pressure Relief Valve Replacement

Removal Procedure
  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  3. Remove the right side wheelhouse splash shield. Refer to Front Fender Liner Replacement in Body Front End.

    4. Object Number: 277956 Size: SH
  4. Remove the compressor pressure relief valve (1) from the compressor head.

Installation Procedure
  1. Using a lint-free clean, dry cloth, carefully clean the pressure relief valve seat area of the rear compressor head.
  2. Coat the new O-ring with mineral base 525 viscosity refrigerant oil.

    3. Important: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system.

  3. Install the new O-ring.

    4. Object Number: 277956 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  4. Install the compressor relief valve (1) into the compressor head.

    5. Tighten
    Tighten the valve to 9 N·m (80 lb in).

  5. Install the right side wheelhouse splash shield. Refer to Front Fender Liner Replacement in Body Front End.
  6. Lower the vehicle.
  7. Evacuate, recharge and leak test the system. Refer to Refrigerant Recovery and Recharging .