GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2003 🢒 Malibu 🢒 HVAC 🢒 HVAC Systems - Manual 🢒 Too Hot in Vehicle

Test Description

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

  1. The specified values are from the A/C System Performance Test.

    2.

  2. The voltage will vary between 0-12 volts during normal operation. The HVAC control assembly connector must be connected during this step.

Step

Action

Values

Yes

No

Schematic Reference: HVAC Schematics

Connector End View Reference: HVAC Connector End Views

DEFINITION: The temperature cannot be adjusted, or the cooling is insufficient during A/C operation.

1

Did you perform the HVAC Diagnostics System Check?

--

Go to Step 2

Go to Diagnostic System Check - HVAC Systems - Manual

2
  1. Turn ON the ignition, with the engine OFF.
  2. Place the blower motor switch in each speed position.

Does the blower motor operate in any of the speed positions?

--

Go to Step 3

Go to Blower Motor Inoperative

3

Does the blower motor operate in the desired speed[s]?

--

Go to Step 4

Go to Blower Motor Malfunction

4
  1. Place the mode switch in the vent position.
  2. Place the blower motor switch in the maximum speed position.
  3. Place the outside air switch in the ON position.
  4. Place the recirculation switch in the ON position.

Does the recirculation door move from the recirculation position to the outside air position?

--

Go to Step 5

Go to Air Recirculation Malfunction

5

When the A/C is ON, does the customer concern occur?

--

Go to Step 6

Go to Step 8

6
  1. Start the engine.
  2. Place the blower motor switch in the maximum speed position.
  3. Place the mode switch in the bi-level position with recirculation ON.
  4. Place the air temperature switch in the coldest position.

Does the A/C compressor operate?

--

Go to Step 7

Go to HVAC Compressor Clutch Does Not Engage

7

Perform the refrigerant system performance test. Refer to Air Conditioning (A/C) System Performance Test in Heating, Ventilation and Air Conditioning.

Did you find and correct the condition?

--

Go to Step 18

Go to Step 8

8
  1. Turn ON the ignition, with the engine OFF.
  2. Observe the air temperature actuator drive shaft.
  3. Place the air temperature switch from the coldest position to the warmest position.

Does the air temperature actuator drive shaft rotate at all?

--

Go to Step 9

Go to Step 10

9

Inspect the air temperature door and the air temperature actuator for the following conditions:

    • Misaligned air temperature actuator.
         Refer to Air Temperature Actuator Replacement .
    • Broken or binding linkages or air temperature door
    • Obstruction that prevents the air temperature door from operating within its full range of motion
    • Missing seals to the air temperature door
    • Misaligned seals to the air temperature door

Did you find and correct the condition?

--

Go to Step 18

Go to Testing for Intermittent Conditions and Poor Connections in Wiring Systems

10

Test the ignition 3 voltage circuit of the air temperature actuator for an open or a high resistance. Refer to Circuit Testing and Wiring Repairs in Wiring Systems.

Did you find and correct the condition?

--

Go to Step 18

Go to Step 11

11

Test the ground circuit of the air temperature actuator for an open. Refer to Circuit Testing and Wiring Repairs in Wiring Systems.

Did you find and correct the condition?

--

Go to Step 18

Go to Step 12

12

Test the air temperature door position signal circuit of the air temperature actuator for an open, high resistance, short to ground, or short to voltage. Refer to Circuit Testing and Wiring Repairs in Wiring Systems.

Did you find and correct the condition?

--

Go to Step 18

Go to Step 13

13

Important: The HVAC control assembly connector must be connected to correctly perform tests.

  1. Turn ON the ignition, with the engine OFF.
  2. Measure the voltage from the air temperature door position signal circuit of the air temperature actuator to a good ground.
  3. Place the air temperature switch from the coldest position to the warmest position.

Does the voltage measure within the specified values with a smooth transition between COLD to HOT?

0-12 V

Go to Step 14

Go to Step 15

14

Inspect for poor connections at the harness connector of the air temperature actuator. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems.

Did you find and correct the condition?

--

Go to Step 18

Go to Step 16

15

Inspect for poor connections at the harness connector of the HVAC control assembly. Refer to Testing for Intermittent Conditions and Poor Connections and Connector Repairs in Wiring Systems.

Did you find and correct the condition?

--

Go to Step 18

Go to Step 17

16

Replace the air temperature actuator. Refer to Air Temperature Actuator Replacement .

Did you complete the replacement?

--

Go to Step 18

--

17

Replace the HVAC control assembly. Refer to Heater and Air Conditioning Control Replacement .

Did you complete the replacement?

--

Go to Step 18

--

18

Operate the system in order to verify the repair.

Did you correct the condition?

--

System OK

Go to Step 2