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Makes 🢒 Chevrolet 🢒 2004 🢒 Malibu 🢒 HVAC 🢒 HVAC Systems - Manual 🢒 Air Conditioning Compressor Replacement

Air Conditioning Compressor Replacement L61

Tools Required

J 39400-A Halogen Leak Detector

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. Object Number: 1203534 Size: SH
  3. Remove the right front fender liner. Refer to Front Fender Liner Replacement .
  4. Remove the right radiator air deflector retainers.
  5. Remove the right radiator air deflector.
  6. Remove the engine drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 2.2L (L61).

    7. Object Number: 1201972 Size: SH
  7. Remove the compressor hose nut from the compressor.
  8. Remove the compressor hose from the compressor.
  9. Remove the compressor wire harness connector.
  10. Remove the compressor mounting bolts.

    11. Object Number: 1201878 Size: SH
  11. Remove the compressor.

    12. Important: Cap all A/C components immediately to prevent system contamination.

  12. Remove and discard the sealing washers.

Installation Procedure

    Important: Use a low viscosity, poly-alkylene glycol (PAG) oil. Use of the incorrect oil can result in compressor failure.

  1. If replacing the compressor, refer to Compressor Oil Balancing .
  2. Uncap A/C components.
  3. Install new sealing washers. Refer to Sealing Washer Replacement .
  4. Install the compressor.

    5. Object Number: 1201878 Size: SH

    Notice: Refer to Fastener Notice in the Preface section.

  5. Install the compressor mounting bolts.

    6. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).

  6. Install the compressor wire harness connector.

    7. Object Number: 1201972 Size: SH
  7. Install the compressor hose to the compressor.
  8. Install the compressor hose nut to the compressor.

    9. Tighten
    Tighten the nut to 20 N·m (15 lb ft).

  9. Install the engine drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 2.2L (L61).

    10. Important: Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur.


    Object Number: 1203534 Size: SH
  10. Install the right radiator air deflector.
  11. Install the right radiator air deflector retainers.
  12. Install the right front fender liner. Refer to Front Fender Liner Replacement .
  13. Lower the vehicle.
  14. Evacuate and charge the refrigerant system Refer to Refrigerant Recovery and Recharging .
  15. Leak test the fittings using theJ 39400-A .

Air Conditioning Compressor Replacement LX9

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure
  1. Recover refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. Remove the engine drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.5L (LX9).
  3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

    4. Object Number: 1203530 Size: SH
  4. Remove the right front fender liner. Refer to Front Fender Liner Replacement .
  5. Remove the right radiator air deflector retainers.
  6. Remove the right radiator air deflector.

    7. Object Number: 1201986 Size: SH
  7. Remove the compressor hose nut from the compressor.
  8. Remove the compressor hose from the compressor.

    9. Object Number: 1201921 Size: SH
  9. Remove the compressor hose and liquid line bolt from the condenser.
  10. Remove the compressor hose from the condenser.
  11. Remove the liquid line from the condenser.
  12. Remove the compressor wire harness connector.
  13. Remove the compressor mounting bolts.

    14. Object Number: 1201903 Size: SH
  14. Remove the compressor.

    15. Important: Cap all A/C components immediately to prevent system contamination.

  15. Remove and discard the sealing washers.

Installation Procedure

    Important: Use a low viscosity, poly-alkylene glycol (PAG) oil. Use of the incorrect oil can result in compressor failure.

  1. If replacing the compressor, refer to Compressor Oil Balancing .
  2. Uncap A/C components.
  3. Install new sealing washers. Refer to Sealing Washer Replacement .
  4. Install the compressor.

    5. Object Number: 1201903 Size: SH

    Notice: Refer to Fastener Notice in the Preface section.

  5. Install the compressor mounting bolts.

    6. Tighten
    Tighten the bolts to 50 N·m (37 lb ft).

  6. Install the compressor wire harness connector.

    7. Object Number: 1201921 Size: SH
  7. Install the liquid line to the condenser.
  8. Install the compressor hose to the condenser.
  9. Install the compressor hose and liquid line bolt to the condenser.

    10. Tighten
    Tighten the bolt to 20 N·m (15 lb ft).


    Object Number: 1201986 Size: SH
  10. Install the compressor hose to the compressor
  11. Install the compressor hose nut to the compressor.

    12. Tighten
    Tighten the nut to 20 N·m (15 lb ft).

    Important: Radiator air deflectors must be properly installed or reduced A/C and engine cooling system performance could occur.


    Object Number: 1203530 Size: SH
  12. Install the right radiator air deflector.
  13. Install the right radiator air deflector retainers.
  14. Install the right front fender liner. Refer to Front Fender Liner Replacement .
  15. Lower the vehicle.
  16. Install the engine drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.5L (LX9).
  17. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
  18. Leak test the fittings using theJ 39400-A .