GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2006 🢒 Malibu 🢒 HVAC 🢒 HVAC Systems - Automatic 🢒 Compressor Clutch Assembly Replacement

Compressor Clutch Assembly Replacement L61

Tools Required

    • J 37872 Universal Spanner Wrench
    • J 6083 Snap Ring Pliers

Removal Procedure
  1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.

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

    6. Important: Discharge of the A/C system is not required.

  6. Remove the compressor mounting bolts.
  7. Remove the compressor from the engine with compressor line attached.

    8. Object Number: 872553 Size: SH

    Important: Remove the 3 adjustable dowels from the J 37872 .

    Install three 5/16 x 1 inch bolts in place of the dowels.

  8. Remove and discard the compressor clutch plate bolt.

    9. Use the J 37872 to hold the compressor clutch plate from turning.


    Object Number: 872556 Size: SH
  9. Remove the compressor clutch plate from the compressor.

    10. Object Number: 872558 Size: SH
  10. Remove the compressor pulley snap ring using the J 6083 .

    11. Object Number: 872560 Size: SH
  11. Remove the compressor pulley from the compressor.

    12. Object Number: 872563 Size: SH
  12. Remove the compressor clutch coil snap ring using the J 6083 .

    13. Object Number: 872561 Size: SH
  13. 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. Object Number: 872561 Size: SH
  2. Install the compressor clutch coil to the compressor.

    3. Object Number: 872563 Size: SH
  3. Install the compressor clutch coil snap ring using the J 6083 .

    4. Object Number: 872560 Size: SH
  4. Install the compressor pulley to the compressor.

    5. Object Number: 872558 Size: SH
  5. Install the compressor pulley snap ring using the J 6083 .
  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. Object Number: 872556 Size: SH
  7. Install the compressor clutch plate to the compressor.

    8. Object Number: 187363 Size: SH

    Important: Make certain that the drive plate does not drag against the pulley when the pulley is rotated.

  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. Object Number: 872553 Size: SH

    Important: Make certain that the new drive plate bolt has colored adhesive on at least 5 threads.

  9. Install the clutch drive plate bolt.

    10. Notice: Refer to Fastener Notice in the Preface section.

  10. Tighten the compressor clutch drive plate bolt.

    11. Use the J 37872 to hold the compressor clutch plate from turning.

    Tighten
    Tighten the bolt to 12 N·m (106 lb in).

  11. Install the compressor to the engine.
  12. Install the compressor mounting bolts.

    13. Tighten
    Tighten the bolt to 50 N·m (37 lb ft).

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

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


    Object Number: 1203534 Size: SH
  14. Install the right radiator air deflector.
  15. Install the right radiator air deflector retainers.
  16. Install the right front fender liner. Refer to Front Fender Liner Replacement in Body Front End.
  17. Lower the vehicle.