GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2008 🢒 Malibu Classic 🢒 HVAC 🢒 Heating, Ventilation, and Air Conditioning 🢒 Air Conditioning Compressor Replacement

Air Conditioning Compressor Replacement L61

Special Tools

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 .

    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 .

    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 Air Conditioning 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 .

    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 the J 39400-A .

Air Conditioning Compressor Replacement LZ4


Object Number: 1686450 Size: MF

Callout

Component Name

Preliminary Procedure

  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. Remove the drive belt. Refer to Drive Belt Replacement .
  3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
  4. Remove the right front fender liner. Refer to Front Fender Liner Replacement .
  5. Disconnect the A/C compressor electrical connector.

1

A/C Compressor Hose Nut

Notice: Refer to Fastener Notice in the Preface section.

Tip
Remove the A/C compressor hose from the A/C compressor and cap hose.

Tighten
20 N·m (15 lb ft)

2

Sealing Washer

Tip
Remove and discard sealing washers. Refer to Sealing Washer Replacement .

3

A/C Compressor Nut

Tip
Tighten in sequence with A/C compressor mounting bolts.

Tighten
50 N·m (37 lb ft)

4

A/C Compressor Bolt (Qty: 2)

Tip
Tighten the A/C compressor mounting bolts and nut in sequence.

Tighten
50 N·m (37 lb ft)

5

A/C Compressor Assembly

Procedure

  1. Use a low viscosity, poly-alkylene glycol (PAG) oil. Use of the incorrect oil can result in compressor failure.
  2. When replacing the A/C compressor, balance the compressor. Refer to Air Conditioning Compressor Oil Balancing .
  3. Using J 39400 leak test A/C compressor fittings.

Special Tools

J 39400 Electronic Halogen Leak Detector