Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSCHEVROLET2003MALIBU V6-3.1L VIN JREPAIR AND DIAGNOSISHEATING AND AIR CONDITIONINGCOMPRESSOR HVACSERVICE AND REPAIRCOMPRESSOR REPLACEMENT
2003 Chevrolet Malibu V6-3.1L VIN J
Compressor Replacement
2003 Chevrolet Malibu V6-3.1L VIN JSECTION Compressor Replacement
COMPRESSOR REPLACEMENT
REMOVAL PROCEDURE
1. Recover the refrigerant.
IMPORTANT: When replacing a failed compressor, inspect the expansion orifice tube for material build up. Clean or replace as necessary. Refer to Expansion (Orifice) Tube Replacement.
2. Remove the drive belt.
3. Raise the vehicle. Refer to Vehicle Lifting.
4. Remove the right front fender liner.
5. Disconnect the electrical connection from the compressor.
6. Remove the hose assembly mounting bolt from the compressor.
7. Remove the hose assembly from the compressor.
8. Remove and discard the sealing washers.
9. Remove the compressor mounting bolts.
10. Remove the compressor and the spacer.
11. If you will replace the same compressor Refer to Compressor Oil Balancing.
INSTALLATION PROCEDURE
1. If a new A/C compressor is being installed, add 60 ml (2 oz) of PAG oil to the compressor.
IMPORTANT: new A/C compressors are shipped WITHOUT poly-alkylene glycol (PAG) oil. Use of the incorrect PAG oil can result in compressor failure.
2. Install the crankcase oil drain bolt (1) to the compressor.
NOTE: Refer to Fastener Notice in Service Precautions.
Tighten
Tighten the drain bolt (1) to 20 N.m (15 lb ft).
3. Install the spacer and the compressor.
4. Install the compressor bolts to the engine.
Tighten
Tighten the bolts to 50 N.m (37 lb ft).
5. Install new sealing washers to the compressor.
6. Install the hose assembly to the compressor.
7. Install the hose assembly bolt to the compressor.
Tighten
Tighten the bolt to 33 N.m (24 lb ft).
8. Connect the electrical connection to the compressor.
9. Install the right front fender liner.
10. Lower the vehicle.
11. Install the drive belt.
12. Evacuate and charge the refrigerant system.
REMOVAL PROCEDURE
1. Recover the refrigerant.
IMPORTANT: When replacing a failed compressor, inspect the expansion orifice tube for material build up. Clean or replace as necessary. Refer to Expansion (Orifice) Tube Replacement.
2. Remove the drive belt.
3. Raise the vehicle. Refer to Vehicle Lifting.
4. Remove the right front fender liner.
5. Disconnect the electrical connection from the compressor.
6. Remove the hose assembly mounting bolt from the compressor.
7. Remove the hose assembly from the compressor.
8. Remove and discard the sealing washers.
9. Remove the compressor mounting bolts.
10. Remove the compressor and the spacer.
11. If you will replace the same compressor Refer to Compressor Oil Balancing.
INSTALLATION PROCEDURE
1. If a new A/C compressor is being installed, add 60 ml (2 oz) of PAG oil to the compressor.
IMPORTANT: new A/C compressors are shipped WITHOUT poly-alkylene glycol (PAG) oil. Use of the incorrect PAG oil can result in compressor failure.
2. Install the crankcase oil drain bolt (1) to the compressor.
NOTE: Refer to Fastener Notice in Service Precautions.
Tighten
Tighten the drain bolt (1) to 20 N.m (15 lb ft).
3. Install the spacer and the compressor.
4. Install the compressor bolts to the engine.
Tighten
Tighten the bolts to 50 N.m (37 lb ft).
5. Install new sealing washers to the compressor.
6. Install the hose assembly to the compressor.
7. Install the hose assembly bolt to the compressor.
Tighten
Tighten the bolt to 33 N.m (24 lb ft).
8. Connect the electrical connection to the compressor.
9. Install the right front fender liner.
10. Lower the vehicle.
11. Install the drive belt.
12. Evacuate and charge the refrigerant system.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.