GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2002 🢒 Malibu 🢒 HVAC 🢒 HVAC Systems - Manual 🢒 Air Conditioning Compressor Replacement

Removal Procedure

    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 .

  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. Remove the drive belt. Refer Drive Belt Replacement Engine Mechanical - 3.1L.
  3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  4. Remove the right front fender liner. Refer to Front Fender Liner Replacement in Body Front End.

    5. Object Number: 588076 Size: SH
  5. Disconnect the electrical connection from the compressor.

    6. Object Number: 588082 Size: SH
  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. Object Number: 588126 Size: SH
  9. Remove the compressor mounting bolts.
  10. Remove the compressor and the spacer.
  11. If you will replace the same compressor, drain and measure as much of the oil from the compressor as possible using the following procedure:
    12. 11.1. Drain the oil from both the suction and the discharge ports into a clean container.
    11.2. Remove the compressor crankcase oil drain plug and drain the crankcase oil into the same container.
    11.3. Measure and record the amount of oil drained from the compressor. This measurement will be used during the compressor installation procedure.
    11.4. Properly discard the used PAG oil.

Installation Procedure

    Important: NEW A/C compressors are shipped WITHOUT poly-alkylene glycol (PAG) oil. Use of the incorrect PAG oil can result in compressor failure.

  1. If a NEW A/C compressor is being installed, add 60 ml (2 oz) of PAG oil to the compressor.

    2. Object Number: 301171 Size: SH

    Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

  2. Install the crankcase oil drain bolt (1) to the compressor.

    3. Tighten
    Tighten the drain bolt (1) to 20 N·m (15 lb ft).


    Object Number: 588126 Size: SH
  3. Install the spacer and the compressor.
  4. Install the compressor bolts to the engine.

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


    Object Number: 588082 Size: SH
  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.

    8. Tighten
    Tighten the bolt to 33 N·m (24 lb ft).


    Object Number: 588076 Size: SH
  8. Connect the electrical connection to the compressor.
  9. Install the right front fender liner. Refer to Front Fender Liner Replacement in Body Front End.
  10. Lower the vehicle.
  11. Install the drive belt. Refer Drive Belt Replacement Engine Mechanical - 3.1L.
  12. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .