GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Chevrolet 🢒 2006 🢒 Malibu 🢒 HVAC 🢒 Heating, Ventilation and Air Conditioning 🢒 Liquid Line Replacement

Tools Required

J 39400-A Halogen Leak Detector

Removal Procedure
  1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
  2. Remove the refrigerant pressure sensor wire harness connector.
  3. Remove the refrigerant pressure sensor.

    4. Object Number: 1201929 Size: SH
  4. Remove the liquid line bracket bolt.
  5. Remove the air cleaner assembly.

    6. Refer to the following:

    •  Air Cleaner Assembly Replacement for the 2.2L Engine
    •  Air Cleaner Assembly Replacement for the 3.5L Engine
    •  Air Cleaner Assembly Replacement for the 3.9L Engine
  6. Remove the surge tank from the surge tank bracket.
  7. Remove the suction hose and liquid line nut from the thermal expansion valve (TXV).
  8. Remove the suction hose and liquid line from the TXV.

    9. Object Number: 1201931 Size: SH
  9. Remove the suction hose from the dash clip.
  10. Remove the liquid line from the dash clip.
  11. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .

    12. Object Number: 1203530 Size: SH
  12. Remove the right front fender liner. Refer to Front Fender Liner Replacement .
  13. Remove the right radiator air deflector retainers.
  14. Remove the right radiator air deflector.
  15. Remove the liquid line and compressor hose bolt from the condenser.

    16. Object Number: 1201921 Size: SH
  16. Remove the liquid line and compressor hose from the condenser.

    17. Object Number: 1201935 Size: SH
  17. Remove the liquid line from the rail clip.
  18. Lower the vehicle.

    19. Object Number: 1201937 Size: SH
  19. Remove the liquid line.

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

  20. Remove and discard the sealing washers.

Installation Procedure
  1. Uncap A/C components.
  2. Install new sealing washers. Refer to Sealing Washer Replacement .

    3. Object Number: 1201937 Size: SH
  3. Install the liquid line.
  4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .

    5. Object Number: 1201921 Size: SH
  5. Install the liquid line and compressor hose to the condenser.

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

  6. Install the liquid line and compressor hose bolt to the condenser.

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


    Object Number: 1201935 Size: SH
  7. Install the liquid line to the rail clip.

    8. Object Number: 1203530 Size: SH

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

  8. Install the right radiator air deflector.
  9. Install the right radiator air deflector retainers.
  10. Install the right front fender liner. Refer to Front Fender Liner Replacement .
  11. Lower the vehicle.

    12. Object Number: 1201931 Size: SH
  12. Install the suction hose and liquid line to the TXV.
  13. Install the suction hose and liquid line nut to the TXV.

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

  14. Install the liquid line to the dash clip.
  15. Install the suction hose to the dash clip.
  16. Install the air cleaner assembly.

    17. Refer to the following:

    •  Air Cleaner Assembly Replacement for the 2.2L Engine
    •  Air Cleaner Assembly Replacement for the 3.5L Engine
    •  Air Cleaner Assembly Replacement for the 3.9L Engine

    Object Number: 1201929 Size: SH
  17. Install the liquid line bracket bolt.

    18. Tighten
    Tighten the bolt to 10 N·m (89 lb in).

  18. Install the refrigerant pressure sensor.

    19. Tighten
    Tighten the bolt to 5 N·m (44 lb in).

  19. Install the refrigerant pressure sensor wire harness connector.
  20. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and Recharging .
  21. Leak test the fittings using the J 39400-A .
  22. Install the surge tank to the surge tank bracket.