Does anyone have the instructions on how to replace ac compressor on a 2005 Malibu maxx 3.5 liter engine? It looks like a challenge. Thanks

 

I'm an expert on auto A/C systems. How much do you know about automotive A/C systems? If you have worked on a compressor before, I can likely help you out.

 

Thanks for the reply. I have been doing my repairs for a long time. I am a retired engineer. Me and my Son own a small car lot in S.C.. We do a lot of repairs to save money. This car is making noise at the ac clutch and I need to replace the ac.Any help would be appreciated. Thanks

 

Looks like the Malibu Maxx 3.5 V6 is mounted down low on the motor. I'd jack it up, work from the bottom. Looks like three hold-down bolts going into the block to me. Does the system have any pressure left?

 

Yes it still has pressure. I have read that I need to remove the headlights and the front bumper to gain asses. I was hoping that I could find a write up on it with what all has to be removed. Thanks

 

I don't envy you all that. If the A/C is working properly, you may just need a new magnetic clutch, but I'd wager you'd still have to take off all those parts.

 

After looking underneath and from the top it looks like the inner fender well,bumper,headlights,radiator,and condensor will have to be removed. Any suggestions will be appreciated.

 

Can you show us any pics or vids? I can't find anything on the Malibu Maxx online. In regards to the front body work

 

I'm a shade tree mechanic and I have one tree.

This is the procedure for just the compressor R&R on a 2005 Chevrolet Malibu Maxx

Removal
-Take a pic or make a drawing of the serpentine belt pully positions.
-Wear mechanic gloves you will cut your hands if you don't.
-Loosen the serpentine belt using a 3/8 ratchet or breaker bar.
Remove the air intake hose. 10 mm bolt and 5/16 for the clamps.
-Raise the car with a floor jack and remove the RF wheel. Place a jack stand under it for safety. 19 mm socket for lug nuts
-On the lower front inner fender plastic cover remove the push fasteners and X-mas fasteners using a trim tool. This will allow access for compressor removal. It's very tight but doable. Save the fasteners.
-From the front of the engine bay on the compressor disconnect the electrical plug and remove the 2 bolts.15 mm There is a dog bone spacer that will fall when you pull the bolts so hang onto it. for the install.
-Underneath the car remove the 3rd bolt from the compressor and let it rest in the engine bay. 15 mm
-From the front, remove nut on the A/C hoses at the compressor. 13mm
- Wiggle, pull and cuss until you get the compressor out of the side front hole in the fender well. Take a bow your halfway there.

Install
-From the RF wheel side wiggle push and cuss until you get the new compressor back into the engine compartment.
-Replace the O-rings on the A/C hoses at the compressor and tighten nut. 13mm
-Reconnect the electrical plug into the compressor.
-From the engine bay install the compressor 15 mm bolts with the dog bone spacer in place. Do not tighten just get some turns on the bolts.
-From underneath install the 3rd compressor bolt and snug it.
-From the engine compartment tighten the 2 compressor bolts.
-From underneath tighten the 3rd compressor bolt.
-Install the serpentine belt. Recommend a new one. You're doing it anyway.
-Install lower fender inner plastics using the saved push fasteners.
-Install RF tire and torque lug nuts to 100 ft lbs.
-Pull a vacuum on the A/C system.
-Start engine, turn on A/C system and Install 17oz R134-A Freon.
-Check for leaks and cold air at the air vents.
-Clean greasy hand prints on the car and take a ride and use the recirculate button on dash. Should be really cold.
Your have completed the R&R for the A/C compressor so take a bow and pat yourself on the back.
Good luck and Hope this helps.