I had a irregular problem with the ac on a 2006 chevy cobalt. Only setting 1 worked right, then when i would switch to 2 or higher the air would still blow, but the ac compressor would turn off and i would only receive room temp air blowing on me. I found the problem was a connector on the back of the ac control unit was having i intermittent connection on one of its pins.
I temporarily fixed it by having the ac head unit plugged in and gently rotating it up side down 2 times. Which twisted the harness a little causing the connector to have pressure on it and forcing all the pins/holes in connectors to connect. I also made a make shift shim outta a plastic piece which i used to fill the little amount of clearance of free play the connector had when plugged in.
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