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 MANUALSCHEVROLET1992CAPRICE WAGON RWD V8-305 5.0LREPAIR AND DIAGNOSISHEATING AND AIR CONDITIONINGCOMPRESSOR HVACSERVICE AND REPAIRMAJOR COMPRESSOR REPAIR PROCEDURESCONTROL SWITCHES
1992 Chevrolet Caprice Wagon RWD V8-305 5.0L
Control Switches
1992 Chevrolet Caprice Wagon RWD V8-305 5.0LSECTION Control Switches
Remove or Disconnect
1. Recover the refrigerant.
2. Disconnect the electrical connector from the switch in the rear head of the compressor.
3. Remove the switch retaining ring (Fig. 31) using J 5403 internal snap ring pliers.
4. Remove switch from compressor by pulling on terminal housing.
5. Remove old O-ring seal from switch cavity using J 9553-1 O-ring removal tool or equivalent.
If switch will be reinstalled in compressor, a new O-ring seal must be used and preferably a new retainer ring should also be used. A new switch kit has the O-ring and retainer ring included.
Install or Connect
1. Check switch cavity and O-ring groove in the rear head for dirt or foreign material and clean as necessary. Install new O-ring coated with clean 525 viscosity refrigerant oil into groove in switch cavity.
2. Lubricate the switch housing with clean 525 viscosity refrigerant oil and carefully insert switch into switch cavity until switch bottoms in cavity.
3. Using J 5403 snap ring pliers, install switch retaining ring with high point of curved sides adjacent to the switch housing. Be sure retaining ring is properly seated in the switch cavity retainer ring groove.
1. Recover the refrigerant.
2. Disconnect the electrical connector from the switch in the rear head of the compressor.
3. Remove the switch retaining ring (Fig. 31) using J 5403 internal snap ring pliers.
4. Remove switch from compressor by pulling on terminal housing.
5. Remove old O-ring seal from switch cavity using J 9553-1 O-ring removal tool or equivalent.
If switch will be reinstalled in compressor, a new O-ring seal must be used and preferably a new retainer ring should also be used. A new switch kit has the O-ring and retainer ring included.
Install or Connect
1. Check switch cavity and O-ring groove in the rear head for dirt or foreign material and clean as necessary. Install new O-ring coated with clean 525 viscosity refrigerant oil into groove in switch cavity.
2. Lubricate the switch housing with clean 525 viscosity refrigerant oil and carefully insert switch into switch cavity until switch bottoms in cavity.
3. Using J 5403 snap ring pliers, install switch retaining ring with high point of curved sides adjacent to the switch housing. Be sure retaining ring is properly seated in the switch cavity retainer ring groove.
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.