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 MANUALSCHEVROLET2002EXPRESS 1 TON VAN V8-8.1L VIN GREPAIR AND DIAGNOSISHEATING AND AIR CONDITIONINGREFRIGERANT PRESSURE SENSOR / SWITCHSERVICE AND REPAIRCOMPRESSOR CONTROL SWITCHES INSTALL
2002 Chevrolet Express 1 Ton Van V8-8.1L VIN G
Compressor Control Switches Install
2002 Chevrolet Express 1 Ton Van V8-8.1L VIN GSECTION Compressor Control Switches Install
TOOLS REQUIRED
J 5403 Snap Ring Pliers
IMPORTANT: If you reinstall an existing control switch in the compressor, use a new O-ring and a new retainer ring. An O-ring and a retainer ring are included in a new switch kit.
1. Lubricate the new O-ring using clean refrigerant oil.
2. Install the new O-ring into the groove in the switch cavity.
3. Lubricate the control switch housing using clean refrigerant oil.
4. Install the switch (2) into the switch cavity until the switch bottoms in the cavity.
5. Using the J 5403, install the switch retaining ring. Ensure that the high point of the curved sides is adjacent to the switch housing. Ensure that the retaining ring is properly seated in the switch cavity retaining groove.
6. Leak test according to bench test procedure.
J 5403 Snap Ring Pliers
IMPORTANT: If you reinstall an existing control switch in the compressor, use a new O-ring and a new retainer ring. An O-ring and a retainer ring are included in a new switch kit.
1. Lubricate the new O-ring using clean refrigerant oil.
2. Install the new O-ring into the groove in the switch cavity.
3. Lubricate the control switch housing using clean refrigerant oil.
4. Install the switch (2) into the switch cavity until the switch bottoms in the cavity.
5. Using the J 5403, install the switch retaining ring. Ensure that the high point of the curved sides is adjacent to the switch housing. Ensure that the retaining ring is properly seated in the switch cavity retaining groove.
6. Leak test according to bench test procedure.
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.