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 1/2 TON VAN V6-4.3L VIN WREPAIR AND DIAGNOSISHEATING AND AIR CONDITIONINGCOMPRESSOR HVACSERVICE AND REPAIRCOMPRESSOR REPLACEMENT
2002 Chevrolet Express 1/2 Ton Van V6-4.3L VIN W
Compressor Replacement
2002 Chevrolet Express 1/2 Ton Van V6-4.3L VIN WSECTION Compressor Replacement
TOOLS REQUIRED
J 39400-A Halogen Leak Detector
REMOVAL PROCEDURE
1. Remove the air cleaner assembly.
2. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging.
3. Disconnect the clutch coil electrical connector (1) from the compressor.
4. Disconnect the A/C high pressure switch electrical connector (2) from the compressor.
5. Remove the drive belt.
6. Remove the compressor hose assembly.
7. Remove the mounting bolts (2) from the compressor.
8. Remove the compressor from the vehicle.
9. If replacing the A/C compressor, drain and measure as much of the oil from the removed compressor as possible.
9.1. Drain the oil from both the suction and discharge ports of the removed A/C compressor into a clean container.
9.2. Remove the A/C compressor crankcase oil drain plug and drain the crankcase oil into the same container.
9.3. Measure and record the amount of oil that was drained from the removed A/C compressor.
This measurement will be used during installation of the replacement A/C compressor.
INSTALLATION PROCEDURE
IMPORTANT: The compressor is shipped without oil.
1. Add oil to the compressor. Refer to Refrigerant System Capacities if replacing the compressor.
2. Install the compressor (1) to the vehicle.
NOTE: Refer to Fastener Notice in Service Precautions.
3. Install the compressor retaining bolts to the mounting bracket.
Tighten
Tighten the bolts to 50 N.m (37 lb ft).
4. Install the compressor hose assembly.
5. Install the drive belt.
6. Connect the clutch coil electrical connector (1) to the compressor.
7. Connect the A/C high pressure switch electrical connector (2) to the compressor.
8. Install the air cleaner assembly.
9. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
10. Leak test the fittings of the components using the J 39400-A.
J 39400-A Halogen Leak Detector
REMOVAL PROCEDURE
1. Remove the air cleaner assembly.
2. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging.
3. Disconnect the clutch coil electrical connector (1) from the compressor.
4. Disconnect the A/C high pressure switch electrical connector (2) from the compressor.
5. Remove the drive belt.
6. Remove the compressor hose assembly.
7. Remove the mounting bolts (2) from the compressor.
8. Remove the compressor from the vehicle.
9. If replacing the A/C compressor, drain and measure as much of the oil from the removed compressor as possible.
9.1. Drain the oil from both the suction and discharge ports of the removed A/C compressor into a clean container.
9.2. Remove the A/C compressor crankcase oil drain plug and drain the crankcase oil into the same container.
9.3. Measure and record the amount of oil that was drained from the removed A/C compressor.
This measurement will be used during installation of the replacement A/C compressor.
INSTALLATION PROCEDURE
IMPORTANT: The compressor is shipped without oil.
1. Add oil to the compressor. Refer to Refrigerant System Capacities if replacing the compressor.
2. Install the compressor (1) to the vehicle.
NOTE: Refer to Fastener Notice in Service Precautions.
3. Install the compressor retaining bolts to the mounting bracket.
Tighten
Tighten the bolts to 50 N.m (37 lb ft).
4. Install the compressor hose assembly.
5. Install the drive belt.
6. Connect the clutch coil electrical connector (1) to the compressor.
7. Connect the A/C high pressure switch electrical connector (2) to the compressor.
8. Install the air cleaner assembly.
9. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
10. Leak test the fittings of the components using the J 39400-A.
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.