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 CONDITIONINGREFRIGERANT PRESSURE SENSOR / SWITCHHIGH PRESSURE SENSOR / SWITCHSERVICE AND REPAIR
2002 Chevrolet Express 1/2 Ton Van V6-4.3L VIN W
High Pressure Sensor / Switch: Service and Repair
2002 Chevrolet Express 1/2 Ton Van V6-4.3L VIN WSECTION Service and Repair
AIR CONDITIONING (A/C) HIGH PRESSURE SWITCH REPLACEMENT
TOOLS REQUIRED
^ J 43600 ACR 2000 Refrigerant Station
^ J 5403 Snap Ring Pliers
^ J 9553-01 O-Ring Remover
^ J 39400-A Halogen Leak Detector
REMOVAL PROCEDURE
1. Remove the engine cover.
2. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging.
3. Clean the control switch area before removing the snap ring.
4. Disconnect the electrical connector from the switch (2) in the rear head of the compressor.
5. Remove the switch snap ring with 90 degree snap ring pliers.
6. Remove the switch (2) from the compressor.
7. Remove the old O-ring seal from the switch cavity using the J 9553-01.
8. Inspect the switch cavity and the O-ring groove in the rear head for din or foreign material. Clean the components as necessary.
INSTALLATION PROCEDURE
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 is included in a new switch kit.
1. Lubricate the new O-ring using clean 525 viscosity refrigerant oil.
2. Install the new O-ring into the groove in the switch cavity.
3. Lubricate the control switch housing using clean 525 viscosity 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 snap ring with 90 degree snap ring pliers. Ensure that the high point of the curved sides is adjacent to the switch housing. Ensure that the snap ring is properly seated in the switch cavity retaining groove.
6. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
7. Leak test the fittings of the components using the J 39400-A.
8. Install the engine cover.
TOOLS REQUIRED
^ J 43600 ACR 2000 Refrigerant Station
^ J 5403 Snap Ring Pliers
^ J 9553-01 O-Ring Remover
^ J 39400-A Halogen Leak Detector
REMOVAL PROCEDURE
1. Remove the engine cover.
2. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging.
3. Clean the control switch area before removing the snap ring.
4. Disconnect the electrical connector from the switch (2) in the rear head of the compressor.
5. Remove the switch snap ring with 90 degree snap ring pliers.
6. Remove the switch (2) from the compressor.
7. Remove the old O-ring seal from the switch cavity using the J 9553-01.
8. Inspect the switch cavity and the O-ring groove in the rear head for din or foreign material. Clean the components as necessary.
INSTALLATION PROCEDURE
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 is included in a new switch kit.
1. Lubricate the new O-ring using clean 525 viscosity refrigerant oil.
2. Install the new O-ring into the groove in the switch cavity.
3. Lubricate the control switch housing using clean 525 viscosity 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 snap ring with 90 degree snap ring pliers. Ensure that the high point of the curved sides is adjacent to the switch housing. Ensure that the snap ring is properly seated in the switch cavity retaining groove.
6. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
7. Leak test the fittings of the components using the J 39400-A.
8. Install the engine cover.
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.