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 V8-5.7L VIN RREPAIR AND DIAGNOSISHEATING AND AIR CONDITIONINGCOMPRESSOR HVACSERVICE AND REPAIRCOMPRESSOR SEALING WASHERS REPLACEMENT
2002 Chevrolet Express 1/2 Ton Van V8-5.7L VIN R
Compressor Sealing Washers Replacement
2002 Chevrolet Express 1/2 Ton Van V8-5.7L VIN RSECTION Compressor Sealing Washers Replacement
TOOLS REQUIRED
J 39400-A Halogen Leak Detector
REMOVAL PROCEDURE
1. Remove the air cleaner assembly.
2. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging.
3. Disconnect the compressor hose assembly at the compressor.
4. Remove the sealing washers.
INSTALLATION PROCEDURE
IMPORTANT:
^ Install the sealing washers, keeping the dirt and foreign material from adhering to the sealing surfaces of the washers, the hose block, or the compressor ports.
^ Clean all surfaces with a lint-free rag.
^ DO NOT reuse the sealing washer.
^ DO NOT oil the sealing washers prior to assembly.
1. Install the sealing washer onto the pilots of suction/discharge block fitting.
2. Ensure that the washers are flush against the surface of the block fitting.
3. Install the hose block to the compressor.
4. Ensure that the sealing washers are seated within the compressor machined surfaces.
5. Connect the hose assembly to the compressor.
NOTE: Refer to Fastener Notice in Service Precautions.
6. Hold the block in place and hand tighten the attachment bolt.
Tighten
Tighten the bolt to 45 N.m (33 lb ft).
7. Evacuate and Recharge the refrigerant. Refer to Refrigerant Recovery and Recharging.
8. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A.
9. Install the air cleaner assembly.
J 39400-A Halogen Leak Detector
REMOVAL PROCEDURE
1. Remove the air cleaner assembly.
2. Recover the refrigerant from the system. Refer to Refrigerant Recovery and Recharging.
3. Disconnect the compressor hose assembly at the compressor.
4. Remove the sealing washers.
INSTALLATION PROCEDURE
IMPORTANT:
^ Install the sealing washers, keeping the dirt and foreign material from adhering to the sealing surfaces of the washers, the hose block, or the compressor ports.
^ Clean all surfaces with a lint-free rag.
^ DO NOT reuse the sealing washer.
^ DO NOT oil the sealing washers prior to assembly.
1. Install the sealing washer onto the pilots of suction/discharge block fitting.
2. Ensure that the washers are flush against the surface of the block fitting.
3. Install the hose block to the compressor.
4. Ensure that the sealing washers are seated within the compressor machined surfaces.
5. Connect the hose assembly to the compressor.
NOTE: Refer to Fastener Notice in Service Precautions.
6. Hold the block in place and hand tighten the attachment bolt.
Tighten
Tighten the bolt to 45 N.m (33 lb ft).
7. Evacuate and Recharge the refrigerant. Refer to Refrigerant Recovery and Recharging.
8. Leak test the fitting(s) of the repaired or reinstalled component using the J 39400-A.
9. Install the air cleaner assembly.
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.