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.
SYS.OK|MANUAL.DB● LIVE
HOMESERVICE MANUALSCHEVROLET2004AVALANCHE 2500 2WD V8-8.1L VIN GREPAIR AND DIAGNOSISHEATING AND AIR CONDITIONINGCOMPRESSOR HVACSERVICE AND REPAIRCOMPRESSOR REPLACEMENT
2004 Chevrolet Avalanche 2500 2WD V8-8.1L VIN G
Compressor Replacement
2004 Chevrolet Avalanche 2500 2WD V8-8.1L VIN GSECTION Compressor Replacement
COMPRESSOR REPLACEMENT
TOOLS REQUIRED
J 39400-A Halogen Leak Detector
REMOVAL PROCEDURE
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Remove the intake air resonator replacement.
3. Install a ratchet into the air conditioning (A/C) belt tensioner adapter opening.
4. Rotate the A/C belt tensioner clockwise in order to relieve the tension on the belt.
5. Remove the A/C belt from the A/C compressor.
6. Slowly release the tension on the A/C belt tensioner.
7. Remove the discharge hose bolt from the A/C compressor.
8. Remove the discharge hose from the A/C compressor.
9. Remove the suction hose bolt from the A/C compressor.
10. Remove the suction hose from the A/C compressor.
11. Discard the sealing washers. Cap all of the openings.
12. Disconnect the electrical connections.
13. Remove the A/C compressor mounting bolts.
14. Remove the A/C compressor (2) from the bracket (1).
15. If replacing the A/C compressor. Refer to Compressor Oil Balancing.
INSTALLATION PROCEDURE
1. Install the A/C compressor (2) to the A/C bracket (1).
2. Install the A/C compressor mounting bolts.
NOTE: Refer to Fastener Notice in Service Precautions.
Tighten the bolts to 50 N.m (37 lb ft).
3. Connect the electrical connector to the A/C compressor.
4. Install the A/C discharge hose to the compressor using new sealing washers.
5. Install the A/C discharge hose bolt to the A/C compressor.
Tighten the bolt to 16 N.m (12 lb ft).
6. Install the A/C suction hose to the compressor using new sealing washers.
7. Install the A/C suction hose bolt to the A/C compressor.
Tighten the bolt to 16 N.m (12 lb ft).
8. Install the intake air resonator replacement.
9. Install the A/C drive belt.
10. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
11. Leak test the fittings of the component using the J 39400-A.
TOOLS REQUIRED
J 39400-A Halogen Leak Detector
REMOVAL PROCEDURE
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.
2. Remove the intake air resonator replacement.
3. Install a ratchet into the air conditioning (A/C) belt tensioner adapter opening.
4. Rotate the A/C belt tensioner clockwise in order to relieve the tension on the belt.
5. Remove the A/C belt from the A/C compressor.
6. Slowly release the tension on the A/C belt tensioner.
7. Remove the discharge hose bolt from the A/C compressor.
8. Remove the discharge hose from the A/C compressor.
9. Remove the suction hose bolt from the A/C compressor.
10. Remove the suction hose from the A/C compressor.
11. Discard the sealing washers. Cap all of the openings.
12. Disconnect the electrical connections.
13. Remove the A/C compressor mounting bolts.
14. Remove the A/C compressor (2) from the bracket (1).
15. If replacing the A/C compressor. Refer to Compressor Oil Balancing.
INSTALLATION PROCEDURE
1. Install the A/C compressor (2) to the A/C bracket (1).
2. Install the A/C compressor mounting bolts.
NOTE: Refer to Fastener Notice in Service Precautions.
Tighten the bolts to 50 N.m (37 lb ft).
3. Connect the electrical connector to the A/C compressor.
4. Install the A/C discharge hose to the compressor using new sealing washers.
5. Install the A/C discharge hose bolt to the A/C compressor.
Tighten the bolt to 16 N.m (12 lb ft).
6. Install the A/C suction hose to the compressor using new sealing washers.
7. Install the A/C suction hose bolt to the A/C compressor.
Tighten the bolt to 16 N.m (12 lb ft).
8. Install the intake air resonator replacement.
9. Install the A/C drive belt.
10. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
11. Leak test the fittings of the component using the J 39400-A.
RENDER: 1.0x
NO RELATED
Recommended Tools & Savings
Use the Manual With the Right Hardware
Pair factory procedures with proven DIY tools so the instructions are easier to execute.
Affiliate disclosure: We may earn a commission at no extra cost to you.
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.