The Chevrolet S-10 pickup truck series was manufactured with an optional air conditioning system, which uses a compressor to circulate freon coolant. The compressor can wear out and fail for many reasons, usually resulting from a loss of lubricant. The average backyard mechanic can replace a compressor in a Chevy S-10 truck in about an hour.
Evacuate the air conditioning system by taking the truck to a garage or oil change facility. They will usually evacuate the system for free, as they get compensated for collecting it. It is not wise or legal to vent the freon into the atmosphere.
Disconnect the battery by turning the positive terminal bolt in a counterclockwise direction.
Disconnect the freon coolant lines from the compressor by turning the line nuts counterclockwise with a line wrench. There may be latent pressure form the evacuation that will escape and cause a hissing sound, but it should not alarm you. Set the lines aside, but leave them attached to the rest of the system.
Disconnect the wiring harness adapter plug on the top of the compressor by pulling the blade connector free of the terminal.
Remove the primary drive belt from the compressor pulley wheel by pushing on the tension pulley arm firmly until there is enough slack to remove it from the idle pulley wheel. Release the tension pulley and there will now be enough slack to remove the belt from the compressor pulley wheel.
Remove the compressor by turning all of the mount nuts counterclockwise, while holding the hex head bolts in place with another socket wrench. Once free from the bolts, the compressor comes directly out of the engine compartment.
Replace the compressor by positioning it into the mount and securing the mount bolts and nuts clockwise. Reattach the wiring harness terminal and freon lines (check the nut gaskets for damage). Wrap the primary drive belt over the compressor pulley wheel, grooves down. Press the tension pulley arm and slide the belt back underneath the idle pulley. Release the pulley and the belt will tighten to the proper tension.
Reattach the battery terminal bolt, start the car, and recharge the air conditioning system with the proper amount of freon, in this case about two pounds. Add additional lubricant for the new compressor.
