The air conditioning compressor is one of the main components of any AC system, including that on a Chevy Express van. If you need to replace the van's compressor to repair the air conditioning system, you must take into account the pressure of the refrigerant, as well as the components that are in the way, such as the air filter assembly. The process may vary if you are working on a 1997 or older Express van.
Discharge the refrigerant from the air conditioning system. Do this by taking the van to a licensed automotive air conditioning technician to safely handle this process.
Loosen the clamp connecting the inlet tube to the air filter with a screwdriver. Release the clamps for the air filter housing and remove the housing cover and air filter. Unbolt and remove the housing, then loosen the other clamp and remove the duct.
Rotate the drive belt tensioner with a breaker bar and socket to loosen the drive belt and remove it from the pulleys.
Raise the van's front end with a jack. Place jack stands under the front end and lower the van onto them. Remove the right wheel, then remove the fender well splash shield with a Torx or Allen wrench. You'll need to do this on any 2003 or newer Express.
Disconnect the two electrical connectors on the compressor. There is a clutch connector in the front and a high-pressure switch in the back.
Detach the discharge and suction lines, loosening the bolt for their manifold with a wrench. Plug the open fittings with rubber.
Remove the compressor's mounting bolts with your wrench. Remove the compressor from its mounting bracket and from the engine compartment.
Position the new compressor in the mounting bracket and secure it with the mounting bolts.
Connect the discharge/suction lines with the bolt on their manifold. Reconnect the electrical connectors. Reconnect the splash shield and reattach the wheel. Raise the van above the jack stands. Remove the jack stands and lower the front of the van to the ground.
Slip the drive belt onto its pulleys in the same path as before. Follow the diagram on the radiator shroud for the routing path. Rotate the tensioner with the breaker bar. Slip the belt on the tensioner and gently release the tensioner to tighten the belt.
Reinstall the air cleaner assembly and intake duct. Use a new air filter if the old one is dirty.
Take the van to have its air conditioning sytem evacuated and recharged.
