GM Astro/Safari 1985-1996 Repair Guide

Air Conditioning Compressor

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REMOVAL & INSTALLATION



2.5L Engine

See Figure 1

Refer to, Discharging The Air Conditioning System in General Information & Maintenance and discharge the air conditioning system. The system should be discharged by a qualified technician with proper recovery equipment. It is illegal to discharge refrigerant into the atmosphere and you may need a permit to purchase new refrigerant. If you do not possess the proper equipment, training and permits to perform refrigerant recovery, allow a repair shop to do that step for you.

  1. Disconnect the negative battery cable.
  2.  
  3. Disengage the electrical connectors from the compressor.
  4.  
  5. At the rear of the compressor, remove the bracket from the exhaust manifold.
  6.  
  7. Remove the compressor-to-front bracket bolts, the drive belt and the compressor from the vehicle.
  8.  

To install:
  1. Install the compressor and torque the compressor-to-front bracket bolts to 22 ft. lbs. (30 Nm) and the compressor-to-rear bracket bolts to 18 ft. lbs. (25 Nm).
  2.  
  3. Refer to the, Drive Belt Adjusting procedures in General Information & Maintenance and adjust the air conditioning drive belt.
  4.  
  5. Refer to, Charging The Air Conditioning System in General Information & Maintenance , evacuate and charge the air conditioning system.
  6.  
  7. Connect the negative battery cable and start the engine to check for proper operation.
  8.  



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Fig. Fig. 1: Air conditioning compressor mounting-2.5L engine

4.3L Engine

See Figures 2, 3, 4 and 5



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Fig. Fig. 2: Air conditioning compressor mounting-4.3L engine with radial compressor



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Fig. Fig. 3: Air conditioning compressor mounting-4.3L (VIN Z) engine with axial compressor, except 1996 models



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Fig. Fig. 4: Air conditioning compressor mounting-4.3L (VIN W) engine with axial compressor, except 1996 models



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Fig. Fig. 5: Air conditioning compressor mounting-1996 4.3L engine

Refer to Discharging The Air Conditioning System in General Information & Maintenance and discharge the air conditioning system. The system should be discharged by a qualified technician with proper recovery equipment. It is illegal to discharge refrigerant into the atmosphere and you may need a permit to purchase new refrigerant. If you do not possess the proper equipment, training and permits to perform refrigerant recovery, allow a repair shop to do that step for you.

  1. Disconnect the negative battery cable.
  2.  
  3. Disengage the electrical connectors from the compressor.
  4.  
  5. From the rear of the compressor, remove the intake manifold-to-compressor support bracket.
  6.  

If the engine is equipped with a carburetor, disconnect the vacuum brake from the carburetor for access.

  1. Remove the drive belt idler bracket-to-intake manifold bolts, the drive belt and the bracket from the vehicle.
  2.  
  3. Remove the compressor-to-mounting bracket bolts and the compressor from the vehicle.
  4.  

To install:
  1. Install the compressor and torque the compressor-to-front bracket bolts to 25 ft. lbs. (34 Nm), the idler belt-to-engine bracket bolts to 16 ft. lbs. (22 Nm) and the compressor support bracket bolts to 61 ft. lbs. (83 Nm).
  2.  
  3. Refer to the, Drive Belt Adjusting procedures in General Information & Maintenance and adjust the air conditioning drive belt.
  4.  
  5. Refer to, Charging The Air Conditioning System in General Information & Maintenance , evacuate and recharge the air conditioning system.
  6.  
  7. Connect the negative battery cable and start the engine to check performance.
  8.  

 
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