Tools You'll Likely Need:
* Socket wrench set (metric)
* Wrenches (metric)
* Screwdrivers (Phillips and flathead)
* A/C clutch puller (essential, avoids damaging the compressor)
* Shop rags or towels
* Safety glasses
* Gloves
* Refrigerant recovery system (highly recommended; discharging refrigerant into the atmosphere is illegal and harmful to the environment)
Steps:
1. Recover Refrigerant: This is the most important step. You MUST recover the refrigerant from the system using a proper refrigerant recovery system before disconnecting any lines. Failure to do so is illegal and environmentally damaging. If you don't have access to this equipment, take your van to a qualified mechanic.
2. Disconnect Electrical Connector: Locate the electrical connector to the A/C clutch. It's usually a simple plug-in connector. Disconnect it.
3. Remove the Belt: Remove the serpentine belt (or the specific belt driving the A/C compressor) to access the A/C clutch. Consult your repair manual for the proper procedure for removing the belt on your specific engine.
4. Remove the Clutch Nut: Use the appropriate socket wrench to remove the large nut in the center of the A/C clutch. This nut is usually very tight, so use a wrench that fits snugly and potentially a breaker bar for extra leverage.
5. Use the A/C Clutch Puller: This is critical. The A/C clutch is usually held onto the compressor shaft by a small pressure fit. Attempting to remove it without a puller can damage the compressor shaft. The puller will hook onto the clutch and provide the force needed to remove it safely. Follow the instructions included with your clutch puller.
6. Inspect the Compressor and Clutch: Once the clutch is removed, inspect the compressor pulley shaft for any damage. Also, inspect the clutch itself for wear.
7. Installation (Reversing the steps): Installation is simply the reverse of removal, but make sure you carefully align the clutch on the compressor shaft before tightening the nut.
Important Considerations:
* Refrigerant: Improper handling of refrigerant is dangerous and illegal. Use a professional-grade recovery system.
* Repair Manual: A repair manual specific to your 1986 Chevy G-20 is essential. It will provide detailed diagrams, torque specifications, and important warnings.
* Safety: Wear safety glasses and gloves. Be careful when working with sharp tools and hot engine components.
* Professional Help: If you're not comfortable performing this repair, take your van to a qualified mechanic. Improperly repairing your A/C system can cause more damage and be costly.
This is a general guide. Always refer to a repair manual for your specific vehicle to ensure you perform the repair safely and correctly. Improper repair can damage your A/C system and potentially void any warranties.
