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Re: 1992 Chevy Astro van AC problems and compressor bypass pulley
To remove the compressor: Remove the upper fan shroud to access the serpentine belt tensioner and remove the belt. The refrigerant needs to be drained. Remove the bolt on the rear of the compressor that holds the manifold connection to the compressor. Remove 4 bolts holding the compressor to the mounting bracket. Disconnect the clutch field electrical connector. Move the compressor forward and disconnect the high pressure cut out switch connector on the rear of the compressor. Lift the compressor out. Install the new bracket and pulley. Reinstall the serpentine belt and fan shroud.
Removal of the clutch requires a special puller. You can "borrow" the puller at Advance Auto Parts or Autozone. You will need to remove the upper fan shroud for access to the front of the compressor. Do not remove the serpentine belt. Disconnect the coil wire from the ignition coil. Turn the ignition to the RUN position. Turn the HVAC mode switch to the AC position. Remove the center bolt holding the clutch to the compressor shaft. Turn the ignition to the OFF position. Install the special tool and press the clutch off. Reconnect the ignition coil wire.
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