Compressor Cylinder And Shaft Assembly - Chevrolet 1980 Light Duty Truck Repair Manual

1D-42 AIR CO NDITIO NING COMPRESSOR OVERHAUL
5. Re-install com pressor Shell as described in "R-4
Compressor Shell an d /o r
procedures.
6. "Evacuate and Charge the Refrigerant System"
according to the D IS C H A R G IN G ,
E V A C U A T IN G A N D C H A R G IN G
FOR C.C.O.T. A /C
C O N D IT IO N IN G section.
V A L V E
P L A T E
Figure 1D -112 Replacing R-4 Discharge Valve Plate
R-4 COMPRESSOR CYLINDER AND
SHAFT ASSEMBLY
Remove
1. "Discharge the Refrigerant System" according to the
D IS C H A R G IN G , A D D IN G OIL, E V A C U A T IN G A N D
C H A R G IN G P R O C E D U R E S
SYSTEM S in the A IR C O N D IT IO N IN G section.
2. R em ove the Clutch Plate and Hub assembly as
described in "R-4 Compressor Clutch Plate and Hub"
Rem oval procedure.
3. Perform Steps 1 through 4 o f "R-4 Compressor
Clutch Rotor a n d /o r Bearing" R em oval procedure
not loosen or remove the pulley rim mounting screws,
so as to remove the Clutch R otor and Bearing, Clutch Coil
and Pulley Rim as a T O T A L assembly. Be careful not to
drop the Puller G uide J-25031, when rem oving the
assembly.
4. R em ove the Shaft Seal as described in "R-4
C ompressor Shaft Seal" R em oval procedure.
5. R em ove the Front H ead as described in "R-4
Compressor Front Head" Rem oval procedure.
O -Rings "Replacement
A D D IN G OIL,
P R O C E D U R E S
SYSTEM S in the A IR
P ISTO N A N D
R E E D ASSY.
FO R C.C.O.T. A /C
but do
6. R em ove the Thrust and Bellville W ashers as
described in "R-4 Com pressor
Washers" R em oval procedures.
7. R em ove the com pressor Shell as described in "R-4
Compressor Shell" R em oval procedure.
8. R em ove the D ischarge V alve Plate and Retainer as
described in "R-4 Com pressor D ischarge Valve Plate a n d /
or Retainer" Rem oval procedure.
9. R em ove the H igh Pressure R elief Valve and Pressure
Switch (if so equipped) as described in "R-4 Com pressor
High Pressure R elief Valve or Pressure Switch" R em oval
procedure.
Replace
1. Replace above parts in opposite order.
2. "Evacuate and Charge the Refrigerant System"
according to the D IS C H A R G IN G ,
E V A C U A T IN G A N D C H A R G IN G
FOR C.C.O.T. A /C
C O N D IT IO N IN G section.
A-6 AND R-4 COMPRESSOR LEAK
TESTING (EXTERNAL AND INTERNAL)
Bench-Check Procedure
1. Install Test Plate J-9625
compressor.
2. A ttach center hose o f M anifold Gage Set on
Charging Station to a refrigerant drum standing in an
upright position and open valve on drum.
3. C onnect Charging Station H IG H and LOW pressure
lines to corresponding fittings on Test Plate J-9625, using
J-5420 G age Adapters.
NOTICE:
Suction port (low -side) o f compressor has
large internal opening. D ischarge port (hi-side) has
smaller internal opening into com pressor.
4. Open LOW pressure control, H IG H pressure control
and R E F R IG E R A N T control on Charging Station to allow
refrigerant vapor to flow into com pressor.
5. U sing Leak D etector
leaks at Pressure R elief Valve, Pressure Switch (if so
located) on com pressor, com pressor Shell to cylinder,
com pressor front head seal (and also rear head seal and oil
charge port on A -6 com pressor), and com pressor Shaft Seal.
After checking, shut off LO W pressure control and H IG H
pressure control on Charging Station.
6. If an external leak is present, perform the necessary
corrective measures and recheck for leaks to make certain
the leak has been corrected.
7. Loosen the M anifold G age hose connections to the
Gage Adapters J-5420 connected to the LOW and H IG H
sides and allow the vapor pressure to release from the
compressor.
8. D isconnect both G age Adapters J-5420 from the
Test Plate J-9625.
9. R otate the C O M PL E T E com pressor assembly (
the crankshaft or drive plate hub
to distribute oil to all cylinder and piston areas.
Thrust and Bellville
A D D IN G OIL,
PR O C E D U R E S
SYSTEM S in the A IR
on Rear H ead
, check for
not
) slow ly several turns
o f