Pontiac Fiero 1988 Service Manual page 102

HR-6 AIR CONDITIONING C O M P R E S S O R 19
two ( 2 ) cylinder sections and remove the center
cylinder O-ring.
Depending on piston position, a piston may pull
out of a cylinder bore but with recommended
alignment and reasonable care in rejoining the
cylinder halves, no damage will occur to the
piston or piston ring and the piston will re-enter
the cylinder bore "in-line".
3- Fasten the front head in the J-33026, holding fixture
(Fig. 29) and insert the cylinder and shaft assembly
into the front head, shaft end down.
4. Lubricate the new center cylinder O-ring, O-ring
groove of the front cylinder and the O-ring seal surface
of the rear cylinder half w i t h clean 525 viscosity
refrigerant oil to facilitate assembly. Assemble the
O-ring to the center cylinder O-ring groove.
5. Insert a piece of 1/4" diameter drill rod or smooth
1/4" diameter drill shank through the discharge
crossover passage in both cylinder halves to align the
cylinder. For proper piston to cylinder bore alignment
the two halves must align.
6. Using both hands, carefully press the cylinder halves
together and remove the drill or drill rod used for
alignment.
If sufficient force cannot be applied to force the
cylinder halves together supported in the holding
fixture, remove the cylinder and shaft assembly and
place the rear of the assembly on a clean, flat surface.
Apply pressure of both hands to force the cylinder
together.
7. Assemble the compressor per previous Cylinder and
Shaft Replace procedure.
C O M P R E S S O R L E A K T E S T I N G (EXTERNAL
AND INTERNAL)
B E N C H - C H E C K P R O C E D U R E
1. Install test plateJ-9625-A on rear head of compressor.
2. Attach center hose of manifold gage set on charging
station to a refrigerant drum standing in an upright
position and open valve on drum.
3. Connect charging station high and low pressure lines
to corresponding fittings on test plate J-9625-A, using
J-5420 gage adapters or hoses equipped w i t h valve
depressors. Suction port (low-side) of compressor has
large internal opening. Discharge port (high-side) has
smaller internal opening into compressor (Fig. 42).
4. Open low pressure control, high-pressure control and
refrigerant control on charging station to allow
refrigerant vapor to flow into compressor.
5. Using a leak detector, check for leaks at pressure relief
valve, rear head switch location, compressor front and
rear head seals, center cylinder seal, through bolt head
gaskets and compressor shaft seal. After checking, shut
off low pressure control and high-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 manifold gage hose connections to the
gage adapters J-5420 connected to the low and high
sides and allow the vapor pressure to release from the
compressor. If valve depressor-type hoses are used,
loosen hose connections at gage manifold to release
vapor pressure from compressor.
8. Disconnect both gage adapters J-5420 or hoses from
the test plate J-9625-A.
9. Add 3 oz. new 525 viscosity refrigerant oil to the
compressor assembly. Rotate the c o m p l e t e
compressor assembly (not the crankshaft or drive
plate hub) slowly several turns to distribute oil to all
cylinder and piston areas.
10. Install a shaft nut on the compressor crankshaft if the
drive plate and clutch assembly are not installed.
11. Using a box-end wrench or socket and handle, rotate
the compressor crankshaft or clutch drive plate on the
crankshaft several turns to insure piston assembly to
cylinder wall lubrication.
12. Connect the charging station high-pressure line or a
high-pressure gage and gage adapter J-5420 to the test
plate J-9625-A high-side connector.
13. Attach an adapter J-5420 or depressor-type hose to the
suction or low pressure port of the test plate J-9625-A
to open the Schrader-type valve. Oil w i l l drain out of
the compressor suction port adapter if the compressor
is positioned w i t h the suction port downward.
14. Attach the compressor to the J-33026 holding fixture
and mount the compressor in a vise so that the
compressor w i l l be in a horizontal position and the
shaft can be turned w i t h a wrench.
15. Using a wrench, rotate the compressor crankshaft or
drive plate hub ten ( 1 0 ) complete revolutions at a
speed of approximately one-revolution per second.
Turning the compressor at less than one-revolution
per second can result in a lower pump-up pressure and
disqualify a good pumping compressor.
18. Observe the reading on high-pressure gage at the
completion of the tenth revolution of the compressor.
The pressure reading for a good pumping compressor
should be 690 kPa (100 psi) or above. A pressure
reading of less than 620 kPa ( 90 psi) would indicate
one or more suction and/or discharge valves leaking
an internal leak, or an inoperative valve, and the
compressor should be disassembled and checked for
cause of leak. Repair as needed, reassemble and repeal
the pump-up test. Externally leak test.
17. When the pressure pump-up test is completed, release
the air pressure from the high-side and remove the
gage adapters J-5420 and test plate J-9625-A.
18. Tilt the compressor so that the compressor suctior
and discharge ports are down. Drain the oil from the
compressor.
19. Allow the compressor to drain for 10 minutes, thei
refill w i t h the proper amount of oil. The oil may b<
poured into the suction port. If further assembly o
processing is required, a shipping plate or test plat<
J-962 5-A should be installed to keep out air, dirt an<
moisture until the compressor is installed.