Pontiac Fiero 1988 Service Manual page 115

103=12 V-5 AIR CONDITIONING COMPRESSOR OVERHAUL
necessary. Install new O-ring coated with clean
refrigerant oil into groove in switch cavity.
2. Lubricate switch housing with clean refrigerant
oil and carefully insert switch into switch cavity
until switch bottoms in cavity.
3. Using J-5403 snap ring pliers, install switch
retaining ring with high point of curved sides
adjacent to the switch housing. Be sure retaining
ring is properly seated in the switch cavity
retainer ring groove. Leak test per procedure.
CONTROL VALVE ASSEMBLY
Fig. 4
Remove or Disconnect
0
1.
2.
3.
Discharge A/C System.
Control valve retaining ring using J-5403 internal
snap ring pliers.
Control valve assembly.
-•«- Install or Connect
1. When reassembling control valve, coat O-rings
with 525 viscosity refrigeration oil and push in
place with thumb pressure.
2. Using J-5403 snap ring pliers, install valve
retaining ring with high point of curved sides
against valve housing. Be sure retaining ring is
properly seated in ring groove. Leak test per
procedure.
REAR HEAD, HEAD GASKET, REAR VALVE
PLATE, SUCTION REED PLATE AND CYLINDER
TO REAR HEAD O-RING
4-> Remove or Disconnect
1.
2.
4.
Discharge A/C system and remove compressor
from car. Drain oil from compressor into a
container, measure, record and discard oil.
Clutch drive and hub assembly, pulley rotor and
bearing assembly and clutch coil.
Six (6) compressor through bolts and gaskets.
Discard gaskets.
Using a wood block and plastic headed hammer,
tap around the edge of the rear head to disengage
head from the compressor cylinder. Separate the
rear head, head gasket, rear valve plate, suction
reed plate and cylinder to rear head O-ring.
Discard the head gasket and the O-ring.
-•<- Install or Connect
1.
3.
Place rear head on clean flat surface. Position
head with control valve at 6 o'clock position.
Guide pins in mounting holes at 11 and 5 o'clock
positions.
Head gasket over guide pins, with elongated hole
at upper left pin (11 o'clock).
Rear valve plate over guide pins with elongated
hole at upper left pin. Lower into place.
Suction reed plate over guide pins. Remove guide
pin at 5 o'clock position.
Lubricate a new cylinder to rear head O-ring with
clean 525 viscosity refrigerant oil and install
1 - PLASTIC HEADED HAMMER
2 - WOOD BLOCK
3— REAR HEAD
4— FRONT HEAD
520022-1P3
Fig. 2 8 Tapping Front or Rear Head Free of Cylinder
O-ring in cylinder O-ring groove. O-ring seal
surface of rear head may be oiled to ease
assembly.
7. With O-ring in place on rear of cylinder assembly
locate relief boss for compressor guide pin at 6
o'clock position, directly above hole in the side of
the rear head. Carefully lower cylinder and front
head assembly over guide pin to rear head.
8. Using both hands, press cylinder and front head
assembly down into rear head.
9. Add new through bolt gasket to through bolts
and install into compressor assembly. Be sure
four (4) of the through bolts thread into the rear
head before removing the guide pins. Alternately
tighten the through bolts in progressive torque
until a torque of 8-10 N-m (72-84 in. lbs.) is
achieved on all six (6) bolts.
10. New shaft seal kit.
11. Add amount of new 525 viscosity refrigerant oil
to be added and determined in Step 1 of Remove.
Install test plate J-9625-A. Place shaft nut on
shaft and rotate compressor shaft several times.
12. Leak test complete compressor assembly.
13. Remove shaft nut and install clutch parts on
compressor.
14. Install compressor assembly on car.
15. Evacuate and charge A/C system.