Pontiac Fiero 1988 Service Manual page 116

V-5 AIR CONDITIONING COMPRESSOR OVERHAUL 1D3-13
CYLINDER TO FRONT HEAD O-RING
H-"*l
Remove or Disconnect
1. Discharge A/C system remove compressor from
car. Drain oil from compressor into a container,
measure, record and discard oil.
2. Clutch drive and hub assembly, pulley rotor and
bearing assembly and clutch coil.
3. Shaft seal parts and discard.
4. Six (6) compressor through bolts and gaskets.
Discard gaskets.
5. Using a plastic headed hammer, tap the front
head at the mounting locations to disengage the
head from the compressor cylinder.
6. Front head, and cylinder to front head O-ring.
Discard O-ring.
Note assembly sequence of thrust washer and
bearing for reassembly.
|hmJ Install or Connect
1. Rest the rear head on support block J-35372.
Install one (1) assembly guide pin J-34993 through
11 o'clock hole. Locate control valve at 6 o'clock.
2. Lubricate a new cylinder to front head O-ring
with clean 525 viscosity refrigerant oil and install
O-ring in cylinder O-ring groove.
3. Thrust washers and bearing in same order as
removed.
4. Align guide pin recess in front head with guide
pin and using both hands, press down on the front
head to force it over O-ring on cylinder assembly.
5. Add new through bolt gasket to the through bolts
and install the bolts into the compressor
assembly. Be sure four (4) of the through bolts
thread into the rear head before removing the
guide pin. Assemble clamp to holding fixture.
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.
6. New shaft seal kit.
7. Add amount of new 525 viscosity refrigerant oil
to be added as determined in Step 1 of Remove.
Install test plate J-9625-A.
8. Leak test complete compressor.
9. Remove shaft nut and install clutch parts on
compressor.
10. Install compressor assembly on car.
11. Evacuate and charge A/C system.
1—THROUGH BOLT GASKET (6) REQUIRED
2-J-35372
520023-1D3
Fig. 29 Front Head Installed: Thru Bolts and Gaskets In
Place
L E A K T E S T I N G ( E X T E R N A L )
Bench-Check Procedure
1. Install test plate J-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 with valve depressors. Suction port
(low-side) of compressor has large internal
opening. Discharge port (high-side) has smaller
internal opening into compressor (Fig. 3).
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 J-29547, 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 and remove test
plate.