R E Frig Eran T H O Se F A I L U R; C O M P Resso - Chevrolet CHEVY VAN G10 SERIES Service Manual

A IR C O N D IT IO N IN G 1A-24
R E FR IG E R A N T HOSE FAILUR E
A fter a leak or ru p tu re has occurred in a refrigerant hose, or
if a fitting has loosened and caused a considerable loss o f
refrigerant and oil, th e entire system should be evacuated and
recharged after repairs have been m ade. I f th e system has been
open to atm osphere for any prolonged period o f tim e the
receiver-dehydrator should be replaced.
These systems inco rpo rate com pressor inlet and o u tlet
hoses w hich are swaged to the com pressor con nector block
inlet and o u tlet lines.
Because o f the extrem e length o f the hoses on these
systems, hose leaks m ay be repaired using th e following
procedure:
1. Locate the leak. This may require rem oving the body
inner side panels to gain access to the hoses on the C-63
system .
2. Discharge the system .
3. C ut o u t the leaking p o rtio n o f the hose, m aking sure th at
all o f the failed p o rtio n is rem oved. I f only a very small
p o rtio n o f th e hose was rem oved, it m ay be possible to
splice the tw o ends together using a special hose co n ­
nector and tw o hose clam ps. If several inches o f hose
m ust be rem oved, a new piece o f hose should be spliced
in using tw o connectors an d four hose clamps. Dip the
ends o f th e hoses in clean refrigeration oil before in ­
stalling the hoses o n to the con n ecto r. Never push the end
o f the hose bey o n d the locating bead o f the connector.
T orque the clam p to 35-42 in. lbs.
C A U T IO N : Be sure to replace the hose in the body
in the same manner as when removed. If the hose
protective grommets
should be replaced.
4. Evacuate, charge and check the system.
COMPRESSOR (Fig. 30)
Removal
1. D isconnect b attery ground cable.
2. D isconnect com pressor clutch connector.
3. Purge the system o f refrigerant.
4. Release the belt tension at th e idler pulley and remove
the belt fro m the com pressor pulley. O n some vehicles it
m ay be necessary to remove the crankshaft pulley in
order to remove the belt.
5. Rem ove the fro n t air conditioning d istrib utor duct de­
scribed later in this section.
6. Rem ove the tw o bolts and tw o clam ps th a t hold the
engine cover and rem ove the cover.
7. Rem ove the air cleaner to aid access to the com pressor.
8. Remove fitting and m uffler assembly and cap or tape all
open connections.
9. Remove the nuts and bolts attaching the com pressor to
the bracket.
10. Rem ove th e engine oil tube support bracket b o lt and n ut
from the com pressor, also com pressor clutch ground
lead.
11. Remove b o lt and n u t holding m uffler assembly to front
o f com pressor (also holds vacuum line on pow er assisted
are badly m utilated, they
brake equipped vehicles, if necessary, remove vacuum
hose at m anifold end).
Before beginning any com pressor disassembly, drain and
measure oil in the com pressor. C heck for evidence o f co n ­
tam in atio n to determ ine if rem ainder o f system requires
servicing. Com pressor Servicing inform ation is located in the
Chassis Overhaul Manual.
Installation
1. If the oil drained from the com pressor show ed no
evidence o f co n tam ination, replace a like am o u n t o f fresh
refrigeration oil in to the com pressor before reinstallation.
If it was necessary to service the entire system because o f
excessive contam ination in the oil rem oved, install a full
charge o f fresh refrigeration oil in the com pressor. (See
Checking Com pressor Oil Charge in the Service M anual.)
2. Position com pressor on the m ounting bracket and install
all n u ts, bolts, lock washers, and m o u n t oil dip stick
tube, m uffler, vacuum brake hose ( if equipped), and
ground wire.
3. Install the connector assembly to the com pressor rear
head, using new " 0 " rings co ated w ith clean refrigeration
oil.
4. C onnect the electrical lead to the coil and install and
adjust com pressor b elt, using idler pulley. See " Com ­
pressor Belt Tension A djustm ent."
5. Evacuate, charge and check the system .
6. Replace air cleaner, engine cover and air d istrib u to r duct.
Compressor Belt Tension Adjustment (Fig. 30)
A djust the com pressor belt to the specifications show n in
the Tune-Up chart in the Engine section o f the Service M anual.
N O T E : On some vehicles it may be necessary to
increase idler pulley slack adjustment. This may be
accomplished by (1) Remove and discard the idler
adjustment bolt. (2) Remove the idler backing plate
and elongate all 3 adjusting slots 1 /2 inch inboard or
COMPRESSOR
Fig. 3 0 —Compressor and Idler Pulley Installation
MOUNTING
BRACKET
C H E V Y V A N SH O P M A N U A L