1988 PONTIAC FIERO Service Repair Manual

1191-"1 8-4 AIR CONDITIONING COMPRESSOR OVERHAL
CLUTCH COIL AND PULLEY RIM
Fig. 29 thru 34
Clutch coil and pulley rim installation
and removal procedures for the six-pole
clutch are the same as the four-pole clutch
with the exception of Steps
1 through 4 of
the
clutch rotor and/or bearing - Six-Pole
Clutch, removal or disconnect must
be used.
V-Groove Drive
Remove
or Disconnect
1. Perform Steps I through 4 of CLUTCH ROTOR
AND BEARING removal procedure but do not
loosen or remove the pulley rim mounting screws
until the Clutch Rotor, Coil and Pulley Rim
assembly have been removed from the Front
Head. Be careful not to drop the Puller Guide
5-2503 1 when removing the assembly.
2. Remove the pulley rim mounting screws and
special lock washers. Discard the lock washers
and screws.
3. Slide the pulley rim off the Rotor and Hub
assembly. The Pulley Rim and the Clutch Coil
are replaceable at this point.
FRONT SURFACE
Fig. 29 Clutch Coil Asm.
Poly-Groove Drive
Remove
or Disconnect
1. Clutch plate and hub assembly
2. Pulley rotor and bearing assemblyusly. Mark the
location of the clutch coil terminals on the
compressor.
3. Install Rotor and Bearing Puller Guide J-25031
to the front head and install Puller J-8433 with
Poly-V-Belt Puller Leg Set
5-24092 and remove
the clutch coil from the front head. Clutch coil
may also be removed by using rotor and bearing
puller guide
J-25031 with puller tool J-25287.
1 -J-24092 PULLER LEGS
2-J-8433 PULLER
3-J-25031 GUIDE
4-CLUTCH
COl L
Fig.
30 Removing Poly-Groove Clutch Coil
V-Groove Drive
Install or Connect
1. Assemble the Clutch Coil, Pulley Rim and the
Clutch Rotor and Bearing assembly. Use new
screws and special lock washers and apply sealer
(Loctite RC-75, Loctite
601, or equivalent) to
screw threads but do not lock the screws in place.
2. Place the assembly on the neck of the Front Head
and seat into place using Rotor
& Bearing
Installer
J-2627 1-A.
Before fully seating the assembly on the Front
Head, be sure the clutch coil terminals are in the
proper location in relation to the compressor and
that the three protrusions on the rear of the
clutch coil align with the locator holes in the
Front Head.

R-4 AIR 60NDlVlONBNG COMPRESSOR OVERHAUL l Dl-1 l
1-J-25287 CLUTCH COIL PULLER
2-5-25031 GUIDE
3-J-25Q88-A HOLDING F IXVUWE
4-CLUTCH COl b 520023.1 DI
Fig. 3 1 Removing Poly-Groove Clutch Coil (Optional
Method)
1-CLUTCH COIL AND HOUSING
ASM.
2-PULLEY
RIM
Fig. 32 Assembling Clutch Coil, Pulley Rim, Rotor & Bearing
3. Install the rotor and bearing assembly retaining
ring and reassemble the Clutch Plate and Hub
assenibly as described in "Clutch Plate and Hub
Assembly"
Repllacement procedure. Check to see
that the clutch plate to clutch rotor air gap is
.5
to l.Omm (.020 to .040 inches).
Rotate the Pulley Rim and Rotor to be sure the
Pulley Rim is rotating "in-line" and adjust or
replace as required.
4. Tighten the pulley rim mounting screws to 11
Nom (100 inch-pounds) torque and lock the
screw heads in place by bending lock washers
similar to original
crimp and lock bends on
washers.
Fig. 33 Pulley Rim Mounting Location Detail
Ill
1- MOUNTING NOTCHES
2- MOUNTING SLOTS
Fig.
34 Pulley Rim Mounting Location Detail - Optional
Design
Poly-Groove Drive
1. Place
the clutch coil assembly on the neck of the
front head with clutch coil terminals in line with
mark scribed in Step
2 of the removal procedure.
2. Place the pulley rotor and bearing assembly on
the neck of the front head and seat the clutch coil
and pulley rotor in place using Rotor and Bearing
Installer
J-2627 1 -A.
Before fully seating the assembly on the front
head, be sure the clutch coil terminals are in
proper location in relation to the compressor and
that the three protrusions on the rear of the
clutch coil housing align with the locator holes in
the front head.
3. Install the pulley-rotor and bearing assembly
retaining ring and reassemble the clutch plate and
hub assembly as described in "Clutch Plate and
Hub Assembly
- Replace."
Install or Gsns~eet 4. Check
to see that the clutch plate to clutch rotor
air gap is 0.5
- f.Omm (0.020" - 0.040").

4 Dl-I 2 R-4 AIR CONDITIONING COMPRESSOR OVERHAUL
MAJOR REPAIR PROCEDURES
Service repair procedures to the
Compressor Shaft Seal,
Pressure Relief Valve
or disassembly
of the Internal Compressor
Cylinder and Shaft Assembly are considered
"MAJOR" SINCE THE REFRIGERATION
SYSTEM MUST BE DISCHARGED,
EVACUATED AND RECHARGED to complete
service and/or because major internal
operating and sealing components of the
compressor are being disassembled and
serviced.
When replacing the shaft seal assembly or
pressure relief valve, even if the compressor remains on
the vehicle during the operation, it will be necessary to
discharge the system of refrigerant (see Section
1B).
Other than clutch repair procedures, the same holds
true for any disassembly of the compressor.
If the compressor shell, front head or cylinder
and shaft assembly are to be serviced or replaced, the
oil in the compressor must be drained, measured and
replaced (see Section
1B) to determine addition of
proper oil quantity to new assembly.
A clean workbench, preferably covered with a
sheet of clean paper, orderliness in the work area and
a place for all parts being removed and replaced is of
great importance, as is the use of the proper, clean
service tools.
NOTICE: Any attempt to use make-shift or
inadequate equipment may result in damage
and/or improper compressor operation.
All parts required for servicing the internal
compressor are protected by a preservation process and
packaged in a manner which will eliminate the
necessity of cleaning, washing or flushing of the parts.
The parts can be used in the internal assembly just as
they are removed from the service package.
Seals and
protective packaging should be left in tact un
ti1 just
prior to installation.
SI-IAFT SEAL
Fig. 35 thru 40
Shaft Seal Design
The shaft seal is a one piece design.
Seal Leak Detection
A shaft seal should not be changed because of an
oil-line on the hood insulator. The Seal is designed to
seep some oil for lubrication purposes. Only change a
Shaft Seal when a leak is detected by evidence of oil
sprayed in large amounts and then only after actual
refrigerant leakage is found by using an approved leak
Detector such as J-29547 or equivalent.
Should an R-4 compressor shaft seal ever have to
be replaced, the accumulator in this R-4 system must
also be removed from the vehicle. The oil in the
accumulator then must be drained, measured and
replaced according to the directions in Section
1B to
determine oil loss.
On-Car
Remove
or Disconnect
1. Discharge A/C system
2. Loosen and reposition compressor in mounting
brackets
3. Clutch Plate and Hub assembly
4. Shaft seal seat retainer ring, using Snap Ring
Pliers J-5403-A
5. Thoroughly clean inside of compressor neck area
and O-ring groove surrounding the shaft, the
exposed portion of the seal seat and the shaft
itself. Any dirt or foreign material getting into
compressor may cause damage.
6. Remove Lip Seal:
e Fully engage the knurled tangs of Seal
Remover-Installer J-23 128-A into the
recessed portion of the Seal by turning the
handle clockwise. Remove the Seal from the
compressor with a rotary-pulling motion.
Discard the Seal. The handle must be
hand-tightened securely. Do not use a
wrench or pliers.
7. Discard the seal seat O-ring from the compressor
neck using 0-Ring Remover J-9553-01.
8. Recheck the shaft and inside of the compressor
neck and O-ring groove for dirt or foreign
material and be sure these areas are perfectly
clean before installing new parts.
Inspection
Seals should not be reused. Always use a new
specification service seal kit on rebuild. Care should be
taken to prevent damage to the lip of the one piece seal.
Make sure that the Seal Seat and Seal Lip are free of
lint and dirt that could damage the seal surface or
prevent sealing.
On-Car
Install
or Connect
1. Dip
the new seal O-ring in clean 525 viscosity
refrigerant oil and assemble onto 0-Ring
Installer J-33011.
2. Insert
the 0-Ring Installer
5-3301 1 completely
down into the compressor neck until the Installer
"bottoms." Lower the moveable slide of the
0-Ring Installer to release the 0-Ring into the
seal seat O-ring lower groove. (The compressor
neck top groove is for the shaft seal retainer ring.)
Rotate the Installer to seat the O-ring and remove
the Installer.
3. Prepare Lip Seal:
Assemble seal to Seal Installer J-23128-A,
by turning handle clockwise, and then push
Seal Protector J-34614, into seal lip. The
stamped steel case side of the lip seal must
be engaged with knurled tangs of installer so
that flared-out side of lip seal is facing and
installed towards the compressor.
4. Install Lip Seal:

R-4 AIR CONDITIONING COMPRESSOR OVERHAUL 101-13.
ONE-PIECE SEAL
J-34614 SHAFT SEAL PROTECTOR I G60230-181.8
Fig. 35 Removing and Installing Seal
Place seal protector 9-34614 over end of
compressor shaft and slide new seal onto the
shaft until it stops. Disengage in
NOTICE: HANDLING AND CARE OF SEAL
PROTECTOR IS IMPORTANT. IF SEAL
PROTECTOR IS NICKED OR THE BOTTOM
FLARED, THE NEW SEAL
MAY BE
DAMAGED DURING INSTALLATION.
5. Install the new seal seat retainer ring with its flat
side against the Seal Seat, using Snap-Ring Pliers
5-5403. Use the sleeve from O-Ring Installer
5-3301 1 to press in on the seal seat retainer ring
so that it snaps into its groove.
6. For Leak Test, pressurize suction side
(low-pressure side) of compressor on vehicle with
Refrigerant-12 vapor to equalize pressure to the
drum pressure. Temporarily install the shaft nut
and, with compressor in horizontal position,
rotate the compressor shaft in normal direction
of rotation several times by hand. Leak test the
Seal and correct any leak found. Remove, discard
and later replace the shaft nut.
7. Remove any excess oil, resulting from installing
the new seal parts, from the shaft and inside the
compressor neck.
8. Install the Clutch Plate and Hub assembly as
described in minor repair procedures.
9. Reinstall compressor belt and tighten bracketry.
10. Evacuate and Charge the Refrigerant System
according to directions in Section
1B.
Off-Car
Install or
Connect
1. Follow applicable on-car procedures.
2. To Leak Test, install leak Test Fixture 5-9625 on
rear head of compressor and connect gage
charging lines, or pressurize suction side (low
pressure side) of compressor on car with
Refrigerant-12 vapor to equalize pressure to the
drum pressure. Temporarily install the shaft nut and,
with compressor in horizontal position and
using a wrench, rotate the compressor shaft in
normal direction of rotation several times by
hand.
Leak test the seal and correct any leak
found. Remove, discard and later replace with a
new shaft nut.
PRESSURE RELIEF VALVE
Fig. 4 1
The Pressure Relief Valve, located in the
compressor rear head casting, should only be replaced
after purging the system of refrigerant,
A new valve
and O-ring coated with 525 viscosity refrigerant oil
should be installed.
HIGH PRESSURE CUT-OFF SWITCH
Fig. 42
Remove or Disconnect
1. Discharge A/C system
2. Electrical connector at switch
3. Switch retaining ring using
J-5403-A internal
snap ring pliers.
4. Switch from compressor by pulling on terminal
housing.
5. Old O-ring seal from switch cavity using
J-9553-01 O-ring removal tool or equivalent.
If high pressure cut-off switch will be reinstalled.
in compressor, a new O-ring seal must be
used
and preferably a new retainer ring should also be
used. A new switch kit has the O-ring and
retainer ring included.
install or Connect
1.
Check switch cavity and O-ring groove in the rear
head for dirt or foreign material and clean as
necessary. Install new O-ring coated with cleall
525 viscosity refrigerant oil into groove in switch
cavity.
2. Lubricate the high pressure cut-off
switgh
housing with clean 525 viscosity refrigerant

1 Dl-14 R-4 AIR CONDITIONING COMPRESSOR OVERHAUL
[il SEAL O-RING
OJ-23128-A 05-33011
J-9553-01 J-34614
G60240.1 Dl-D
Fig. 36 Removing and Installing Seal and 0-Ring Fig.
37 One
Piece Shaft Seal
1-SNAP
RING
2-SEAL SEAT
I Fig. 38 Removing and Installing Shaft Seal Seat
Retaining Ring
and carefully insert switch into switch cavity
until switch bottoms in cavity.
3. Using J-5403-A 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.
FRONT HEAD AND O-RING
Fig. 43,44
Remove or Disconnect
1. Discharge the Refrigerant System according to
the directions in Section
1B.
2. Perform steps 1 through 4 of CLUTCH ROTOR
AND BEARING removal procedure, but do not
loosen or remove the pulley rim mounting screws
so as to remove the Clutch Rotor and Bearing,
Clutch Coil and Pulley Rim as a total assembly.
Be careful not to drop the Puller Guide
5-2503 1
when removing the assembly.
3. Remove and discard the Shaft Seal parts as
described in SHAFT SEAL removal procedure
4. Before removing
front head, mark the cylinder
next to the narrow front head leg position.
5. Remove
the four front head mounting screws and
remove the Front Head assembly.

I 2-ONE-PIECE SEAL I
3-J-34614 - SHAFT SEAL PROTECTOR
Fig. 39 Removing
& Installing One Piece Seal (Off Car)
I J-33011 O-RING INSTALLER I
Fig. 40 Installing Seal Seat 0-Ring (Off Car)
6. Remove and discard the front head O-ring.
Install or Connect
1. Check the Front Head and compressor cylinder
area for any dirt, lint,
etc. and clean if necessary.
Install a new Service thrust washer kit, if
required, as described in THRUST AND
BELLEVILLE WASHERS REMOVAL AND
REPLACEMENT procedures.
2. Dip the new front head O-ring in clean 525
viscosity refrigerant oil and install in the seal
groove on the front head.
-4 AIR CONDITIONING COMPRESSOR OVERHAUL 1 Dl-15
I
1-LEAK TEST
ADAPTER
J 9625
2-HIGH PRESSURE
CUT-OFF
SWITCH
NOTICE:
HIGH PRESSURE
CUT-OFF
SWITCH INSULATORS
ARE COLORED
RED
Fig. 4
1 Compressor Leak Testing Fixture
1-RED INSULATOR
2-HIGH PRESSURE
CUT-OFF SWITCH
3-"0" RlNG
4-SWITCH
RETAINING
RING
Fig. 42 High Pressure Cut-Off Switch and Retainer
I-FRONT HEAD 2-MOUNTING
SCREWS
(4)
Fig. 43 Removing Front Head Mounting Screws
3. Position the Front Head narrow leg, to the
marking previously made on cylinder, and
tighten the front head mounting screws to
27
N-m (20 lb. ft.) torque.
4. Install new specification Service Shaft Seal kit as
described in SHAFT SEAL REPLACEMENT
PROCEDURE.

1D1-16 R-4 AIR CONDITIONING COMPRESSOR OVERHAUL
BELLEVl LLE
2-BELLEVI
LLE
Fig. 44 Removing Front Head Assembly Fig. 45 Replacing Thrust
and Belleville Washers
5. I~stall the Clutch Rotor and Bearing assembly,
Clutch Coil and Pulley Rim assembly to the
Front Head, using Rotor and Bearing Installer
J-2627 1-A.
Before fully seating the assembly onto the Front
Head, be sure the clutch coil terminals are in the
proper location in relation to the compressor and
that the three protrusions on the rear of the
clutch coil align with the locator holes in the
Front Head.
6. Install the rotor and bearing assembly retainer
ring and reassemble the Clutch Plate and Hub
assembly as described in CLUTCH PLATE
AND HUB" replacement procedure. Check to
see that the clutch plate to clutch rotor gap is
.5
- 1.Omm (.020 - .040 inches).
7. Evacuate and charge the refrigerant system
according to the directions in Section
1B.
THRUST AND BELLEVILLE WASHERS
Fig. 45
Remove or Disconnect
1. Discharge the refrigerant system according to the
directions in Section
1B.
2. Remove
the Front Head assembly as described in
"Front Head Removal Procedure." Remove and
discard the front head O-ring seal.
3. Remove the two thrust washers and one belleville
washer from the compressor shaft. Note the
assembled position of the washers.
Install or Connect
1. Install a new thrust washer on the compressor
shaft with the thrust washer tang pointing "UP"
2. Install the new belleville washer on the shaft with
the high center of the washer "UP." Head
and new O-ring onto the compressor as
described in FRONT HEAD replacement
procedure.
MAIN BEARING
Fig. 46,47
Remove or Disconnect
1. Discharge the refrigerant system according to the
direction in Section
1B.
2. Remove the Front Head assembly as described in
FRONT HEAD REMOVAL PROCEDURE.
Discard front head O-ring.
3. Place the Front Head assembly on two blocks, as
shown in Fig. 46, and use Main Bearing Remover
J-24896 to drive the Main Bearing out of the
Front Head.
Fig. 46 Removing Main Bearing
-
3. Install the remaining thrust washer on the shaft Install or Connect
with the tang pointing "DOWN".
4. Lubricate the three washers with clean 525 1. Place the Front Head "with neck-end down" on
viscosity refrigerant oil and assemble the Front a
flat, solid surface.

R-4 AIR CONDITIONING COMPRESSOR OVERHAUL 1 Dl-17
2. Align
the new Main Bearing and the Bearing
Installer
5-24895 squarely with the bearing bore
of the Front Head and drive the bearing into the
Front Head. The Installer J-24895 must seat
against the Front Head to insert the bearing to
the proper clearance depth.
Fig. 47 Installing Main Bearing
3. Assemble the Front Head to the cylinder, using
a new O-ring as described in FRONT HEAD
replacement procedure.
4. Evacuate and charge the refrigerant system
according to the directions in Section
1B.
SHELL AND O-RINGS
Fig. 48 thru 50
Remove or Disconnect
1. Discharge the refrigerant system according to the
directions in Section
1B.
2. Thoroughly clean exterior of compressor to
prevent dirt from getting into compressor during
shell removal.
3. Remove the Clutch Plate and Hub assembly as
described in CLUTCH PLATE AND HUB
removal procedures.
4. Perform Steps 1 through 4 of CLUTCH ROTOR
AND BEARING removal procedure but do not
loosen or remove the pulley rim mounting screws
so as to remove the Clutch Rotor and Bearing,
Clutch Coil and Pulley Rim as a total assembly.
Be careful not to drop the Puller Guide J-25031
when removing the assembly.
5. Pry the shell-retaining strap away from the
cylinder and position the strap high enough to
clear the cylinder as the Shell is removed.
6. Remove Compressor Holding Fixture J-25008-A,
and reverse Holding Fixture with step block
protrusions engaging the compressor Shell.
Install the medium-length metric thread
mounting bolts through the Holding Fixture and
thread them finger-tight on both sides into the
compressor cylinder until the step of the fixture
protrusions contact the compressor Shell. Check
to be sure the step protrusions do not overlap the
cylinder but will pass both sides. Allow
compressor to cool to room temperature before
removing compressor shell.
2-J-25008 -A
HOLDING FIXTURE
Fig. 48 Releasing Shell Retaining Strap
HOLDING FIXTURE
2-SHELL TO
CYLINDER
O-RING
3-ALTERNATELY
TIGHTEN
SCREWS
APPROX.
114 TURN
4-STEP CONTACTS
COMPRESSOR
SHELL
Fig. 49 Removing Shell
7. Alternately tighten each bolt approximately 1/4
turn to push the Shell free of the O-rings on the
cylinder.
If one screw appears to require more force to turn
than the other, immediately turn the other screw
to bring the screw threading sequence in-step or
the Shell will be cocked and made more difficult
to remove. Normal removal does not require
much force on the wrench if the screws are kept
in-step while turning. The Shell can be removed
by hand as soon as the Shell is free of the shell to
cylinder O-rings. Do not turn the screws any
further than necessary to release the Shell.
8. Remove the compressor Shell and remove the
Holding Fixture J-25008-A from the compressor.
Reverse the Holding Fixture to again hold the
compressor by the opposite side, using the
short-length screws with metric threads.
9. Remove and discard both cylinder to Shell
O-rings.