1988 PONTIAC FIERO oil

R-4 AIR CONDITIONING COMPRESSOR OVERHAUL 101-3
1-RETAINER RlNG
2-SHAFT SEAL
4-O-RING, SEAL SEAT
%-SHAFT SEAL KIT
6-SCREW AND WASHER
ASSEMBLY FRONT
HEAD MOUNTING
7-FRONT HEAD
8-MAIN BEARING
9-RING SEAL, FRONT
HEAD TO CYLINDER
11-O-RING, CYLINDER
TO SHELL
12-TH RUST WASHER
13-BELLEVILLE WASHER
14-THRUST WASHER KIT
15-CYLINDER AND SHAFT
ASSEMBLY
16-RETAINER RlNG
17-VALVE PLATE
18-SHIPPING PLATE
19-SCREW
20-O-RING
SUCTION-
DISCHARGE PORTS
21-PRESSURE RELIEF
VALVE
22-O-RING, PRESSURE
RELIEF VALVE
23-SHAFT NUT
24-CLUTCH HUB KEY
25-CLUTCH DRIVE
ASSEMBLY
26-RETAINER RlNG
27-ROTOR
28-ROTOR BEARING
29-ROTOR AND BEARING
ASSEMBLY
*
30-COIL AND HOUSING
ASSEMBLY
31-PULLEY RIM MOUNT-
ING SCREW
32-PULLEY RIM
I
Fig. 5 8-4 Compressor Disassembled View

181-4 R-4 ABR CONDITIONING COMPRESSOR OVERHAUL
SERVICE PROCEDURES
MINOR REPAIR PROCEDURES
THE FOLLOWING OPERATIONS TO THE
R-4 COMPRESSOR CLUTCH PLATE AND 1 -SUCTION
HUB, ROTOR AND BEARING, AND COIL &
PULLEY RIM ARE COVERED AS 'WINOR" 3-DISCHARGE
BECAUSE THEY MAY BE PERFORMED
WITHOUT FIRST DISCHARGING THE
SYSTEM OR REMOVING THE
COMPRESSOR FROM THE VEHICLE. 5-~-25008-~
The two types of drive systems used on the R-4
Compressor (\I-groove type and poly-groove type)
affect only minor repair procedures and are so noted
where required. Major repair procedures are not
Fig. 6 Compressor In Holding Fixture affected by the type of drive system.
The Shaft and 2. Keep the clutch hub from turning with the
Pressure Relief Valve may also be serviced WITHOUT
REMOVING THE COMPRESSOR from the vehicle Clutch
Hub Holding Tool 5-25030/J-33027
remove, and discard the shaft nut, using Thin
but these operations are covered later in this section as
MAJOR REPAIR PROCEDURES because the Wall Socket
5-9399.
system must be discharged, evacuated and recharged
to complete service.
Illustrations used in describing these operations
show the compressor removed from the vehicle only to
more clearly illustrate the various operations.
CLUTCH HUB
When servicing the compressor, remove only the
necessary components that preliminary diagnosis
indicates are in need of service. Refer to the AIR
CONDITIONING section and Fig.
4 and Fig. 5 for
information relative to parts nomenclature and
location.
Removal and installation of external compressor
components and disassembly and assembly of internal
components must be performed on a clean workbench.
The work area, tools and parts must be kept clean at
all times.
CLUTCH PLATE AND HUB ASSEMBLY Fig. 7 Removing Shaft Nut Fig. 6 thru 10
CLUTCH PLATE AND HUB ASSEMBLY 3. Thread the Clutch Plate and Hub Assembly INSTALLATION AND REMOVAL Remover 5-33013-I3 into the hub. Hold the body
PROCEDURES FOR THE SIX-POLE of the Remover with a wrench and turn the center
CLUTCH ARE THE SAME AS THE screw into the Remover body to remove the
FOUR-POLE CLUTCH WITH THE Clutch Plate and Hub assembly.
EXCEPTION OF THE CLUTCH HUB
HOLDING TOOL. FOR FOUR-POLE 4. Shaft key
CLUTCH USE J-25030. FOR SIX-POLE
CLUTCH USE J-33027. Install or Connect
a Remove or Disconnect 1. Shaft key in hub key groove. Allow the key to
project approximately
4.8mm (3/16") out of
1. If compressor is on the car, loosen compressor keyway.
mounting brackets, disconnect the compressor
The shaft key is curved slightly to provide an
drive belt and reposition the compressor for
interference fit in the shaft key groove of the hub.
access, if necessary. If compressor has been
removed from the car, attach the compressor to 2. Be Sure the frictional surface of the clutch plate
Holding Fixture
J-'25008-8 and clamp the and
the clutch rotor are clean before installing the
Holding Fixture
in a vise. Clutch
Plate and Hub assembly.
Compressor mounting holes are metric. Use 3.
Align the shaft key with the shaft keyway and
proper metric bolts with holding fixture place the Clutch Plate and Hub assembly onto the
J-25008-A. compressor shaft.

R-4 AIR CONDITIONING COMPRESSOR - OVERHAUL 1 Dl-5
J-33013-8 HUB AND CLUTCH PLATE AND
CLUTCH DRIVE PLATE HUB ASSEMBLY
ASSEMBLY REMOVER
H60070-1 Dl-D
Fig. 8 Clutch Plate And Hub Assembly Removal
1-CLUTCH PLATE AND HUB
ASSEMBLY
2-CLUTCH ROTOR
3-SHAFT KEY
Fig.
9 Installing Shaft Key
NOTICE: To avoid internal damage to the
compressor, do not drive or pound on the clutch
hub or shaft.
4. Install the Clutch Plate and Hub Installer
J-9480-B.
5. Hold the hex portion of the Installer Body
J-9480-B with a wrench and tighten the center
screw to press the, hub onto the shaft until there
is
a .5mm - l.Omm (.020"-.040") inch air gap
between the frictional surfaces of the clutch plate
and clutch rotor.
6. Install a new shaft nut with the small diameter
boss of the nut against the crankshaft shoulder,
using Thin Wall Socket J-9399. Hold the Clutch
Plate and Hub assembly with Clutch Hub
Holding Tool
J-25030/J-33027 and tighten to 14
N-m (10 lb. ft.) torque, using a 0-60 N-m (0-25
1b.ft.) torque wrench.
7. If operation is performed with compressor on car,
connect drive belt, tighten mounting brackets and
adjust belt tension.
1-DRIVE PLATE
INSTALLER
J-9480-B
2-DRIVE PLATE
INSTALLER
BEARING
3-AIR GAP
(.02OU-.040")
4-CLUTCH PLATE
AND HUB ASM.
Fig.
10 Installing Clutch Plate & Hub Asm.
CLUTCH ROTOR AND BEARING:FOUR POLE
CLUTCH
Fig. 11 thru 28
Remove or Disconnect
1. Clutch Plate and Hub assembly
2. Rotor and Bearing assembly retaining ring, using
Snap Ring Pliers J-6083. Mark the location of the
clutch coil terminals.
Fig. 11 Removing Rotor & Bearing Asm. Retainer Ring
If only the Clutch Rotor and/or Rotor Bearing
are to be replaced, bend the lockwashers away
from the pulley rim mounting screws, andremove
the six mounting screws and special lock washers
before proceeding with Step 3. Discard the lock
washers.
3. Install Rotor and Bearing Puller
5-25031 down
into the rotor until the Puller arms engage the
recessed edge of the rotor hub. Hold the Puller
and arms in place and tighten the Puller screw
against the Puller Guide to remove the Clutch

1 D1-6 R-4 AIR CONDITIONING COMPRESSOR OVERHAUL
I-J 25031
ROTOR AND
BEARING
PULLER
GUIDE
2-PULLEY ARM
3-PULLEY RIM SCREW AND
LOCKWASHER
(6) LOCATIONS
Fig.
12 Installing Rotor & Bearing Puller Guide
Rotor and Bearing assembly, being careful not to
drop the Puller Guide.
1 -J-2503 1 ROTOR
AND BEARING
PULLER
2-J-25031 GUIDE
Fig.
13 Removing Clutch Rotor Asm.
4. If
the pulley rim mounting screws and washers
were removed in Step 2, only the Clutch Rotor
and Bearing assembly will be removed for
replacement. The Clutch Coil and Housing
assembly is pressed onto the Front Head of the
compressor and will not be removed unless the
pulley rim mounting screws are left securely in
place and the pulley rim pulls the Coil and
Housing assembly off with the total Clutch Rotor
and Pulley Rim Assembly.
5. Place the Rotor and Bearing assembly on blocks.
Drive the bearing out of the rotor hub with Rotor
Bearing Remover
J-9398-A.
It is not necessary to remove the staking at the
rear of the rotor hub to remove the bearing. However,
it will be necessary to file away the old stake metal for
proper clearance for the new bearing to be installed
into the rotor bore, or the bearing may be damaged.
1 -J-29886
2-J-9398-8
REMOVER
Fig.
14 Clutch Rotor Bearing Removal
Fig.
15 Rotor & Bearing Asm.
Install or Connect
1. Place the Rotor and Hub assembly face down on
a clean, flat and firm surface.
2. Align
the new bearing squarely with the hub bore
and using Pulley and Bearing Installer
5-9481-A
with Universal Handle 5-29886, drive the bearing
fully into the hub. The Installer will apply force
to the outer race of the bearing if used as shown.
3. Using
a center punch with
a 45" angle point, stake
1.1
- 1.4mm (.045"-.055" deep) the bearing in
three places 120" apart, but do not stake too
deeply to avoid distorting the outer race of the
bearing.
4. Replace
rotor and bearing assembly.
On Car
A. Position the Rotor and Bearing assembly on
the front head.
B. With Rotor
& Bearing Installer J-26271-A
(without driver handle) in position and
Rotor and Bearing assembly aligned with
the Front Head, drive the assembly part
way onto the head.
C. Plug clutch coil connector onto Clutch Coil.
D. Position the Clutch Coil so the three
locating tabs will
align with the holes in the
head and continue to drive the Rotor and
Bearing assembly onto the front head.

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