Chevrolet 1980 Light Duty Truck Operating instructions

CHEVROLET
ST 333-80

1980
UNIT REPAIR (OVERHAUL)
MANUAL
covering
IMPALA, CAPRICE, MALIBU,
MONTE CARLO,
CAMARO
and
LIGHT DUTY TRUCKS
(SERIES 10- 0)
FOREWORD
This manual includes procedures involved in disassembly and assembly
of major components of 1980 Impala, Caprice, Malibu, Monte Carlo, Camaro
and Light Duty Trucks. Information on diagnosis, maintenance and adjust
ments, minor service operations, and removal and installation for these
components is contained in either the 1980 Passenger Car or the Light Duty
Truck Service Manuals.
The Section Index on the contents page enables the user to quickly locate
any desired section. At the beginning of each section containing more than
one major subject is a Table of Contents, which gives the page number on
which each major subject begins. An index is placed at the beginning of
each major subject within the section.
Summaries of Special Tools, when required, are found at the end of major
sections.
When reference is made in this manual to a brand name, number, or
specific tool, an equivalent product may be used in place of the recom
mended item.
The manual should be kept in a handy place for ready reference. If pro
perly used, it will enable the technician to better serve the owners of Chev
rolet built vehicles.
All information, illustrations and specifications contained in this literature
are based on the latest product information available at the time of publica
tion approval. The right is reserved to make changes at any time without
notice.
CHEVROLET MOTOR DIVISION
General Motors Corporation
DETROIT, MICHIGAN

IMPORTANT SAFETY NOTICE
Proper service and repair is im portant to the safe, reliable operation o f all
m otor vehicles. The service procedures recom m ended and described in this
service m anual are effective m ethods for perform ing service operations.
Som e o f these service operations require the use o f tools specially designed
for the purpose. The special tools should be used when and as recom m ended.
It is im portant to n ote that this m anual contains various autions and
N otices w hich should be carefully read in order to m inim ize the risk o f
personal injury to service personnel or the possibility that im proper service
m ethods w ill be follow ed which m ay damage the vehicle or render it unsafe.
It also is im portant to understand that these autions and N otices are not
exhaustive. The m anufacturer could not possibly know , evaluate and advise
the service trade o f all conceivable ways in which service m ight be done
or o f the possible hazardous consequences o f each way. onsequently,
the m anufacturer has not undertaken any such broad evaluation. A ccord 
ingly, anyone who uses a service procedure or tool w hich is not recom m end
ed m ust first satisfy him self thoroughly that neither his safety nor vehicle
safety will be jeopardized by the service m ethod he selects.

1980
UNIT REPAIR (OVERHAUL)
MANUAL
CAUTION
This vehicle contains some parts dimensioned in the metric system
as well as in the customary system. Some fasteners are metric and
are very dose in dimension to familiar customary fasteners in the
inch system. It is important to note that, during any vehicle mainte
nance procedures, replacement fasteners must have the same
measurements and strength as those removed, whether metric or
customary. (Num ers on the heads of metric olts and on surfaces
of metric nuts indicate their strength. Customary olts use radial
lines for this purpose, while most customary nuts do not have
strength markings.) Mismatched or incorrect fasteners can result in
vehicle damage or malfunction, or possi ly personal injury. There
fore, fasteners removed from the vehicle should e saved for re-use
in the same locations whenever possi le. Where the fasteners are
not satisfactory for re-use, care should e taken to select a re
placement that matches the original. For information and assis
tance, see your Authorized dealer.
General
SECTION INDEX
SECTION NAME
1D AIR CONDITIONING
COMPRESSOR
B STEERING
4B REAR AXLE
4C FRONT WHEEL DRIVE
5BRAKES
7A AUTOMATIC TRANSMISSION
7B MANUAL TRANSMISSION
7C CLUTCH |
7E TRANSFER CASE
10 METRIC AND
FASTENER INFORMATION
Motors Corporation Printed In U.S.A.

AIR CONDITIONING COMPRESSOR OVERHAUL 1D-1
SECTION 1D
AIR CONDITIONING COMPRESSOR
OVERHAUL
For ompressor REMOVAL AND INSTALLATION, see Air
onditioning Section. For DIS HARGING, A D D IN G OIL,
EVA UATING A ND HARGING PRO EDURES FOR . .O.T.
A / SYSTEMS, see Air onditioning Section.
CONTENTS OF THIS SECTION
Minor Repair Procedures for the A-6
ompressor......................................................................... ID-2
A-6 ompressor lutch Plate and
Hub Assembly ............................................................. 1D-2
A-6 ompressor Pulley and Bearing
Assembly......................................................................... ID-5
A-6 ompressor Pulley Bearing ................................ ID-7
A-6 ompressor lutch oil and
Housing Assembly ...................................................... ID-7
Major A-6 ompressor Repair
Procedures.......................................................................... 1D-8
A-6 ompressor Shaft Seal.......................................... ID-9
Seal Leak Detection ......... . ........................................ ID-9
A-6 ompressor Pressure Relief
Valve or Pressure Switch ...................................... .. ID-11
A-6 ompressor ylinder and Shaft
Assem bly......................................................................... ID-11
Rem oval.......................................................................... ID-12
Disassem bly................................................................... 1D-14
Gaging Operation........................................................ ID-15
A-6 Teflon Piston Ring
Replacement.............................................................. ID-19
Assembly......................................................................... ID-19
Re-Install......................................................................... 1D21
Minor Repair Procedures for the R-4
ompressor......................................................................... ID-26
R-4 ompressor lutch Plate and
Hub Assembly.................................... . ........................ ID-26
R-4 ompressor lutch Rotor
and/or Bearing ............................................................ 1D-26
Replace Rotor and Bearing
Assembly (On ar)................................................ .. ID-30
Replace Rotor and Bearing
Assembly (On Bench).......................................... .. ID-31
R-4 ompressor lutch oil
and/or Pulley R im ..................................................... .. ID-32
R-4 ompressor Inertia Ring
Installation..................................................................... .. ID-32
Major R-4 ompressor Repair
Procedures.......................................................................... .. ID-34
R-4 ompressor Shaft Seal.......................................... .. ID-35
Seal Leak Detection................................................... .. ID-35
R-4 ompressor Shaft Seal
Replacement (On ar)......................................... .. ID-35
R-4 ompressor Shaft Seal
Replacement (Off ar)......................................... .. ID-37
R-4 ompressor Pressure Relief
Valve or Pressure Switch......................................... .. ID-37
R-4 ompressor Front Head
and/or O-Ring ...................4......................................... .. ID-37
R-4 ompressor Thrust and
Belleville Washers .......... ,....................................... . ...... ID-39
R-4 ompressor Main Bearing .................................. .. ID-39
R-4 ompressor Shell and/or
O-Rings ........................................................................... .. ID-39
R-4 ompressor Discharge Valve
Plate and/or Retainer............................................... ... ID-41
R-4 ompressor ylinder and
Shaft Assem bly............................................................. ... ID-42
A-6 and R-4 omp. Leak Testing
(External and Internal) ............................................ ... 1D-42
For all practical purposes, all vehicles make use of the
same air conditioning 4 and 6-cylinder compressors. Actual
differences between compressors are found in their
mounting brackets, pulleys, connector assemblies and
compressor capacitires, none of which will affect the
following Overhaul Procedures.
When servicing the compressor, it is essential that steps
be taken to prevent dirt or foreign material from getting on
or into the compressor parts and system during disassembly
or reassembly of the compressor. LEAN TOOLS AN D
LEAN WORK AREA ARE VERY IM PORTANT FOR
PROPER SERVI E. The compressor connection areas and
exterior of the compressor should be cleaned off as much
as possible prior to any "on car" repairs or removal of the
compressor for workbench service. The parts must be kept
clean at all times and any parts to be reassembled should
be cleaned with naphtha, Stoddard solvent,
kerosene or equivlent solvent and dried off with dry air.
When necessary to use a cloth on any part, it should be of
a non-lint producing type.
Although certain service operations can be performed
without completely removing the compressor from the
vehicle, the operations described herein are based on bench
over-haul with the compressor removed from the vehicle.

1D-2 AIR CONDITIONING COMPRESSOR OVERHAUL
They have been prepared in sequence in order of
accessibility of the components. Pad fender/skirt and secure
compressor near top of fender skirt with wire, rope, etc.
when performing on-car service.
When an A-6 or R-4 compressor is removed from the
vehicle for servicing, the amount of oil remaining in the
compressor should be drained and measured. This oil should
then be discarded and new 525 viscosity refrigerant oil
added to the compressor (See Figure ID-1, and " . .O.T.
Refrigerant Oil Distribution" in the Air onditioning
section).
Should an A-6 compressor, its compressor shaft seal or
any other component ever be removed for servicing because
it was determined to be the cause of excessive signs of oil
leakage in the A / system, then the oil in the A-6
compressor must be drained, measured and replaced
according to " . .O.T. Refrigerant Oil Distribution" in the
Air onditioning section to determine oil loss. The
accumulator in this A-6 system then must also be removed
- oil drained - measured, etc. according to same section.
NOTICE: Do not kink or place excessive tension on
refrigerant lines or hoses.
MINOR REPAIR PROCEDURES FOR
THE A-6 COMPRESSOR
THE FOLLOWING OPERATIONS TO THE A-6
COMPRESSOR CLUTCH PLATE AND HUB, PULLEY
AND BEARING, AND COIL AND HOUSING ARE
COVERED AS "MINOR" BECAUSE THEY MAY BE
PERFORMED WITHOUT FIRST PURGING THE
SYSTEM OR REMOVING THE COMPRESSOR FROM
THE VEHICLE.
The ompressor Shaft Seal assembly, Pressure Relief
Valve and Pressure Switch may also be serviced WITHOUT
REMOVING THE OMPRESSOR from the vehicle but
these operations are covered later in this section as "Major
Repair Procedures" because the system MUST FIRST BE
PURGED of Refrigerant-12.
Illustrations used in describing these operations show
the compressor removed from the vehicle only to more
clearly illustrate the various operations.
When servicing the compressor, remove only the
necessary components that preliminary diagnosis indicates
are in need of service. Refer to the AIR ONDITIONING
section and Figure ID-2 and Figure ID-3 for information
relative to parts nomenclature and location.
Removal and illustration 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. Parts Tray J-9402 (Figure ID-38) should be used for
all A-6 internal compressor parts being removed, as well as
for replacement parts.
A-6 COMPRESSOR CLUTCH PLATE
AND HUB ASSEMBLY
Remove
1. Place Holding Fixture J-9396 in a vise and clamp the
compressor in the Holding Fixture.
Figure 1D-1 A-6 Compressor
2. Keep clutch hub from turning with lutch Hub
Holder J-25030 or J-9403, and remove locknut from end of
shaft using Thin Wall Socket J-9399 (Figure ID-4).
NOTICE: To avoid internal damage to the compressor,
DO NOT DRIVE OR POUND on the lutch Plate
and Hub assembly OR on the end of the shaft. If proper
tools to remove and replace clutch parts are not used,
it is possible to disturb the position of the axial plate
(keyed to the main shaft), resulting in compressor
damage and seal leakage due to shifting of the
crankshaft.
3. Thread lutch Plate and Hub assembly Remover
J-9401 into hub. Hold body of Remover with a wrench and
tighten center screw to remove lutch Plate and Hub
assembly (Figure ID-5).
4. Remove square drive key from shaft or drive plate
hub.
5. Remove hub spacer retainer ring using Snap-Ring
Pliers J-5403 (# 2 1 ), and then remove hub spacer (Figure
ID-6).
6. Inspect driven plate for cracks or stresses in the drive
surface. Do not replace driven plate for a scoring condition
(Figure ID-7).
If the frictional surface shows signs of damage due
to excessive heat, the lutch Plate, Hub, Pulley and
Bearing should be replaced. heck further for the
underlying cause of the damage (i.e. low coil-voltage - coil
should draw 3.2 amps at 12 volts - or binding of the
compressor internal mechanism (cylinder and shaft
assembly), clutch air gap too wide (see Figure ID -11),
broken drive plate to hub assembly sprints, etc.
Replace
1. Insert the square drive key into the hub of driven
plate; allow it to project approximately 3/16" out of the
keyway. _
2. Line up the key in the hub with key way in the shaft
(Figure ID-8).

Figure 1D-2 Exploded View of A-6 Compressor
is.
I '■
O-RINGS
o
I PRESSURE RELIEF
V VALVE
6 J ^0-ringO-RING
O-RING
\ FRONT HEAD
\ SHAFT SEAL ASSEMBLY
/ A \ I SEAL SEAT
I SEAL SEAT RETAINER RING
j / ABSORBENT SLEEVE
' SLEEVE RETAINER
CLUTCH COIL RETAINER RING
COMPRESSOR SHELL
, - ^ / v 1 CLUTCH COIL AND HOUSING ASSEMBLY
\ SUCTION SCREEN OIL U I I PULLEY
■\ INNER OIL PUMP GEAR DRAIN PLUG
/
! J OILPICK-U
^ \ O-RING. 1
LOCKNUT I / ( , y
REAR HEAD / • ' j W j J \ 1 / <( > y ’
OUTER OIL PUMP COVER / , * * f O
REAR DISCHARGE VALVE PLATE ASSEMBLY ®
REAR SUCTION REED / / f AXIAL PLATE
BUSHING* / I 0 / )
V J \
G* /
NEEDLE BEARING / 4
O-RING j
REAR CYLINDER HALF
BEARING
BEARING RETAINER
\ PULLEY RETAINER RING
CLUTCH PLATE AND
HUB ASSEMBLY
SHAFT
LOCK NUT
SUCTION
CROSSOVER COVER ^
x
TEFLON PISTON RING --------.TH RU ST BEARING
y W K i * 7 w
/ T V A , / ~ FRONT CYLINDER HALF
TEFLON RING TYPE PISTON f
TEFLON PISTON RING _ _ 9 j
NEEDLE BEARING
SHAFT
DISCHARGE CROSSOVER TUBE ^ DOWEL PINS
THRUST RACES O-RING*
BUSHING*
FRONT
SUCTION REED
♦DISCHARGE CROSSOVER TUBE O-RING OR BUSHING FRONT DISCHARGE
VALVE PLATE ASSEMBLY
4978
AIR CONDITIONING COMPRESSOR OVERHAUL 1D-

1D-4 AIR CONDITIONING COMPRESSOR OVERHAUL
FRONT
SUCTION REED DISCHARGE VALVE PLATE
SHAFT SEAL ASM.
TEFLON PISTON RING SHELL PULLEY
PULLEY BEARING
REAR HEAD-
O IL PUMP
GEARS
PRESSURE RELIEFt
VALVE
OIL PICK-UP TUBE
O IL SUMP
REAR CYLINDER
HALF THRUST BEARING CLUTCH COIL
AND HOUSING
CLUTCH PLATE
AND
HUB ASSEMBLY
^S E A L SEAT
RETAINER RING
SEAL SLEEVE
Figure 1D- A-6 Compressor Cross Section
4987
■ !
A CLUTCH PLATE
0 & HUB
CLUTCH PLATE
& HUB ASM
REMOVER
J-9401
Fi&ure 1D-4 Removing A-6 Shaft Lock Nut Figure 1D-5 Removing A-6 Clutch Plate and Hub Assembly

AIR CONDITIONING COMPRESSOR OVERHAUL ID-5
SNAP-RING
PLIERS (#21)
J-540
RETAINER
NG
4968
Figure 1D-6 Removing or Installing Retainer Ring in A-6 Clutch
Drive Plate
Figure 1D-7 A-6 Clutch Driven Plate and Drive Plate
Figure 1D-8 Aligning A-6 Drive Plate Key
3. Install the Drive Plate Installer J-9480-1 as
illustrated. This Installer has a left hand thread on the body
(Figure ID-9).
4. Press the driven plate onto the shaft until there is
approximately 3/32" space between the frictional faces of
the lutch Drive Plate and Pulley.
Figure 1D-9 Installing A-6 Drive Plate
NOTICE: Make certain key remains in place when
pressing hub on shaft.
A ZERO thrust race is approximately 3/32" thick and
may be used to roughly gage this operation. Use lutch Hub
Holder J-25030 or J-9403 tp hold lutch Plate and Hub if
necessary.
5. Install the hub spacer and, using Snap-Ring Pliers
J-5403 (#2 1), install the retainer ring (see installed Retainer
Ring in Figure ID -10), with convex side of ring facing
spacer.
6. Using Thin-Wall Socket J-9399 and lutch Hub
Holder J-25030 or J-9403 to install a new shaft locknut with
shoulder or circular projection on the locknut facing
towards retainer ring. Tighten the nut to 14-26 lb.ft.
torque. Air gap between the frictional faces should now be
.022" to .057" (Figure ID-11). If not, check for
mispositioned key or shaft.
7. The pulley should now rotate freely.
8. Operate the refrigeration system in the MAX A /
control selector (mode) lever position and warm engine (off
fast idle) speed at 2000 PRM. Rapidly cycle the compressor
clutch by turning the A / control selector (mode) lever
from OFF-to-MAX at least 15 times at approximately one
second intervals to burnish the mating parts of the clutch.
A-6 COMPRESSOR PULLEY AND
BEARING ASSEMBLY
Remove
1. Remove lutch Plate and Hub assembly as described
in "A-6 ompressor lutch Plate and Hub Assembly"
Removal procedure.
2. Remove pulley retainer ring, using Snap-Ring Pliers
J-6435 (# 26 ), Figure ID-12.
3. Pry out absorbent sleeve retainer, and remove
absorbent sleeve from compressor neck.
4. Place Puller Pilot J-9395 over end of compressor
shaft.
HOLDING FIXTURE
J-9 96
KEYWAY
IN SHAFT
5073

1D-6 AIR CONDITIONING COMPRESSOR OVERHAUL
Figure 1D-10 Installing Hub Retainer Ring On A-6 Compressor
Figure 1D-11 Checking A-6 Air Gap
NOTICE: It is important that Puller Pilot J-9395 be
used to prevent internal damage to compressor when
removing pulley. Under no circumstances should
Puller be used DIRE TLY against drilled end of shaft.
5. Remove Pulley and Bearing Assembly, using Pulley
Puller J-8433 (Figure ID -13).
Inspection
heck the appearance of the Pulley and Bearing
assembly (see Figure ID-7). The frictional surfaces of the
Figure 1D-12 Removing A-6 Pulley Retainer Ring
Pulley and Bearing asssembly should be cleaned with
naphtha, Stoddard solvent, kerosene or
equivalent solvent before reinstallation.
Replace
1. If original Pulley and Bearing assembly is to be
reinstalled, wipe frictional surface of pulley clean. If
frictional surface of pulley shows any indication of damage
due to overheating, the Pulley and Bearing assembly should
be replaced.
2. heck bearing for brineling, excessive looseness,
noise, and lubricant leakage. If any of these conditions exist,
bearing should be replaced. See "A-6 ompressor Pulley
Bearing" Replacement procedure.
3. Press or tap Pulley and Bearing assembly on neck
of compressor until it seats, using Pulley and Bearing
Installer J-9481 with Universal Handle J-8092 (Figure 1D-
14). The Installer will apply force to inner race of bearing
and prevent damage to bearing.
SNAP RING
PLIERS J-64 5
(#26)
RETAINER
RING
PULLEY
ASSEMBLY
Figure 1D-1 Removing A-6 Pulley and Bearing Assembly
PULLEY AND
BEARING
ASSEMBLY
PULLER PILOT
J-9 95
5066
PULLER

AIR CONDITIONING COMPRESSOR OVERHAUL 1D-7
PULLEY AND
BEARING
INSTALLER
J-9481
UNIVERSAL
HANDLE
J-8092
J-9398 with Universal Handle J-8092, drive Bearing
assembly out of pulley (Figure ID -16).
Figure 1D-14 Installing A-6 Pulley and Bearing Assembly
4. heck pulley for binding or roughness. Pulley should
rotate freely.
5. Install retainer ring, using Snap Ring Pliers J-6435
(# 2 6).
6. Install absorbent sleeve retainer in neck of
compressor. Using sleeve from Seal Seat Remover-Installer
J-23128, install retainer so that outer edge is recessed 1/32"
from compressor neck face.
7. Install lutch Plate and Hub assembly as described
in "A-6 ompressor lutch Plate and Hub Assembly"
Replacement procedure.
A-6 COMPRESSOR PULLEY BEARING
Remove
1. Remove lutch Plate and Hub assembly as described
in "A-6 ompressor lutch Plate and Hub Assembly"
Removal procedure.
2. Remove Pulley and Bearing assembly as described
in "A-6 ompressor Pulley and Bearing Assembly"
Removal procedure.
3. Remove pulley bearing retainer ring with a small
screwdriver or pointed tool (Figure ID -15).
Replace
1. Install new bearing in pulley using Pulley and
Bearing Installer J-9481 with Universal Handle J-8092
(Figure ID -17). The Installer will apply the force to the
outer race of the bearing.
NOTICE: DO NOT LEAN NEW BEARING
ASSEMBLY WITH AN Y TYPE OF SOLVENT.
Bearing is supplied with correct lubricant when
assembled and requires no other lubricant at any time.
2. Install bearing retainer ring, making certain that it
is properly seated in ring groove.
3. Install Pulley and Bearing assembly as described in
"A-6 ompressor Pulley and Bearing Assembly"
Replacement procedure.
4. Install lutch Plate and Hub assembly as described
in "A-6 ompressor lutch Plate and Hub Assembly"
Replacement procedure.
A-6 COMPRESSOR CLUTCH COIL AND
HOUSING ASSEMBLY
Remove
1. Remove lutch Plate and Hub assembly as described
in " ompressor lutch Plate and Hub Assembly" Removal
procedure.
2. Remove Pulley and Bearing assembly as described
in "A-6 ompressor Pulley and Bearing Assembly"
Removal procedure.
NOTICE: Position of terminals on coil housing and
scribe location on compressor front head casting.
Figure 1D-16 Removing Bearing From A-6 Pulley Assembly
U N IV E R S A L H A N D LE
J-8092
PULL Y &
IN S T A LL E R
P U L LE Y
A S S E M B L
BEARING
RETAINER
RING
Figure 1D-15 Removing A-6 Pulley and Bearing Retainer Ring
4. Place Pulley and Bearing assembly on inverted
Support Block J-21352 and, using Pulley Bearing Remover 3. Remove coil housing retaining ring, using Snap-Ring
Pliers J-6435 (# 26 ) (Figure ID -18).

1D-8 AIR CONDITIONING COMPRESSOR OVERHAUL
UNIVERSAL
HANDLE
J-8092
W i
PULLEY AND
BEARING
INSTALLER
J-9481 4952
THIS RIDGE
OF TOOL
MUST BE
UP WHEN
INSTALLING
BEARING
SUPPORT
BLOCK
J-21 52
Figure 1D-17 Installing Bearing on A-6 Pulley
4. Lift oil and Housing assembly off compressor.
Replace
1. Position coil and housing assembly on compressor
front head casting so that electrical terminals line up with
marks previously scribed on compressor (Figure ID -19).
2. Align locating extrusions on coil housing with holes
in front head casting.
3. Install coil housing retainer ring with flat side of
ring facing coil, using Snap-Ring Pliers J-6435 (# 26 ).
4. Install Pulley and Bearing assembly as described in
"A-6 ompressor Pulley and Bearing Assembly"
Replacement procedure.
Figure 1D-19 Installing A-6 Coil Housing
5. Install lutch Plate and Hub assembly as described
in "A-6 ompressor lutch Plate and Hub Assembly"
Replacement procedure.
MAJOR A-6 COMPRESSOR REPAIR PROCEDURES
Service repair procedures to the ompressor Shaft Seal,
Pressure Relief Valve, Pressure Switch or disassembly of the
Internal ompressor ylinder and Shaft Assembly are
considered "Major" since the refrigeration system must be
completely purged of refrigerant before proceeding and/or
because major internal operating and sealing components of
the compressor are being disassembled and serviced. Should
an A-6 compressor, it’s compressor shaft seal, or any other
component ever be removed for servicing because it was
determined to be the cause of excessive signs of oil leakage
in the A-6 A / system, then the oil in the compressor must
be drained, measured and replaced according to " . .O.T.
Refrigerant Oil Distribution" in the Air onditioning
section to determine oil loss. The accumulator in this A-6
system must then also be removed - oil drained - measured,
etc. according to same section.
When replacing the shaft seal assembly (see Figure 1D-
20), pressure relief valve (see Figure ID-26) or pressure
switch (see Figures ID-27 and 28), even if the compressor
remains on the vehicle during the operation, it will be
necessary to purge the system of refrigerant as outlined in
the Air conditioning section (see "Discharging, Adding Oil,
Evacuating and harging Procedures for . .O.T. A /
Figure 1D-18 Removing A-6 Coil Housing Retainer Ring
ELECTRICAL
TERMIN
4959

AIR CONDITIONING COMPRESSOR OVERHAUL 1.D-9
Systems"). The same holds ture for any disassembly of the
internal A-6 compressor cylinder and shaft assembly.
If the A-6 ompressor Internal ylinder and Shaft
Assembly is to be serviced or replaced, then the oil in the
compressor must be drained, measured and replaced
according to " . .O.T. Refrigerant Oil Distribution" in the
Air onditioning section 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. Any attempt to
use make-shift or inadequate equipment may result in
damage and/or improper compressor operation.
These procedures are based on the use of the proper
service tools and the condition that an adequate stock of
service parts is available. 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.
Piston shoe discs and shaft thrust races will be
identified by "number" on the parts themselves for reference
to determine their size and dimension (see Figure ID-38).
A-6 COMPRESSOR SHAFT SEAL
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 determined
by test.
Should an A-6 compressor shaft seal ever have to be
replaced because it was determined to be the cause of
excessive signs of oil leakage in the A / system, then the
oil in the A-6 compressor must be drained, measured and
replaced according to " . .O.T. Refrigerant Oil
Distribution" in the Air onditioning section to determine
oil loss. The accumulator in this A-6 system must then also
be removed - oil drained - measured, etc. according to same
section.
S P E C IF IC A T IO N P A R T S
S E A L I C A R S O N M A T E R IA L .
L A R G E C H A M F E R O N
IN S ID E D 1 A M T E R .
S E A T ! C E R A M IC M A T E R IA L
W IT H P O L IS H E D
F A C E .
O R IN G S I N E O P R E N E , T H U S
I C A P A B L E O F
: G IV IN G H E A T
R E S IS T A N C E A N D
___________ | L IF E E P E C T A N C Y .
0858
Figure 1D-20 Specification A-6 and R-4 Compressor Shaft Seal
Kit
Remove
1. "Discharge the Refrigerant System" according to the
DIS HARGING, A D D IN G OIL, EVA UATING A ND
HARGING PRO EDURES FOR . .O.T. A /
SYSTEMS in the AIR ONDITIONING section.
2. Remove the lutch Plate and Hub assembly and
shaft key as described in "A-6 ompressor lutch Plate and
Hub Assembly" Removal procedure.
3. Pry out the sleeve retainer and remove the absorbent
sleeve. Remove the shaft seal seat retaining ring, using Snap-
Ring Pliers J-5403 (#2 1). See Figure ID-21.
4. Thoroughly clean inside of compressor neck area
surrounding the shaft, the exposed portion of the seal seat
and the shaft itself. This is absolutely necessary to
prevent any dirt or foreign material from getting into
compressor.
5. Place Seal Protector J-22974 over the end of the shaft
to prevent chipping the ceramic seat. Fully engage the
knurled tangs of Seal Seat Remover-Installer J-23128 into
the recessed portion of the seal seat by turning the handle
clockwise. Remove the Seal Seat from the compressor with
a rotary-pulling motion (Figure ID-22). Discard the Seat.
Figure 1D-21 Removing or Installing A-6 Shaft Seal Seat
Retaining Ring
NOTICE: DO NOT tighten the handle with a wrench
or pliers; however, the handle must be hand-tightened
securely to remove the seat.
6. With Seal Protector J-22974 still over the end of the
shaft, seat Seal Remover-Installer J-9392 down over shaft
end, turning clockwise, while pressing down, to engage
remover tangs with the tabs on the Seal assembly. Then lift
the Shaft Seal assembly out (see Figure ID-23). Discard the
Seal.
7. Remove and discard the seal seat O-Ring from the
compressor neck, using O-Ring Remover J-9533 (see Figure
ID-22).
8. Recheck the shaft and inside of the compressor neck
for dirt or foreign material and be sure these areas are
perfectly clean before installing new parts.

1D-10 AIR CONDITIONING COMPRESSOR OVERHAUL
Figure 1D-22 Removing A-6 Shaft Seal Seat and O-Ring
Figure 1D-2 Replacing A-6 Seal and O-Ring
Inspection
Seals should not be reused. Always use a new seal kit
on rebuild (see Figure ID-20). Be extremely careful that the
face of the Seal to be installed is not scratched or damaged
in any way. Make sure that the Seal Seat and Seal are free
of lint and dirt that could damage the seal surface or prevent
sealing.
Replace
1. oat the new seal seat O-ring in clean 525 viscosity
referigerant oil and assemble onto O-Ring Installer J-21508
(see Figure ID-23).
2. Insert the O-Ring Installer J-21508 completely
down into the compressor neck until the installer
"bottoms". Lower the movable slide of the O-Ring Installer
to release the O-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 Installer (See Figure ID-24).
3. oat the O-ring and seal face of the new Seal
assembly with clean 525 viscosity refrigerant oil. arefully
mount the Seal assembly to Seal Installer J-9392 by engaging
the tabs of the Seal with the tangs of the Installer (Figure
ID-23).
4. Place Seal Protector J-22974 (Figure ID-23) over
end of compressor shaft and carefully slide the new Seal
assembly down onto the shaft. Gently twist the Installer
J-9392 LO K-WISE, while pushing the seal assembly
down the shaft until the Seal assembly engages the flats on
the shaft and is seated in place. Disengage the Installer by
pressing downward and twisting counter-clockwise.
5. Attach the ceramic Seal Seat to the Seal Seat
Remover and Installer J-23128 and dip the ceramic Seat in
clean 525 viscosity refrigerant oil to coat the seal face and
outer surface. arefully install the Seat over the compressor
shaft end and Seal Protector J-22974 and push the Seat into
place with a rotary motion. Take care not to dislodge the
seat O-ring. However, be sure Seal Seat makes a good seal
with O-ring. Remove Installer J-23128 and Seal Protector
J-22974 (Figure ID-22).
6. Install the new seal seat retainer ring with its flat
side against the Seal Seat, using Snap-Ring Pliers J-5403
(# 21 ). See Figure ID-21. Use the sleeve from Seal Seat
Remover-Installer J-23128 (Figure ID-22) to press in on the
seal seat retainer ring so that it snaps into its groove.
7. Install ompressor Leak Test Fixture J-9625 (Figure
ID-25) on rear head of compressor and connect gage
charging lines or pressurize SU TION 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
and oil sump down, rotate the compressor shaft in normal
direction of rotation several times by hand. Leak test the
Seal with Electronic Leak Detector J-23400. orrect any
leak found. Remove, discard and later replace the shaft nut.
8. Remove any excess oil, resulting from installing the
new seal parts, from the shaft and inside the compressor
neck.
9. Install the new absorbent sleeve by rolling the
material into a cylinder, overlapping the ends, and then
slipping the sleeve into the compressor neck with the overlap
towards the top of the compressor. With a small screwdriver

AIR CONDITIONING COMPRESSOR OVERHAUL ID-11
Figure 1D-25 Leak Testing A-6 Compressor
or similar instrument, carefully spread the sleeve until the
ends of the sleeve butt at the top vertical centerline.
10. Position the new metal sleeve retainer so that its
flange face will be against the front end of the sleeve. Pulley
Puller Pilot J-9395 (see Figure ID-13) may be used to install
the retainer. Press and tap with a mallet, setting the retainer
and sleeve into place (retainer should be recessed
approximately 1/32" from the face of the compressor neck).
(See Figure ID-24).
11. Reinstall the lutch Plate and Hub assembly as
described in "A-6 ompressor lutch Plate and Hub
Assembly" Replacement procedure. Some compressor
shaft seal leaks may be the result of mispositioning of
the axial plate on the compressor shaft. The
mispositioning of the axial plate may be caused by improper
procedures used during pulley and driven plate removal,
pounding, collisions or dropping the compressor. If the axial
plate is mispositioned, the carbon face of the shaft seal
assembly may not contact the seal seat and the rear thrust
races and bearing may be damaged.
To check for proper positioning of the axial plate on
the shaft, remove the clutch driven plate and measure the
distance between the front head extension and the flat
shoulder on the shaft as shown in Figure ID-24. To measure
this distance, use a wire gage (the clearance should be
between .026" and .075"). If the shaft has been pushed
back in the axial plate (measurement greater than .075"),
disassemble the compressor and replace the shaft and axial
plate assembly rear thrust races and thrust bearing.
If there also appears to be too much or insufficient air
gap between the drive and driven plates, dislocation of the
shaft should be suspected. If the carbon seal is not seating
against the seal seat, it will not be possible to completely
"Evacuate the System" as outlined under
DIS HARGING, A D D IN G OIL, EVA UATING AN D
HARGING PRO EDURES FOR . .O.T. A /
SYSTEMS in the AIR ONDITIONING section.
12. "Add Oil, Evacuate and harge System" (see
DIS HARGING, A D D IN G OIL, EVA UATING A ND
HARGING PRO EDURES FOR . .O.T. A /
SYSTEMS in the AIR ONDITIONING section).
A-6 COMPRESSOR PRESSURE RELIEF
VALVE OR PRESSURE SWITCH
When necessary to replace the Pressure Relief Valve (or
Pressure Switch if so located), located in the compressor
rear head casting (Figure ID-26 and Figures ID-27 and 28),
the valve/switch assembly should be removed after
PURGING THE SYSTEM OF REFRIGERANT. A new
valve/switch and O-ring coated with 525 viscosity
refrigerant oil should be installed (see DIS HARGING,
ADD IN G OIL, EVA UATING AND HARGING
PRO EDURES FOR . .O.T. A / SYSTEMS in the
AIR ONDITIONING section).
A-6 COMPRESSOR INTERNAL
MECHANISM (CYLINDER AND SHAFT
ASSEMBLY)
Service operations to the A-6 compressor Rear Head
or Internal Mechanism ylinder and Shaft) of the
compressor should be performed with the system PURGED
OF REFERIGERANT according to the DIS HARGING,
AD DIN G OIL, EVA UATING A ND HARGING
PRO EDURES FOR . .O.T. A / SYSTEMS in the
AIR ONDITIONING section. The compressor must also
be removed from the vehicle to insure that the necessary
degree of cleanliness may be maintained. Additionally,
" ompressor lutch Plate and Hub, Pulley and Bearing,
lutch oil and Housing and Shaft Seal" Removal
procedures, as described earlier in the OVERHAUL
section, all are to have been followed. lean hands, clean
tools and a clean bench, preferably covered with clean
paper, are of extreme importance.
OIL DRAIN FITTING
LEAK TEST
ADAPTER
J-9625

1D-12 AIR CONDITIONING COMPRESSOR OVERHAUL
DISCHARGE SYSTEM BEFORE
REMOVING HIGH PRESSURE
RELIEF VALVE
5040
HI PR
RELIEF
VALVE REAR HEAD
Figure 1D-26 A-6 High Pressure Relief Valve
O r in g COMPRESSOR
PRESSURE SWITCH SNAP RING
6363
Figure 1D-27 Compressor Pressure Switch
An inspection should be made of the Internal
Mechanism ( ylinder and Shaft) assembly to determine if
any service operations should be performed. A detailed
inspection of parts should be made to determine if it is
feasible to replace them.
Removal
1. Before proceeding with disassembly, wipe exterior
surface of compressor clean.
2. All oil in compressor should be drained and
measured. Assist draining by positioning compressor with
oil drain plug down. Record the amount of oil drained
from the compressor (See "C.C.O.T. Refrigerant Oil
Distribution" in the AIR CONDITIONING section).
3. Invert compressor and Holding Fixture J-9396, with
front end of compressor shaft now facing downward (Figure
1-29).
Figure 1D-29 A-6 Compressor Installed in Holding Fixture
Additional oil may leak from the compressor at this
time. All oil must be drained into a container so that
TOTAL amount can be measured. (SEE STEP 2 ABOVE).
A liquid measuring cup may be used for this purpose.
Drained oil should then be discarded.
4. Remove four locknuts from threaded studs on
compressor shell and remove rear head. Tap uniformly
around rear head if head is binding (Figure ID-29).
5. Wipe excess oil from all sealing surfaces on rear head
casting webs, and examine sealing surfaces (Figure ID-30)
If any damage is observed, the Rear Head should be
replaced.
6. Remove Suction Screen and examine for any damage
or contamination. lean or replace if necessary.
7. Paint an identifying mark on exposed face of innei
and outer Oil Pump Gears and then remove gears.
Identifying marks are to assure that gears, if re-used, will
be installed on identical position.
8. Remove and discard rear head to shell O-ring.
9. arefully remove Rear Discharge Valve Plate
assembly. Use two small screwdrivers under reed retainers
to pry up on assembly (Figure ID-31). Do not position
screwdrivers between reeds and reed seats.
10. Examine Valve Reeds and Seats. Replace entire
assembly if any reeds or seats are damaged.
11. Using two small screwdrivers, carefully remove
Rear Suction Reed (Figure ID-32). Do not pry up on
horseshoe-shaped reed valves.
12. Examine reeds for damage, and replace if necessary,
13. Using Oil Pick-Up Tube Remove J-5139 (Figure
ID-33), remove Oil Pick-Up Tube. Remove O-ring from oil
inlet.
6364
Figure 1D-28 A-6 Compressor Pressure Switch on A, B

AIR CONDITIONING COMPRESSOR OVERHAUL 1D-1
R AR H AD
S ALING
SURFAC S
SH LL TO H AD
RING
OIL PUMP
ROTORS
5042
Figure 1D- 0 A-6 Rear Head Removal
14. Loosen compressor from Holding Fixture J-9396,
place Internal ylinder and Shaft Assembly Support Block
J-21352 over oil pump end of shaft and, while holding
Support Block in position with one hand, lift compressor
from Holding Fixture with other hand. Invert compressor
(shaft will now be facing upward) and position on bench
with Internal Assembly Support Block resting on bench.
15. Lift Front Head and ompressor Shell Assembly
up, leaving Internal ylinder and Shaft Assembly resting on
Internal Assembly Support Block.
Figure 1D- Removing A-6 Oil Pick-Up Tube
NOTICE: To prevent damage to shaft, DO NOT TAP
ON END OF OMPRESSOR SHAFT to remove
Internal ylinder and Shaft Assembly. If Internal
Assembly will not slide out of compressor shell, tap on
Front Head with a plastic hammer.
16. Rest compressor shell on its side and push Front
Head assembly through ompressor Sheel, being careful
not to damage sealing areas on inner side of front head.
Discard O-ring. It may be necessary to tap on outside of
front head, using a plastic hammer, to overcome friction of
O-ring seal between front head and compressor shell.
17. Wipe excess oil from sealing surfaces on front head
casting webs and examine sealing surface. If any surface
damage is observed, the head should be replaced.
18. Remove Front Discharge Valve Plate assembly and
Front Suction Reed Plate. Examine reeds and seats. Replace
necessary parts.
19. Remove Suction ross-Over over by prying with
screwdriver between cylinder casting and cover (Figure 1D-
34).
20. Examine Internal ylinder and Shaft Assembly for
any obvious damage. If Internal Assembly has sustained
major damage, due to loss of refrigerant or oil, it may be
necessary to use the Service Internal ylinder and Shaft
Assembly rather than replace individual parts.
Figure 1D- 2 Removing A-6 Rear Scution Reed
OIL PICK-UP TUBE
REMOVER J-51 9
iL PICK-UP TUBE
Figure 1D- 1 Removing A-6 Rear Discharge Valve Plate
REED RETAINERS
REAR DISCHARGE
VALVE PLATE
ASSEMBLY

ID-14 AIR CONDITIONING COMPRESSOR OVERHAUL
Figure 1D- 4 Removing A-6 Suction Cross-Over Cover
CYLINDER
ASSEMBLY
SUCTION
PASS
COVER
Figure 1D- 6 Separating A-6 Cylinder Halves
A-6 COMPRESSOR INTERNAL
CYLINDER AND SHAFT ASSEMBLY
Disassembly
Use Parts Tray J-9402 (Figure ID-38) to retain
compressor parts during disassembly.
1. Remove Internal ylinder and Shaft Assembly from
compressor as described in "A-6 ompressor Internal
Mechanism ( ylinder and Shaft Assembly)” Removal
procedure.
2. Identify by pencil mark, or some other suitable
means, each piston numbering them as 1, 2 and 3 (Figure
ID-35).
Figure 1D- 5 Numbering A-6 Piston and Cylinder Bores
Number the piston bores in the front cylinder half in
like manner, so that pistons can be replaced in their original
locations.
3. Separate cylinder halves, using a wood block and
mallet (Figure ID-36). Make certain that discharge cross
over tube does not contact axial plate when separating
cylinder halves (a new Service Discharge ross-Over Tube
will be installed later - see Step 5 of Internal ylinder and
Shaft Assembly procedure).
NOTICE: UN DER NO IR UMSTAN E SHOULD
SHAFT BE STRU K AT EITHER END in an effort
to separate upper and lower cylinder halves because the
shaft and the axial plate could be damaged.
4. arefully remove the rear half of the cylinder from
the pistons and set the front cylinder half, with the piston,
shaft and axial plate in ompressing Fixture J-9397.
5. Pull up on compressor shaft and remove piston
previously identified as No. 1, with balls and shoe discs,
from axial plate, a. Inspect the Teflon piston rings for
nicks, cuts or metal particles imbedded in exposed ring
surface and replace the piston rings as required if either
condition exists. See "A-6 Teflon Piston Ring" Replacement
procedure.
6. Remove and discard the piston shoe discs.
7. Remove and examine piston balls, and if satisfactory
for re-use, place balls in No. 1 compartment of Parts Tray
J-9402 (Figure ID-38).
8. Place piston in No. 1 compartment of Parts Tray
J-9402, with notch in casting web at front end of piston
(Figure 1D- 7) into the dimpled groove of Parts Tray
compartment.
9. Repeat Steps 5 through 9 for Pistons No. 2 and No.
3. 10. Remove rear combination of thrust races and thrust
bearing from shaft. Discard races and bearing.
11. Remove shaft assembly from front cylinder half. If
the Discharge ross-Over Tube remained in the front
cylinder half, it may be necessary to bend discharge cross
over tube slightly in order to remove shaft.
12. Remove front combination of thrust races and
bearing from shaft. Discard races and bearing (Fig. ID-39).
13. Examine surface of Axial Plate and Shaft. Replace
as an assembly, if necessary.
A certain amount of shoe disc wear on axial plate is
normal, as well as some markings indicating load of needle
bearings on shaft.
14. Remove Discharge ross-Over Tube from cylinder
half, using self-clamping pliers. This is necessary only on
original factory equipment, as ends ofthe tube are
swedged into cylinder halves. The discharge cross-over tube
in Internal ylinder and Shaft Assemblies that have been
previously serviced have an O-ring and bushing at EA H
FRONT
CYLINDER
HALF
PISTON
SUPPORT
BLOCK J-21