Chevrolet 1988 Light Duty Truck Operating instructions

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TABLE OF CONTENTS
1988
UNIT REPAIR
MANUAL
COVERING
LIGHT DUTY
TRUCKS
The Table of Contents on this page in
dicates the sections covered in this man
ual. At the beginning of each individual
section is a Table of Contents which gives
the page number on which each major
subject begins.
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 recommended item.
All inforination illustrations and speci
fications contained in this Manual are
based on the latest product information
available at the time of publication ap
proval. The right is reserved to make
changes at any time without notice.
Throttle Body Injection is not included
in this manual. Unit repair information on
TBI is included in the Service Manual.
ST333-88
Printed in U.S.A.
(c) 1987 General Motors Corporation September 1987
All rights reserved.
SEC. SECTION NAME
OA GENERAL INFORMATION
1AIR CONDITIONING
1B1 A6 Air Conditioning Compressor
1B2 DA-6 Air Conditioning Compressor
1B3 R-4 Air Conditioning Compressor
1B4 DA-V5 Air Conditioning Compressor
1B5 HR-6 Air Conditioning Compressor
3STEERING
3B2 Manual Steering Gear
3B3 Power Steering
4AXLES
4B Rear Axle
4B1 71/2 and 75/s-lnch Ring Gear
4B2 81/2-lnch Ring Gear
4B3 91/2-lnch Ring Gear
4B4 101/2-lnch Ring Gear
4B5 Dana Rear Axles
4B6 12-Inch Ring Gear (Rockwell)
4B7 Locking Differentials
4C Front Axle
4C1 81/2-lnch Ring Gear
4C2 93/4-lnch Ring Gear (Dana)
4C3 T Truck Front Axle
4C4 K Truck Front Axle
BRAKES
6 ENGINE
6A General Engine Mechanical
6A1 2.5 Liter L4
6A2 2.8 Liter V6
6A3 4.3 Liter V6
6A4 4.8 Liter L6
6A5 V8 Engine
6A7 6.2 Liter Diesel
6C1 Model 1MEF Carburetor
6C2 Model M4MEF Carburetor
6D Engine Electrical
7TRANSMISSION
7A Automatic Transmission
7A1 700-R4 Automatic Transmission
7A2 400/475 Automatic Transmission
7A3 180C Automatic Transmission
7B Manual Transmission
7B1 Hydra-Matic Muncie Transmission
7B2 New Process Transmission
7B3 Borg Warner Transmissions
7D Transfer Case
7D1 New Process 205 Transfer Case
7D2 New Process 207 Transfer Case
7D3 New Process 208 Transfer Case
7D4 New Process 241 Transfer Case
7D5 New Process 231 H.D. Transfer Case

iv

OA-1
SECTION OA
GENERAL INFORMATION
CONTENTS
SUBJECT PAGE
Service Parts Identification L ab e l..........................................................................................................................................OA- 1
Vehicle Identification Plate........................................................................................................................................................OA- 1
Certification Label........................................................................................................................................................................ OA- 1
Engine Identification Num ber...................................................................................................................................................OA- 2
Model Reference...........................................................................................................................................................................OA- 2
Metric Fasteners...........................................................................................................................................................................OA- 2
Fastener Strength Identification.............................................................................................................................................. OA- 3
Six Lobed Socket Head Fasteners..........................................................................................................................................OA- 4
Prevailing Torque Fasteners......................................................................................................................................................OA- 4
Conversion Table...........................................................................................................................................................................0A-10
Decimal and Metric Equivalents...............................................................................................................................................OA-11
2
Service Parts Identification DO NOT REMOVE
1. VIN 6
2. Wheel Base 5. RPO/SEO Codes
3. Model Number 6. Exterior Color WA Numbers
4. Order Num ber 7. Paint System F-05402
Figure 1—Service Parts Identification Label
SERVICE PARTS
IDENTIFICATION LABEL
The Truck Service Parts Identification Label is provided
on all models (figure 1). It is located on the inside of the
glove box door (or on an inner body panel for Forward
Control models). The Label lists the VIN (Vehicle
Identification Number) wheelbase paint information and
all Production options or Special Equipment on the
vehicle when it was shipped from the factory. ALWAYS
REFER TO THIS INFORMATION WHEN ORDERING
PARTS.
VEHICLE IDENTIFICATION
NUMBER
The VIN is the legal identifier of the vehicle. On all
models except Forward Control it is located on a plate
which is attached to the left top of the instrument panel
and can be seen through the windshield from the outside
of the vehicle (figure 2). On Forward Control models the
plate is on the dash and toe panel. To find out the
F-00687
Figure 2—VIN Location
manufacturer model and chassis type engine type GVW
range model year plant code and sequential number
refer to figure 3.
CERTIFICATION LABEL
The Certification Label shows the GVWR and the front
and rear GAWRs and the Payload Rating for your vehicle
(figure 4).
Gross Vehicle Weight (GVW) is the weight of the
orginally equipped vehicle and all items added to it after it
has left the factory. This would include bodies winches
booms etc.; the driver and all occupants; and the load the
vehicle is carrying. The GVW must not exceed the
GVWR. Also the front and rear gross axle weights must
not exceed the front and rear GAWRs.
The Payload Rating shown on the label is the maximum
allowable cargo load (including the weight of the driver
and all occupants) that the vehicle can carry based on all

? 2 / ' ’]& r 0 /2_ I 4 o m t
/^ /-Z j CLt? i Ve^ji ^i c/) r to rJ
OA-2 GENERAL INFORMATION
I Or 3 Kpj '7 \aJ t> J 3 ij L 6 3 7 5
Nation of Origin
0 = U.S. B uilt
? = Canadian Built
3 = Mexican B uilt
Manufacturers
g)= General M otors
Code Make
A
<s>Chevrolet B us'
Chevrolet Incom plete
Chevrolet Truck
DGMC Incomplete
HGM of Canada Bus
J GMC Bus
KGMC MPV
NChevrolet MPV
TGMC Truck
‘ Van with 4th Seat
4
X .
N
Code Series
11/2 Ton
3/4 Ton
1 Ton
J
T L
Check Digit [
Code Body Type
0 Chassis Only
1 Hi-Cube/Cutaway Van
2 Forward Control
3 Four-Door Cab
4 Two-Door Cab
5 Van
6 Suburban
n^) M otor Home Chassis
Utility (Jimmy/Blazer)
9 Extended Cab
0 1
Production Sequence Number J
Code
0
Year
1988
Assembly Plant
B Baltimore MD
EPontiac East Ml
F Flint Ml
JJanesville. Wl
SSt. Louis MO
V Pontiac. Ml
zFort Wayne IN
0
1Pontiac. Ml
Oshawa ON
Moraine OH
Detroit Ml
Scarborough. ON
7 Lordstown OH
8Shreveport LA
GVWR/BRAKE SYSTEM
Code GVWR Range Brake System
B3001-4000 H ydraulic
C4001-5000 H ydraulic
D5001-6000 Hydraulic
E6001-7000 H ydraulic
F7001-8000 H ydraulic
G8001-9000 H ydraulic
H9001-10 000 Hydraulic
&10 001-14 000 Hydraulic
14 001-16 000 Hydra ulic
Line and Chassis Type
Chassis
Code Line Type
CConventional Cab 4 x 2
RConventional Cab 4 x 2
D M ilitary Truck 4 x 4
KC onventional Cab 4 x 4
VC onventional Cab 4 x 4
GVan 4 x 2
9Forward Control 4 x 2
Sm C o n ve ntion a l C ab4 x 2
TSm C o n ve ntion a l C ab4 x 4
MSm Van 4 x 2
Engine Type and Make
Code Producer Type RPO
C DDA 6.2L V8 Diesel LH6
ECPC-North 2.5L L4 TBI LN8
HCPC 5.0L V8 TBI L03
J DDA 6.2L V8 Diesel LL4
KCPC 5.7L V8 TBI L05
MCPC 5.7L V8 4 BBL LT9
NCPC 7.4L V8 TBI L19
RCPC 2.8L V8 TBI LL2
< w ) CPC 4.8L L6 1 BBL L25
CPC 7.4L V8 4 BBL LE8
zCPC 4.3L V6 TBI LB4
F-04181
Figure 3—Vehicle Identification Number
factory installed equipment on the vehicle. The Payload
Rating is reduced if any accessories or other equipment
is added to the vehicle after final date of manufacture.
The weight of these items should be determined and
deducted from the Payload Rating.
The vehicle may also have a GCWR (Gross
C om bination W eight Rating). The GCW (Gross
Combination Weight) is the total weight of the loaded tow
vehicle (including passengers) and a loaded trailer.
The tires on the vehicle must be the proper size and
properly inflated for the load which you are carrying. The
m
MFD. BY GENERAL MOTORS CORPORATION
"2/86 )
av«m BAWRFRT B AW R Dll
ll/ka
TIRE!
RIMS
PSI/kP*
4649/2109 2100/9 3 2 80 Z
P19 /7 R1 M PW7*R15 Q
1 X 6 JJ - m 1
coid 35L24'm 1 %3 if Z
SPARE TIRE
ALL APPLICABLE FEDE-
C L^ S AFE TY STANDARDS IN EFFECT
MAN UFACTUR E SHOWN ABOVE.
IOC 100001 MPV
THIS VEHICLE EQUIPPED FOR 1000/4 3 LIS PAYLOAD
SEE OWNER’S MANUAL FOR ADDITIONAL INFORMATION
F-00597
Figure 4—Certification Label
vehicle Certification Label shows the originally equipped
tire size and recommended inflation pressures.
ENGINE IDENTIFICATION
NUMBER
Refer to figures 5 6 and 7 to determine the location of
the engine I.D. number.
MODEL REFERENCE
Refer to figures 8 through 12 for determining vehicle
model. C R and S models are two wheel drive. K V and
T models are four wheel drive.
METRIC FASTENERS
Models are primarily dimensioned in the metric system.
Many fasteners are metric and are very close in
dimension to well-known customary fasteners in the inch
system. It is most important that replacement fasteners be
of the correct nominal diameter thread pitch and strength.
Original equipment metric fasteners (except “ beauty”
bolts such as exposed bumper bolts and cross recess
head screws) are identified by a number marking
indicating the strength of the material in the fastener as
outlined later. Metric cross recess screws are identified by
a Posidriv or Type 1A shown in figure 13. Either a Phillips
head or Type 1A cross recess screwdriver can be used in
Posidriv recess screw heads but Type 1A cross recess
screwdrivers will perform better.

GENERAL INFORMATION OA-3
example the customary 1/4-20 and 1/4-28 screws are
replaced by the metric M6.0x1 screw which has nearly
the same diameter and has 25.4 threads per inch. The
thread pitch is in between the customary coarse and fine
thread pitches.
Metric and customary thread notation differ slightly. The
difference is shown in figure 14.
FASTENER STRENGTH
IDENTIFICATION
Most commonly used metric fastener strength properly
classes are 9.8 and 10.9 with the class identification
embossed on the head of each bolt. Customary (inch)
strength classes range from grade 2 to 8 with radial line
identification embossed on each bolt head. Markings
correspond to two lines less than the actual grade (i.e.
grade 7 bolt will exhibit 5 embossed radial lines on the
bolt head). Some metric nuts will be marked with single
digit strength identification numbers on the nut face.
Figure 6 shows the different strength markings.
When replacing metric fasteners be careful to use bolts
and nuts of the same strength or greater than the original
fasteners (the same number marking or higher). It is
likewise important to select replacement fasteners of the
correct size. Correct replacement bolts metric fasteners
available in the aftermarket parts channels were designed
to metric standards of countries other than the United
States and may be of a lower strength may not have the
numbered head marking system and may be of a
different thread pitch. The metric fasteners used on GM
NOTICE Most m etric fasteners have a blue
color coating. However, this should not be used
as positive identification as some fasteners are
not color coated.
General Motors Engineering Standards along with
other North American Industries have adopted a portion
of the standard metric fastener sizes defined by ISO
(International Standards Organization). This was done to
reduce the number of fastener sizes used and yet retain
the best strength qualities in each thread size. For

OA-4 GENERAL INFORMATION
PREVAILING TORQUE FASTENERS
A prevailing torque nut is designed to develop an
interference between the nut and bolt threads. This is
most often accomplished by distortion of the top of an
all-metal nut by using a nylon patch on the threads in the
middle of the hex flat. A nylon insert may also be used as
a method of interference between nut and bolt threads
(figure 16).
A prevailing torque bolt is designed to develop an
interference between bolt and nut threads or the threads
of a tapped hole. This is accomplished by distorting some
of the threads or by using a nylon patch or adhesive
(figure 16).
RECOMMENDATIONS FOR REUSE:
1. Clean unrusted prevailing torque nuts and bolts
may be reused as follows:
a. Clean dirt and other foreign material off the
nut or bolt.
b. Inspect the nut or bolt to insure there are no
cracks elongation or other signs of abuse of
overtightening. (If there is any doubt replace
with a new prevailing torque fastener or equal
or greater strength.)
c. Assemble the parts and hand start the nut or
bolt.
d. Observe that before fastener seats it
develops torque per the chart in figure 13 (if
there is any doubt replace with a new
prevailing torque fastener of equal or greater
strength).
e. Tighten the fastener to the torque specified in
the appropriate section of this manual.
2. Bolts and nuts which are rusty or damaged should
be replaced with new parts or equal or greater
strength.
products are designed to new international standards that
may not yet be manufactured by some non-domestic bolt
and nut suppliers. In general except for special
applications the common sizes and pitches are:
M6.0 x 1 M 10x1.5
M8 x 1.25 M 12x1.75
SIX LOBED SOCKET
HEAD FASTENERS
Six lobed socket head (Torx) fasteners are used in some
applications on vehicles covered in this manual (figure
15). The door striker bolt is of this design.
Tools designed for these fasteners are available
commercially. However in some cases if the correct tool
is not available a hex socket head wrench may be used.

GENERAL INFORMATION OA-
Chassis - Cab Bonus/Crew Cab
Pickup Bonus/Crew Cab Suburban
Utility Vehicle
Jimmy (Blazer)
F-02281
Chassis - Cab Regular Cab
Pickup Regular Cab RV MODELS
Figure 8—RV Models

OA-6 GENERAL INFORMATION
G VAN MODELS
RALLY (SPORTVAN) VAN DURA (CHEVY VAN)
P MODELS
VALUE VAN (STEP VAN)
(ALUMINUM) MOTOR HOME CHASSIS
MAGNAVAN (HI-CUBE VAN)
VALUE VAN (STEP VAN)
(STEEL) FORWARD CONTROL CHASSIS
B-09178
CUTAWAY VAN
Figure 9—G and P Models

GENERAL INFORMATION OA-7
CK Pickup Sportside CK Chassis Cab
CK Pickup, Extended Cab CK Chassis, Extended Cab F-04481
Figure 10—CK Models
Figure 11—ST Models

OA-8 GENERAL INFORMATION
Passenger Van
B-09261
Cargo Van
1. Customary Bolt— 1/4-20
2. Metric Bolt— M6.0x1
A. 1/4-inch
B. 6 mm
C. 20 Threads Per Inch
D. 1 Thread Per Millimeter
(25.4 Threads Per Inch) F-00705
Figure 12—M Models Figure 14—Thread Notation
1. Grade 2 (GM 200-M)
2. Grade 5 (GM 280-M)
3. Grade 7 (GM 290-M)
4. Grade 8 (GM 300-M)
5. Manufacturer’s Identification
6. Nut Strength Identification
7. Identification Marks (Posidriv Screw Head)
F-00695
Figure 13—Bolt and Nut Identification Figure 1 —Six Lobed Socket Head Fasteners

GENERAL INFORMATION OA-9
A. Metric Sizes 1. Top Lock Type 6. Nylon Strip Or Patch
B. Inch Sizes 2. Center Lock 7. Nylon Washer Insert
3. Dry Adhesive Coating 8. Nylon Patch
4. Out Of Round Thread 9. Nylon Insert
5. Deformed Thread Profile B-02406
Figure 16—Torque Nuts and Bolt Chart

Figure 17—Conversion Table
CONVERSION TABLE
Multiply by to get equivalent
number of: Multiply to get equivalent
by number of:
LENGTH ACCELERATION
Inch 25.4 millimeters (mm) Foot/sec2 0.304 8 meter/sec2 (m/s2)
Foot 0.304 8 meters (m) Inch/sec2 0.025 4 meter/sec2
Yard 0.9144 meters TORQUE
Mile 1.609 kilometers (km) Pound-inch 0.112 98 newton-meters (N-m)
AREA Pound-foot 1.355 8 newton-meters
Inch" 645.2 millimeters2 (mm2) POWER
Foot2
Yard2
6.45
0.092 9
0.836 1
VOLUME
centimeters2 (cm2)
meters2 (m2)
meters2
Horsepower 0.746 kilowatts (kW)
PRESSURE OR STRESS
Inches of water
Pounds/sq. in. 0.249 1 kilopascals (kPa)
6.895 kilopascals
ENERGY OR WORK
Inch3 16.387
16.387
0.0164
liters
3.785 4
0.764 6
MASS
mm3
Quart 0.946 4
Gallon
Yard3
cm 1
liters (1)
liters
meters3 (m3)
BTU
Foot-pound
Kilowatt-hour
1 055 joules (J)
1.355 8 joules
3 600 000 joules (J $ one W)
or 3.6 x 106
LIGHT
1.076 4 lumens/meter2 (lm/m2)
FUEL PERFORMANCE
Pound
Ton 0.453 6
907.18 kilograms (kg)
kilograms (kg)
Foot candle
Ton 0.907 tonne (t) Miles/gal 0.425 1 kilometers/liter (km/l)
FORCE Gal/mile 2.352 7 liter/kilometer (l/km)
Kilogram
Ounce 9.807 newtons (N) VELOCITY
0.278 0 newtons Miles/hour 1.609 3 kilometers/hr. (km/h)
Pound 4.448 newtons
TEMPERATURE
Degree
Fahrenheit (t°F-32) -r 1.8 degree Celsius (C)
o
cn
CD
0A-10 GENERAL INFORMATION

GENERAL INFORMATION OA-11
DECIMAL AND METRIC EQUIVALENTS
Fractions Decimal In. Metric mm Fractions Decimal In. Metric mm
1/64 0.015625 0.39688 33/64 0.515625 13.09687
1/32 0.03125 0.79375 17/32 0.53125 13.49375
3/64 0.046875 1.19062 35/64 0.546875 13.89062
1/16 0.0625 1.58750 9/16 0.5625 14.28750
5/64 0.078125 1.98437 37/64 0.578125 14.68437
3/32 0.09375 2.38125 19/32 0.59375 15.08125
7/64 0.109375 2.77812 39/64 0.609375 15.47812
1/8 0.125 3.1750 5/8 0.625 15.87500
9/64 0.140625 3.57187 41/64 0.640625 16.27187
5/32 0.15625 3.96875 21/32 0.65625 16.66875
11/64 0.171875 4.36562 43/64 0.671875 17.06562
3/16 0.1875 4.76250 11/16 0.6875 17.46250
13/64 0.203125 5.15937 45/64 0.703125 17.85937
7/32 0.21875 5.55625 23/32 0.71875 18.25625
15/64 0.234375 5.95312 47/64 0.734375 18.65312
1/4 0.250 6.3500 3/4 0.750 19.05000
17/64 0.265625 6.74687 49/64 0.765625 19.44687
9/32 0.28125 7.14375 25/32 0.78125 19.84375
19/64 0.296875 7.54062 51/64 0.796875 20.24062
5/16 0.3125 7.93750 13/16 0.8125 20.63750
21/64 0.328125 8.33437 53/64 0.828125 21.03437
11/32 0.34375 8.73125 27/32 0.84375 21.43125
23/64 0.359375 9.12812 55/64 0.859375 21.82812
3/8 0.375 9.52500 7/8 0.875 22.22500
25/64 0.390625 9.92187 57/64 0.890625 22.62187
13/32 0.40625 10.31875 29/32 0.90625 23.01875
27/64 0.421875 10.71562 59/64 0.921875 23.41562
7/16 0.4375 11.11250 15/16 0.9375 23.81250
29/64 0.453125 11.50937 61/64 0.953125 24.20937
15/32 0.46875 11.90625 31/32 0.96875 24.60625
31/64 0.484375 12.30312 63/64 0.984375 25.00312
1/2 0.500 12.7000 1 1.00 25.40000
B-07676
Figure 18—Decimal and Metric Equivalents

1B1-1
SECTION 1
AIR CONDITIONING
CONTENTS
SUBJECT PAGE
A-6 Air Conditioning Com pressor...............................................................................................................................................1B1-1
DA-6 Air Conditioning Compressor............................................................................................................................................ 1B2-1
R-4 Air Conditioning Com rpessor...............................................................................................................................................1B3-1
DA-V Air Conditioning Compressor..........................................................................................................................................1B4-1
HR-6 Air Conditioning Com pressor............................................................................................................................................ 1B -1
SECTION 1B1
A-6 AIR CONDITIONING COMPRESSOR
CONTENTS
SUBJECT PAGE
Description.........................................................................................................................................................................................1B1- 1
Minor Repair to the Com pressor...............................................................................................................................................1B1- 3
Clutch Plate and Hub Assembly Replacem ent.................................................................................................................1B1- 3
Pulley and Bearing Assembly Replacem ent..................................................................................................................... 1B1- 4
Clutch Coil and Housing Assembly Replacement............................................................................................................1B1- 6
Major Repair to the Com pressor...............................................................................................................................................1B1- 7
Shaft Seal Replacem ent...........................................................................................................................................................1B1- 7
Pressure Relief Valve Replacement......................................................................................................................................1B1- 9
Compressor Disassembly.............................................................................................................................................................1B1-10
Gaging Operation.........................................................................................................................................................................1B1-12
Gaging Procedure...................................................................................................................................................................... 1B1-14
Piston Ring Replacem ent........................................................................................................................................................ 1B1-16
Compressor Assem bly..................................................................................................................................................................1B1-18
Leak T e sting .................................................................................................................................................................................... 1B1-22
Specifications..................................................................................................................................................................................1B1-23
Special Tools.................................................................................................................................................................................... 1B1-24
DESCRIPTION
When servicing the Harrison A-6 compressor prevent
dirt or foreign material from getting on or into the com
pressor parts and system during disassembly or reassem
bly
Keep tools and work area clean. Clean the compressor
exterior before disassembly. Clean parts with trichloroe-
thane naptha or Stoddard solvent kerosene or equiva
lent. Dry with air.
Use a non-lint producing type cloth to clean each part.
Although certain service operations can be performed
without removing the compressor from the vehicle the op
erations described here are based on bench repair with
the compressor removed from the vehicle. They have
been prepared in sequence in order of accessibility of the
components (figure 1).
For compressor removal and installation refer to the
proper truck service manual.
Do not kink or place excessive tension on lines or
hoses.
After removing the compressor from the vehicle drain
and measure the refrigerant oil. Add new 525 viscosity
refrigerant oil after repair. Refer to “ Specifications.”
IDENTIFICATION
An identification label attached to the compressor
provides the name of the manufacturer model number
and build code. If the label is removed or becomes
dislodged during service operation reattach it using an
adhesive sealant such as Loctite 312 or equivalent.

1B1-2 A-6 AIR CONDITIONING COMPRESSOR
F-01538
Nut
Clutch
Ring
Pulley Bearing Ring
Bearing
Pulley
Clutch Coil Ring
Coil
Shell
Sleeve Seal
Flat Seal
Ring
Seat Seal
Shaft Seal
Shaft Seal (O-ring)
Front Head
Seal (Front)
Discharge Valve
Plate (Front)
Reed Suction
Valve (Front)
Pin
Bearing
Drain Screw
Gasket
Sleeve
Seal
Tube
Race
Bearing
Cylinder (Front)
Sleeve
Seal
Piston
Ring (Piston)
Ball
Seal (Ball)
Key
Ring (Piston)
Pin
Shaft
Race
Bearing
Cylinder (Rear)
Seal
Tube
Pin
Plate
Bearing
Discharge Valve
Plate (Rear)
Reed Suction Valve (Rear)
Inner Gear
51. Outer Gear
52. Seal (Rear)
53. Nut
54. Rear Head
55. Seal
56. Pressure Relief Valve
57. Seal
58. Screen
Figure 1—Compressor Component View

A-6 AIR CONDITIONING COMPRESSOR 1B1-3
MINOR REPAIR TO THE COMPRESSOR
Operations to the clutch plate and hub pulley and bear
ing and coil and housing are covered as “ Minor” be
cause they may be performed without purging the system.
Servicing the shaft seal and pressure relief valve are
covered in “ Major Repair Procedures” because the sys
tem must be purged of Refrigerant-12.
Illustrations used in describing these operations show
the compressor removed from the vehicle to illustrate the
various operations.
When servicing the compressor remove the compo
nents that preliminary diagnosis indicates need servicing.
Refer to figure 1 for part name and location.
Keep the work area tools and parts clean. Use Piston
Tray J 9402 (refer to “ Special Tools”) for parts removed
and for replacement parts.
When a compressor is removed from the vehicle for
servicing drain and measure the amount of oil remaining
in the compressor. After servicing add new 525 viscosity
refrigerant oil to the compressor.
CLUTCH PLATE AND HUB
ASSEMBLY REPLACEMENT
|+~»| Remove or Disconnect (Figures 1, 2 and 3)
Tools Required:
J 9396 Compressor Holding Fixture
J 9399 Compressor Shaft Nut Socket
J 9401-A Hub Drive Plate Remover
J 25030 Clutch Hub Holding Tool
• Clamp J 9396 in a vise.
• Compressor to J 9396. Secure with thumb screws
(figure 2).
1. Shaft nut (1) with J 9399.
• Hold the clutch plate and hub assembly (2)
with J 25030 (figure 2).
2. Clutch plate and hub assembly (2).
• Thread J 9401-A into the clutch plate and hub
(2) (figure 3).
• Hold the body of J 9401 with a winch and
tighten the center screw into the remover
body.
3. Shaft key (36).
• Retain the shaft key (36) if usable.
• l Inspect
• All parts and replace as necessary.
f-n~| Install or Connect (Figures 1, 4 and )
Tools Required:
J 9399 Compressor Shaft Nut Socket
J 9480-B Hub and Drive Plate Assembly
Installer
J 25030 Clutch Hub Holding Tool
1. Shaft key (36).

1B1-4 A-6 AIR CONDITIONING COMPRESSOR
Allow the shaft key (36) to extend 4.5 mm
(3/ie-inch) out of the bottom of the hub keyway
(figure 4).
The shaft key (36) is curved to give an
interference fit in the groove.
Important
• Do not drive or pound on the clutch hub or the
shaft (39). Internal damage to the compressor
may result.
Clutch plate and hub assembly (2) (figure 4).
• Install the clutch plate and hub assembly (2)
over the compressor shaft lining up the key
slot on the hub with the keyway slot in the
shaft.
• Install J 9480-B on the threaded end of the
shaft (figure 5).
• Back off J 9480-B body to allow the center
screw to be threaded against the end of the
compressor shaft (39).
• Hold the center screw with a wrench and
tighten the hex portion of J 9480-B body while
pressing the hub onto the shaft (39). After
tightening the body several turns remove
J 9480-B and check that the shaft key (36) is
properly in place in the keyway.
• Air gap between contact surfaces of the clutch
plate and hub assembly (2) and the pulley (6)
should be 0.56-1.34 mm (0.022-0.057-inch).
• Remove J 9480-B.
Inspect
• Position of the shaft (39) (even with or
slightly above the clutch hub).
3. Shaft nut (1).
• Use J 9396 to hold the clutch plate and hub
assembly (2).
Tighten
• Shaft nut (1) to 27 N m (20 ft. lbs.) with
J 9399.
• Hand spin the pulley (6) to check for free
rotation.
PULLEY AND BEARING
ASSEMBLY REPLACEMENT
6 through
+-► Remove or Disconnect (Figures 1
9)
Tools Required:
J 0435 Snap Ring Pliers
J 8092 Driver Handle
J 8433 Heavy Duty Pulley Puller
J 9395 Pulley Puller Adapter
J 9398-A Pulley Bearing Remover
J 9481-A Pulley Bearing and Pulley Installer
J 24092 Pulley Hub Adapter Set
Clutch plate and hub assembly (2).
Pulley bearing retainer (2) with J 6435 (figure 6).
Pulley (6).