A/c Compressor Overhaul Buick Roadmaster VIII

REFRIGERANT OIL & REFRIGERANT SPECIFICATIONS

Note. Due to late changes, always refer to underhood A/C Specification Label in engine compartment or A/C compressor label while servicing A/C system. If A/C Specification Label and specifications in table differ, use label specifications.

REFRIGERANT OIL & REFRIGERANT CAPACITY (CARS) (1)

REFRIGERANT OIL & REFRIGERANT CAPACITY (LIGHT TRUCKS/VANS) (1)

COMPRESSOR APPLICATIONS

Note. Due to late changes, always refer to underhood A/C Specification Label in engine compartment or A/C compressor label while servicing A/C system. If A/C Specification Label and specifications differ, use label specifications.

COMPRESSOR APPLICATIONS (CARS) (1)

COMPRESSOR APPLICATIONS (LIGHT TRUCKS & VANS) (1)

BODY DESIGNATIONS

BODY DESIGNATIONS (GENERAL MOTORS CARS)

BODY DESIGNATIONS (GENERAL MOTORS LIGHT TRUCKS & VANS)

Removal

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove compressor. Using Compressor Fixture (J-9396), mount compressor in a vise. Hold clutch plate using Clutch Plate Spanner (J-25030).
2. Remove clutch plate nut. Install Clutch Plate Remover (J-9401-B) into clutch plate and hub.
3. Hold outer area of clutch plate remover. Tighten center bolt until clutch plate can be removed. Remove key from shaft. (Scheme 14)
4. Remove pulley assembly snap ring. Place Shaft Protector (J-9395) over compressor shaft. Using Puller (J-8433-3 for "V" belts or J-24092 for multi-groove pulleys), remove pulley assembly.
5. If removing bearing from pulley, remove retaining ring from pulley. Drive bearing from pulley using hammer, Bearing Remover (J-9398) and Handle (J-8092).
6. Remove snap ring, and disconnect electrical lead at clutch coil. Place marks on clutch coil and shell for installation reference. Using large screwdriver, carefully pry clutch coil from shell. Clutch coil is held on shell with adhesive.

Installation

1. Ensure all adhesive is removed from shell and clutch coil. Apply trim detail adhesive on back of clutch coil around clutch coil protrusions. Install clutch coil and snap ring. Ensure reference marks align.
2. Drive bearing into pulley (if removed). Install bearing snap ring. Install pulley assembly and snap ring. Install clutch plate key in clutch plate, allowing key to protrude about 3/16" from rear of clutch plate.
3. Install clutch plate on compressor shaft. Install Clutch Plate Installer (J-9480-B) in center of shaft. Hold outer area of clutch plate installer. Tighten center bolt to install clutch plate. Ensure key remains in proper location.
4. Press clutch plate onto compressor until clearance between clutch plate and pulley assembly is .022-.057" (0.56-1.45 mm). Using spanner, install clutch nut, and tighten it to 20 ft. lbs. (27 N.m). Install compressor. Evacuate and recharge system. Perform leak test. See LEAK TESTING in A/C GENERAL SERVICING PROCEDURES article in the AIR CONDITIONING & HEAT Section.

SHAFT SEAL

Information is not available.

Scheme 14

CLUTCH ASSEMBLY

1. Using Clutch Plate Spanner (J-25030 for HR6-HE compressor or J-33027-A for V5 compressor), hold clutch plate and remove crankshaft nut. Use Clutch Plate Remover/Installer (J-33013-B) to remove clutch plate. (Scheme 15)or (Scheme 16). Remove key from shaft.
2. Remove snap ring. Install Guide (J-33023-A) on front head. Position Puller (J-33020) in slots on pulley assembly. Tighten puller and remove pulley assembly.
3. Use hammer and Bearing Remover (J-9398-A) to drive bearing from pulley. Disconnect clutch coil lead.
4. Scribe marks on compressor and clutch coil for installation reference. Remove clutch coil using Puller Adapter (J-33023-A) and 2-jaw puller.

Scheme 15

Scheme 16

1. Align reference marks. Using Puller Adapter (J-33024) and Puller Bar (J-8433-1), press clutch coil onto compressor. Restake clutch coil inner ring in 3 places, 120 degrees apart.
2. If bearing was removed from pulley, place pulley on Support (J-21352-A). DO NOT support pulley on flat surface, or pulley will be damaged. Install bearing in pulley using hammer, Handle (J-29886) and Bearing Installer (J-948-1).
3. With pulley on support, stake pulley in 3 places, 120 degrees apart. Position pulley on compressor.
4. Place Bearing Installer (J-33017) and Puller Guide (J-33023-A) over inner race of bearing. Using puller, press pulley assembly onto compressor. Install snap ring. Install key in clutch plate, allowing key to protrude about 1/8" from rear of clutch plate.
5. Install clutch plate on compressor crankshaft. Using clutch plate remover/installer, press clutch plate onto compressor until a clutch assembly clearance of .020-.030" (.51-.76 mm) is achieved.
6. Using spanner, install crankshaft nut. Tighten crankshaft nut to 12 ft. lbs. (16 N.m). Check components for proper rotation.

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Using Clutch Plate Spanner (J-25030 for HR6-HE compressor or J-33027-A for V5 compressor), hold clutch plate and remove crankshaft nut. Thread Clutch Plate Remover/Installer (J-33013-B) into clutch plate, and remove clutch plate. (Scheme 15)or (Scheme 16).
2. Remove shaft seal snap ring. Ensure all surfaces around seal are clean. Install Shaft Seal Protector (J-34614) over compressor shaft. Insert Shaft Seal Remover/Installer (J-23128-A) into shaft seal.
3. Rotate handle clockwise to seat seal remover/installer in seal. Remove shaft seal. Using "O" Ring Remover (J-9553-01), remove "O" ring.

1. With shaft seal protector in place, lubricate new "O" ring with refrigerant oil and install it on "O" Ring Installer (J-33011).
2. Insert "O" ring installer in compressor until it bottoms. Move slide on "O" ring installer downward until "O" ring is released into groove. Rotate installer to seat "O" ring. Remove "O" ring installer.
3. Lubricate shaft seal with refrigerant oil. Expand seal using shaft seal remover/installer. Install seal on Seal Protector (J-34614). Place seal protector over shaft. Push shaft seal into compressor using a rotary motion until seal bottoms.
4. Install NEW snap ring with flat side against seal. Install clutch plate on compressor crankshaft.
5. Using clutch plate remover/installer, press clutch plate onto compressor until a clutch assembly clearance of .020-.030" (.51-.76 mm) is achieved.
6. Using spanner, install crankshaft nut and tighten it to 12 ft. lbs. (16 N.m). Evacuate and recharge system. Check for leaks.

Scheme 17

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove compressor. Drain oil from compressor, and measure amount drained. Mount compressor on Holding Fixture (J-25008-A), and secure fixture in a vise. Using Clutch Plate Spanner (J-33027-A), remove crankshaft nut.
2. Thread Clutch Plate Remover (J-33013-B) into clutch plate. Hold body of clutch plate remover. Tighten center bolt to remove clutch plate. Remove crankshaft key. (Scheme 17) Remove rotor snap ring.
3. Install Puller Guide (J-25031) on compressor shaft. Using Puller (J-33020), pull rotor from compressor.
4. If removing bearing, remove center screw from puller. Invert assembly on solid surface. Using hammer, Handle (J-29886) and Bearing Remover (J-9398-A), drive bearing from rotor.
5. Scribe reference marks on compressor and clutch coil for installation reference. Install puller guide on compressor shaft. Using Puller (J-25287), pull clutch coil from compressor.

1. Using hammer, Handle (J-29886) and Rotor/Bearing Installer (J-26271-A), install clutch coil. Ensure reference marks align.
2. If bearing was removed, place rotor on Support (J-21352-A). DO NOT support on flat surface, or assembly will be damaged. Using hammer, Handle (J-29886) and Rotor/Bearing Installer (J-26271-A), install bearing in rotor. Stake rotor in 3 places, 120 degrees apart.
3. Install rotor assembly on front head. Drive rotor on front head using hammer, Handle (J-29886) and Rotor/Bearing Installer (J-26271-A). Install snap ring.
4. Install crankshaft key, allowing key to protrude about 3/16" from rear of clutch plate. Install clutch plate on compressor crankshaft.
5. Using Clutch Plate Installer (J-9401-B), press clutch plate onto compressor until clearance between clutch plate and rotor is .020-.030" (.51-.76 mm).
6. Using spanner, install NEW crankshaft nut and tighten it to 10 ft. lbs. (14 N.m). Check components for proper rotation. Using new refrigerant oil, add same amount of oil to compressor as was drained from it. Install compressor. Evacuate and recharge system. Check for leaks.

Removal ("V" Groove Belt Drive)

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove compressor. Drain oil from compressor, and measure amount drained. Mount compressor on Holding Fixture (J-25008-A), and secure fixture in a vise. Remove crankshaft nut using Clutch Plate Spanner (J-33027-A).
2. Thread Clutch Plate Remover (J-33013-B) into clutch plate. Hold body of clutch plate remover. Tighten center bolt to remove clutch plate. Remove crankshaft key. (Scheme 17) Remove rotor snap ring.
3. If removing rotor and bearing only, remove pulley rim bolts. If replacing clutch coil, DO NOT loosen or remove pulley rim bolts. Pulley rim bolts will pull clutch coil off when rotor is removed.
4. If clutch coil is being removed, scribe reference marks on compressor and clutch coil for installation reference. Install Puller Guide (J-25031) on compressor shaft. Using internal-jaw puller, remove rotor assembly from compressor.
5. If removing clutch coil, remove pulley rim bolts. Separate clutch coil from pulley rim. If removing bearing, place clutch assembly on wooden block. Using hammer, Handle (J-29886) and Bearing Remover (J-9398-A), drive bearing from rotor.

1. If bearing was removed, install bearing in rotor using Bearing Installer (J-9481-A). Stake rotor in 3 places, spaced 120 degrees apart.
2. If clutch coil was removed, install coil in pulley rim. Coat pulley rim bolts with Loctite. Install bolts, but DO NOT tighten them yet. CAUTION: Ensure protrusions on rear of clutch coil align with holes in front head.
3. On all applications, install rotor assembly on front head. Using hammer, Handle (J-29886) and Rotor/Bearing Installer (J-26271-A), install rotor assembly. Ensure reference marks align.
4. Install snap ring. Tighten pulley rim bolts to 100 INCH lbs. (11 N.m). Install crankshaft key, allowing key to protrude about 3/16" from rear of clutch plate. Install clutch plate on compressor crankshaft.
5. Using Clutch Plate Installer (J-9401-B), press clutch plate onto compressor until clearance between clutch plate and rotor is .020-.030" (.51-.76 mm).
6. Using spanner, install NEW crankshaft nut and tighten it to 10 ft. lbs. (14 N.m). Check components for proper rotation. Using new refrigerant oil, add to compressor the same amount of oil drained from it. Install compressor. Evacuate and recharge system. Check for leaks.

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Using Clutch Plate Spanner (J-33027-A), remove crankshaft nut. Thread Clutch Plate Remover (J-33013-B) into clutch plate. Hold body of clutch plate remover. Tighten center bolt to remove clutch plate. Remove crankshaft key. (Scheme 17)
2. Remove shaft seal snap ring. Ensure seal area on compressor is clean. Insert Shaft Seal Remover/Installer (J-23128-A) into shaft seal.
3. Rotate handle clockwise and remove shaft seal. Using "O" Ring Remover (J-9553-01), remove "O" ring.

1. Lubricate NEW "O" ring with refrigerant oil, and install it on "O" Ring Installer (J-33011). Insert "O" ring installer in compressor until installer bottoms.
2. Move slide on "O" ring installer downward until "O" ring is released into groove. Rotate installer to seat "O" ring.
3. Coat shaft seal with refrigerant oil. Install seal on shaft seal remover/installer. Expand seal using shaft seal remover/installer.
4. Install Shaft Seal Protector (J-34614) through seal. Install seal on shaft seal protector so seal lip is toward compressor. Remove shaft seal remover/installer.
5. Install shaft seal protector over end of compressor shaft. Push shaft seal into compressor until it bottoms. Install NEW shaft seal snap ring with flat side against seal.
6. Install crankshaft key, allowing key to protrude about 3/16" from rear of clutch plate. Install clutch plate on compressor crankshaft.
7. Using Clutch Plate Installer (J-9401-B), press clutch plate onto compressor until clearance between clutch plate and rotor is .020-.030" (.51-.76 mm).
8. Using spanner, install NEW crankshaft nut and tighten it to 10 ft. lbs. (14 N.m). Check components for proper rotation. Install compressor. Evacuate and recharge system. Check for leaks.

1. Hold clutch using Clutch Holder (J-33027-A). Remove compressor shaft bolt. Remove clutch plate and shims.
2. Remove pulley assembly snap ring. Remove pulley assembly and snap ring. Disconnect clutch coil lead. Remove clutch coil.

1. Install clutch coil so pin in back of coil aligns with hole in front housing. Install snap ring.
2. Install pulley assembly and snap ring. Install clutch plate and shims. Tighten compressor shaft bolt to 10 ft. lbs. (14 N.m). DO NOT use air tools to tighten bolt.
3. Using feeler gauge, measure air gap between clutch plate and pulley surface in 3 areas. Proper clearance is .004-.008" (.10-.20 mm). Adjust shim thickness to obtain correct clearance.
4. Once compressor shaft bolt is tightened, recheck clearance between clutch plate and pulley surface in 4 places. Readjust clearance if necessary.

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove compressor. Drain oil from compressor, and measure amount drained.
2. Remove clutch assembly. Remove front head bolts. Separate front head and "O" ring from compressor. (Scheme 18)
3. Remove felt dust seal and dust seal retainer from front head. Remove shaft seal snap ring. Press seal from front head.

1. Lubricate new shaft seal and seal cavity of front head with refrigerant oil. Press seal into front head, and install snap ring.
2. Lubricate front head "O" ring with refrigerant oil. Install front head "O" ring on cylinder assembly. Install Shaft Protector (J-34614) on compressor shaft. Install front head on cylinder assembly. Ensure dowel pins align.
3. Install all through bolts using NEW washers. Tighten through bolts to 18 ft. lbs. (24 N.m). Remove shaft protector. Install felt dust seal and dust seal retainer. Using INCH-lb. torque wrench, check compressor shaft rotating torque. Rotating torque should be 26 INCH lbs. (3 N.m).
4. Install clutch assembly. Using new refrigerant oil, add same amount of oil to compressor as was drained from it. Install compressor. Evacuate and recharge system. Perform leak test. See LEAK TESTING in A/C GENERAL SERVICING PROCEDURES article in the AIR CONDITIONING & HEAT Section.

Scheme 18

Note. Removing compressor is not necessary to service clutch assembly.

1. Loosen tensioner and remove drive belt from pulley. Remove coolant/washer reservoir screws. Disconnect electrical harness from coolant reservoir. Release heater return pipe clips. Lift coolant/washer reservoir out of the way.
2. Using Clutch Holder (SA9149AC-4) and 10-mm deep socket, remove clutch drive plate center bolt. Insert drive plate holder sleeve into drive plate. Install remover bolt. While holding clutch remover handle, tighten remover bolt to remove drive plate. Take care not to lose shims.
3. Remove pulley snap ring. Position puller Center Adapter (SA9149AC-2) over end of compressor shaft. Attach 3-jaw puller to back of pulley. Tighten puller bolt against center adapter. Remove pulley. Remove clutch coil screws. Disconnect clutch coil wire. Remove clutch coil.

1. Install coil in original position. Tighten screws to 35-52 INCH lbs. (3.9-5.9 N.m). Install drive bolt, Drive Plate Installer (SA9149AC-3) and thrust bearing assembly through center of pulley. Thread pulley installation bolt finger tight into compressor shaft.
2. Tighten nut on installation bolt finger tight, to align pulley to compressor. Tighten nut until pulley bottoms out in compressor. Loosen nut and remove installation bolt. Install snap ring with tapered side out.
3. Install drive plate on holder. Place thrust bearing on installation bolt. Insert installation bolt through drive plate. Place shims on installation bolt. Thread bolt into compressor shaft. Slide drive plate over splines of compressor shaft. While holding end of installation bolt, tighten nut until drive plate bottoms. Loosen nut and remove installation bolt. Install center bolt. Tighten center bolt to 104-130 INCH lbs. (11.8-14.7 N.m).
4. Using a feeler gauge, check clearance between drive plate and pulley. Clearance should be .01"-.02" (.3-.5 mm). If clearance is not as specified, add or remove shims as necessary.

Information is not available.