Chevrolet 1977 Monte Carlo, Repair Manual

Page: 20 / 428

I D - 1 4 AIR C O N D ITIO N IN G COMPRESSOR OVERHAUL
Figure 1D-34 Removing A-6 Suction Cross-Over Cover
CYLIN D E R
A S S E M B L Y
S U C T IO N
PA S S
CO VER
Figure 1D-36 Separating A-6 Cylinder Halves
A-6 COMPRESSOR INTERNAL
CYLINDER A N D SHAFT ASSEMBLY
Disassembly
U se Parts Tray J-9402 (Figure ID -38) to retain
com pressor parts during disassem bly.
1. R em ove Internal Cylinder and Shaft A ssem b ly from
com pressor as described in "A-6 Com pressor Internal
Mechanism (Cylinder and Shaft Assembly)” Removal
procedure.
2. Identify by pencil mark, or som e other suitable
m eans, each piston num bering them as 1, 2 and 3 (Figure
ID -3 5 ).
Figure 1D-35 Numbering A-6 Piston and Cylinder Bores
N um ber the piston bores in the front cylinder h alf in
like m anner, so that pistons can be replaced in their original
locations.
3. Separate cylinder halves, using a w ood block and
m allet (Figure ID -36). M ake certain that discharge cross­
over tube does not contact axial plate w hen separating
cylinder halves (a new Service D ischarge Cross-Over Tube
w ill be installed later - see Step 5 o f Internal Cylinder and
Shaft Assembly procedure).
NOTICE: U N D E R N O C IR C U M S T A N C E S H O U L D
S H A F T BE S T R U C K A T E IT H E R E N D in an effort
to separate upper and low er cylinder halves because the
shaft and the axial plate could be damaged.
4. Carefully remove the rear half o f the cylinder from
the pistons and set the front cylinder half, with the piston,
shaft and axial plate in C om pressing Fixture J-9397.
5. Pull up on com pressor shaft and rem ove piston
previously identified as N o. 1, w ith balls and shoe discs,
from axial plate, a.
Inspect the Teflon piston rings
for
nicks, cuts or m etal particles im bedded in exposed ring
surface and replace the piston rings as required if either
condition exists. See "A-6 T eflon Piston Ring" R eplacem ent
procedure.
6. R em ove and discard the piston shoe discs.
7. R em ove and exam ine piston balls, and if satisfactory
for re-use, place balls in N o . 1 com partm ent o f Parts Tray
J-9402 (Figure ID -38).
8. Place piston in N o. 1 com partm ent o f Parts Tray
J-9402, w ith notch in casting web at front end of piston
(Figure 1D-37) into the dimpled groove
o f Parts Tray
com partm ent.
9. R epeat Steps 5 through 9 for Pistons N o. 2 and N o.
3.
10. R em ove rear com bination o f thrust races and thrust
bearing from shaft. D iscard races and bearing.
11. R em ove shaft assem bly from front cylinder half. If
the D ischarge Cross-O ver Tube rem ained in the front
cylinder half, it m ay be necessary to bend discharge cross­
over tube slightly in order to rem ove shaft.
12. R em ove front com bination o f thrust races and
bearing from shaft. D iscard races and bearing (Fig. ID -39).
13. Exam ine surface o f A xia l Plate and Shaft. R eplace
as an assembly, if necessary.
A certain am ount o f shoe disc wear on axial plate is
normal, as w ell as som e m arkings indicating load o f needle
bearings on shaft.
14. R em ove D ischarge Cross-O ver Tube from cylinder
half, using self-clam ping pliers.
This is necessary only on
original factory equipment,
as ends ofthe tube are
sw edged into cylinder halves. T h e discharge cross-over tube
in Internal Cylinder and Shaft A ssem blies that have been
previously serviced have an O-ring and bushing at EACH
F R O N T
C Y L IN D E R
HALF
P IS T O N
S U P P O R T
BLOCK J-21