![background image](http://html1.mh-extra.com/html/gmc/1982-light-duty-truck/1982-light-duty-truck_service-manual_2235920108.webp)
1C 1-10 AIR C O N D IT IO N IN G COM PRESSO R O VERHAUL
6. Inspect the drive surfaces of the Rotor and Drive Plate to be
sure they are still in good condition. Replace as required.
7. Assemble a new Pulley Rim over the Clutch Coil and mount
the Pulley Rim to the Rotor and Bearing assembly, using the
short notch mounting locations, Figure 1C 1-24. The
mounting notches are located 120° apart radially around the
Pulley Rim.
8. Assemble three (3) new lockwashers on the three (3) new
6.4mm-28 x 13.5mm (1/4-28 X 5/16") mounting screws and
apply Loctite 601 (or equivalent sealer) to the entire thread
surface of the mounting screws and the mounting hole
threads in the Rotor. Assemble the three (3) screws into the
short notch mounting hole locations and tighten finger tight.
9. Align the Pulley Rim so that the bottom of the rim notches
touch the mounting screws at all three (3) mounting
locations. Also center the drilled holes in the Pulley Rim with
the remaining mounting holes in the Rotor. When the rim
is positioned properly, tighten the three (3) mounting screws
to 11 N -m (100 in. lbs.) torque.
10. Temporarily make a trial fit of the Inertia Ring to the Pulley
Rim. If any portion of the sheer edge of the Pulley Rim
prevents the installation of the Inertia Ring, the raised edge
may be filed off to remove the excess metal and facilitate
installation. Do not use undue force or cock the ring in
assembling the Inertia Ring in place over the Pulley Rim that
could cause ring distortion or stress.
11. Assemble the Inertia Ring onto the Pulley Rim being careful
to align the Inertia Ring mounting holes with the mounting
holes in the Pulley Rim. If the Inertia Ring cannot be moved
by hand and must be rotated for centering the mounting
holes, use a drift punch or blunt tool and a hammer to
carefully tap at one of the large clearance notches in the
inertia ring to rotate the ring into position, Fig. 1C 1-25.
12. Install the special lock washers onto the 13mm-28 x 13.5mm
(1/4-28 X 17/32") mounting screws and apply Loctite 601
(or equivalent sealer) to the total screw thread and the threads
of the mounting holes in the rotor.
13. Install the screw and washers into the rotor mounting holes
and tighten finger tight. When all screws are in place, torque
each screw to 11 N*m (100 in. lbs.) torque.
14. Using Rotor and Bearing assembly Installer J-26271 and
Universal Handle J-8092, install the Pulley, Clutch Coil,
Rotor and Bearing assembly onto the Front Head of the
compressor. Be sure to locate the clutch coil terminals in the
proper position.
15. Spin the Rotor and Pulley assembly to asure that the pulley
runs “in line.” If not, the mounting screws will have to be
loosened and the parts aligned.
16. When all screws are torqued in place, lock all mounting
screws in position by flattening the special washer against two
opposite sides of the hex head screw, using vise-grip pliers.
Form a portion of the lock washer down over the pulley rim
or over the Inertia Ring slot to secure the screws in place.
Do not move the screw heads from the torqued position. See
Fig. 1C1-25.
17. Install the Clutch Hub and Drive Plate as described in “R-4
Compressor Clutch Plate and Hub Asm.” Replacement
procedures.
18. Install the compressor drive belt and adjust for proper
tension.
19. Operate the air conditioning system to check for proper
operation.
MAJOR REPAIR PROCEDURES. R-4
COMPRESSOR
Service repair procedures to the Compressor Shaft Seal,
Pressure Relief Valve, or disassembly of the Internal
Compressor Cylinder and Shaft Assembly are considered
"MAJOR" SINCE THE REFRIGERATION SYSTEM MUST BE
COMPLETELY PURGED OF REFRIGERANT before proceeding
and/or because major internal operating and sealing
components of the compressor are being disassembled and
serviced.
When replacing the shaft seal assembly (see Fig. 1C1-28) or
pressure relief valve (see Fig. 1C 1-3) even if the compressor
remains on the vehicle during the operation, it will be necessary
to purge the system of refrigerant (see Section 1B1). Other than
clutch repair procedures, the same holds true for any disassembly
of the compressor.
If the compressor shell, front head or cylinder and shaft
assembly are to be serviced or replaced, the oil in the compressor
must be drained, measured and replaced. (See Section 1B1) to
determine addition of proper oil quantity to new assembly.
A clean workbench, preferably covered with a sheet of clean
paper, orderliness in the work area and a place for all parts being
removed and replaced is of great importance, as is the use of the
proper, clean service tools.
NOTICE:
Any attempt to use make-shift or inadequate
equipment may result in damage and/or improper
compressor operation.
All parts required for servicing the internal compressor are
protected by a preservation process and packaged in a manner
which will eliminate the necessity of cleaning, washing or flushing
of the parts. The parts can be used in the internal assembly just
as they are removed from the service package.
S e a l s a n d p r o t e c t i v e
p a c k a g i n g s h o u l d b e l e f t i n t a c t u n t i l j u s t p r i o r t o i n s t a l l a t i o n .
R-4 C O M P R E S S O R S H A F T S E A L
Seal Leak Detection
A shaft seal should not be changed because of an oil-line on
the hood insulator. The Seal is designed to seep some oil for
lubrication purposes. Only change a Shaft Seal when a leak is
detected by evidence of oil sprayed in large amounts and then only
after actual refrigerant leakage is found by using an approved leak
Detector such as J 23400 or equivalent.
Should an R-4 compressor shaft seal ever have to be replaced,
the accumulator in this R-4 system must also be removed from the
vehicle. The oil in the accumulator then must be drained, measured
and replaced according to the directions in Section 1B1 to
determine oil loss.
Remove (On Car)
1. “Discharge the Refrigerant System” according to the
direction in Section 1B1.
2. Loosen and reposition compressor in mounting brackets, if
necessary.
3. Remove Clutch Plate and Hub assembly from compressor as
described in Minor Repairs.
4. Remove the shaft seal seat retainer ring, using Snap Ring
Pliers J 5403.
5. Thoroughly clean inside of compressor neck area
surrounding the shaft, the exposed portion of the seal seat and
tfce shaft itself. Any dirt or foreign material getting into
compressor may cause damage.
6. 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 (Fig. 1C1-26). Discard the Seat. The handle
must be hand-tightened securely. Do not use a wrench or
plier.
7. With Seal Protector J 22974 still over the end of the shaft,
set Seal Remover-Installer J 9392 down onto shaft end,
turning clockwise, while pressing down to engage Remover
Summary of Contents for 1982 Light Duty Truck
Page 1: ......
Page 28: ...HEATER 1A 3 Fig lA 2 Heater Control C K Models Fig lA 3 Heater Control G Models...
Page 37: ...Fig 1A 11 T E E V A L V E A S M TEE AND VALVE C36...
Page 38: ...HEATER 1A 13 Fig 1A l2 Distributor Ducts G Models Fig 1A l5 Control Assembly G Models...
Page 39: ...1A 14 HEATER V IE W A V IE W B Fig 1A l7 Control Cable Routing G Models...
Page 42: ...HEATER 1A 19 Fig 1A 23 Auxiliary Heater Hose Routing...
Page 56: ...AIR CONDITIONING IB 13 Chart 1B 4 Pressure Cycling CCOT System Diagnosis...
Page 64: ...Fig 1B 17 C60 System Vacuum Diagram C K Series...
Page 65: ......
Page 66: ...Fig 1B 19 C60 Motor Home Chassis Wiring Diagram SWITCH AIR CONDITIONING IB 2 3...
Page 67: ...IB 24 AIR CONDITIONING Fig IB 20 1 P A C Harness Wiring...
Page 68: ...AIR CONDITIONING IB 25 VIE W A Fig IB 21 A C Compressor wiring...
Page 76: ...AIR CONDITIONING IB 33 Fig 1B 26 Compressor Mounting...
Page 91: ...IB 48 AIR CONDITIONING Fig 1B 59 C K Models Refrigerant Lines L6...
Page 150: ......
Page 162: ......
Page 164: ...2D 2 BODY Fig 2D 4 Typical Utility Vehicle Model...
Page 182: ...2D 20 BODY Fig 2D 51 Rear Door Controls Fig 2D 52 Rear Door Outside Handle and Lock Cylinder...
Page 193: ...BODY 2D 31 BELTS 3RD SEAT Fig 2D 82 Seat Belt Installation Suburban Driver Seat Suburban...
Page 194: ...2D 32 BODY Fig 2D 85 Passenger s Bucket Seat Chassis Cab...
Page 195: ...BODY 2D 33 Fig 2D 88 Rear Bench Seats Suburban...
Page 196: ...2D 34 BODY Fig 2D 89 CK Utility Seat Attachments...
Page 197: ...BODY 2D 35 Fig 2D 90 Seat Separator Compartment and Door CK Models...
Page 222: ......
Page 223: ...BODY 2D 61 Fig 2D 139 Front Seat Belt Installation...
Page 228: ......
Page 234: ......
Page 252: ...3B2 8 MANUAL STEERING GEAR Fig 3B2 11 Manual Steering Gear Exploded View...
Page 256: ......
Page 273: ...POWER STEERING SYSTEM 3B3 17 with LE3 Engine Exc HC4 LE4 LG9 LF4 LS9 LT9 and JB7 HC4 and JB8...
Page 342: ......
Page 389: ...REAR SUSPENSION 3D 7 Fig 3D 17 Rear Spring Installation C K Models...
Page 428: ...4 B 1 4 REAR AXLE Fig 4B 8 Gear Tooth Nomenclature Fig 4B 9 G ear Tooth Contact Pattern Check...
Page 444: ......
Page 454: ......
Page 468: ...4 B 5 2 REAR AXLE Fig 4B5 2 Rockwell Assembly...
Page 480: ...4 B 5 1 4 REAR AXLE...
Page 482: ...i...
Page 502: ......
Page 520: ......
Page 533: ...Fig 5 5 Front Brake Pipes and Hoses C K Models BRAKES 5 13...
Page 534: ...Fig 5 6 Front Brake Pipes and Hoses G M odels 5 14 B R A K E S...
Page 535: ...Fig 5 7 Front Brake Pipes and Hoses P Models BRAKES 5 15...
Page 536: ...5 16 BRAKES Fig 5 8 Rear Brake Hoses...
Page 538: ...5 18 BRAKES Fig 5 10 Parking Brake System Typical...
Page 539: ...BRAKES 5 19...
Page 570: ...5 50 BRAKES Fig 5 57 Power Steering Hose Routing C K Models...
Page 571: ...BRAKES 5 51 Fig 5 58 Power Steering Hose Routing G Models...
Page 572: ...Fig 5 59 Power Steering H ose Routing P Models 5 52 BRAKES...
Page 577: ...BRAKES 5 57 4 CONT A SECONDARY DIAPHRAGM B SECONDARY POWER 4 CONT C PRIMARY D Fig 5 5A Service...
Page 604: ......
Page 625: ...NOTES ENGINE 6 21...
Page 626: ......
Page 629: ...IN LINE 6 6A1 3 OIL PRESSURE SENDING UNIT Fig 6A1 1 In Line Engine Lubrication...
Page 630: ...6A1 4 IN LINE 6 Fig 6 A l 2 P Series Engine Front Mount...
Page 631: ...IN LINE 6 6A1 5 Fig 6Al 3 P Series Engine Rear Mount Fig 6 A l 4 C Series Engine Rear Mounts...
Page 634: ...6A1 8 IN LINE 6 Fig 6Al 7 K Series Engine Rear Mount...
Page 660: ......
Page 663: ...SMALL BLOCK 6A4 3 Fig 6A4 T Engine Lubrication...
Page 664: ...6A4 4 SMALL BLOCK Fig 6A4 2 Engine Lubrication...
Page 665: ...Fig 6A4 3 P Series Engine Mount Bracket...
Page 667: ...SMALL BLOCK 6A4 7 Fig 6A 4 5 P Series Engine Front Mount...
Page 668: ...6A4 8 SMALL BLOCK...
Page 669: ...SMALL BLOCK 6A4 9 Fig 6A 4 7 K Series Engine Mounts...
Page 670: ...6A4 10 SMALL BLOCK Fig 6A 4 8 C Series Engine Mounts...
Page 703: ...MARK IV 6A5 7 Fig 6A 5 6 P Series Engine Front Mount...
Page 704: ...6A5 8 MARK IV Fig 6 A 5 7 C Series Engine Mounts...
Page 731: ...6 2 DIESEL 6A7 3...
Page 760: ...6B 6 ENGINE COOLING Fig 6B 7 A C and A I R Adjustment...
Page 771: ...ENGINE COOLING 6B 17 Fig 6B 20 Engine O il C o o le r 6 2L Diesel...
Page 784: ......
Page 807: ...CARBURETOR MODEL 2SE 6C2 9 Fig 6C2 6 Typical 2SE Carburetor Assembly...
Page 820: ......
Page 830: ...6C4 10 CARBURETOR MODEL M4ME M4MC 101368 Fig 6C4 12 M 4M C M 4M E Carburetor Exploded View...
Page 848: ......
Page 876: ......
Page 888: ...6D 12 ENGINE ELECTRICAL Fig 6D 6C Generator Mounting Fig 6D 7C Generator Mounting...
Page 919: ...ENGINE ELECTRICAL 6D 43...
Page 934: ...Fig 6D 8E Starter M otor Mounting...
Page 974: ......
Page 1011: ...Figure 350C 25A Neutral Engine Running AUTOMATIC TRANSMISSION 350C 11...
Page 1054: ...Fig 7A 1C 400 Autom atic Transmission Side Cross Section Typical...
Page 1152: ...700 R4 40 AUTOMATIC TRANSMISSION Figure 700 R4 76 Transmission Assembly Exploded View...
Page 1162: ......
Page 1189: ...89MM MANUAL TRANSMISSION 7B3 5 Fig 7 3 4 4 Speed 89mm Exploded View...
Page 1219: ...CLUTCH 7C 5 Fig 7C 6 C K Truck Clutch Controls...
Page 1220: ...Fig 7C 7 G Truck Clutch Controls...
Page 1221: ...CLUTCH 7C 7 Fig 7C 8 P Truck Clutch Controls...
Page 1234: ...7E 2 TRANSFER CASE Fig 7E 1 Model 208 Transfer Case Cross Section...
Page 1252: ...7E 20 TRANSFER CASE Fig 7E 39 Transfer Case Attachment Typical...
Page 1278: ...8A 16 ELECTRICAL BODY AND CHASSIS Fig 8A 11 License Plate Lamps C K Series...
Page 1280: ...8A 18 ELECTRICAL BODY AND CHASSIS VIEW A VIEW B Fig 8A 15 CK Series Rear Lamp W iring...
Page 1281: ...ELECTRICAL BODY AND CHASSIS 8A 19 Fig 8A 16 CK Series Auxiliary W iring...
Page 1290: ...8B 8 ELECTRICAL AND WIRING Fig 8B 13 Seat Belt Reminder System Schematic...
Page 1292: ......
Page 1346: ...8C 54 INSTRUMENT PANEL AND GAGES Fig 8C 46 CK Series W iring 3 of 29...
Page 1351: ...INSTRUMENT PANEL AND GAGES 8C 59 SUBURBAN Fig 8C 51 CK Series W iring 8 of 29...
Page 1364: ...8C 72 INSTRUMENT PANEL AND GAGES Fig 8C 64 CK Series W iring 21 of 29...
Page 1365: ...INSTRUMENT PANEL AND GAGES 8C 73 CAB CRFW CAB CHASSIS Fig 8C 65 CK Series W iring 22 of 29...
Page 1366: ...8C 74 INSTRUMENT PANEL AND GAGES Fig 8C 66 CK Series W iring 23 of 29...
Page 1374: ...8C 82 INSTRUMENT PANEL AND GAGES Fig 8C 74 G Series W iring 2 of 19...
Page 1375: ...INSTRUMENT PANEL AND GAGES 8C 83 Fig 8C 75 G Series W iring 3 of 19...
Page 1376: ...8C 84 INSTRUMENT PANEL AND GAGES Fig 8C 76 G Series W iring 4 of 19...
Page 1379: ...INSTRUMENT PANEL AND GAGES 8C 87 Fig 8C 79 G Series W iring 7 of 19...
Page 1383: ...INSTRUMENT PANEL AND GAGES 8C 91 Fig 8C 83 G Series W iring 11 o f 19...
Page 1384: ...8C 92 INSTRUMENT PANEL AND GAGES BUS BARGWO Fig 8C 84 G Series W iring 12 of 19...
Page 1390: ...8C 98 INSTRUMENT PANEL AND GAGES Fig 8C 90 G Series W iring 18 of 19...
Page 1391: ...INSTRUMENT PANEL AND GAGES 8C 99 Fig 8C 91 G Series W iring 19 of 19...
Page 1392: ...8C 100 INSTRUMENT PANEL AND GAGES Fig 8C 92 P Series W iring 1 of 11...
Page 1393: ...INSTRUMENT PANEL AND GAGES 8C 101 Fig 8C 93 P Series W iring 2 of 11...
Page 1396: ...8C 104 INSTRUMENT PANEL AND GAGES Fig 8C 96 P Series W iring 5 of 11...
Page 1399: ...INSTRUMENT PANEL AND GAGES 8C 107 Fig 8C 99 P Series W iring 8 of 11...
Page 1401: ...INSTRUMENT PANEL AND GAGES 8C 109 START RUN OF LOCK ACC Fig 8C 101 P Series W iring 10 of 11...
Page 1415: ...ACCESSORIES 9 13 RADIO NOISE BLOWER MOTOR Fig 9 6R Radio Diagnosis Chart B...
Page 1416: ...9 14 ACCESSORIES D E A D R A D IO A M R A D IO I Fig 9 7R Radio Diagnosis Chart C...
Page 1417: ...ACCESSORIES 9 15 DEAD RADIO AM FM RADIO Fig 9 8R Radio Diagnosis Chart D...
Page 1435: ...t f l i t 1...