1B3-14 R-4 AIR CONDITIONING COMPRESSOR
LEAK TESTING
Tools Required:
J 9625-A Pressure Test Set
J 5420 Straight Fitting
J 25008-A Holding Fixture
J 23500-01 Portable C harging Station
1. Install J 9625 on the rear head of the compressor.
2. Attach the center hose of the manifold gage set on the
charging station to a refrigerant drum standing in an
upright position and open the valve on the drum.
3. Connect the charging station high and low pressure
lines to corresponding fittings on J 9625-A, using
J 5420 if hoses are not equipped with valve depre
ssors.
• Suction port (low-side) of the com pressor has a
large internal opening. The discharge port (hi-
side) has a sm aller internal opening into the
compressor.
4. Open the low-pressure control, high-pressure control
and refrigerant control on the charging station to
allow refrigerant vapor to flow into the compressor.
5. Using a leak detector, check for leaks at the pressure
relief valve, com pressor shell to cylinder, com pressor
front head seal, and com pressor shaft seal. After
checking, shut off the low pressure control and high
pressure control on the charging station.
6. If an external leak is present, perform the necessary
corrective measures and recheck for leaks to make
certain the leak has been corrected.
7. Loosen the m a n ifo ld g age hose c o n n e c tio n s to
J 5420 connected to the low and high sides and allow
the vapor pressure to release from the compressor.
8. Disconnect J 5420 from J 9625-A.
9. Rotate the com plete com pressor assem bly (not the
crankshaft or drive plate hub) slowly several turns to
distribute oil to all cylinder and piston areas.
10. Install a shaft nut on the com pressor crankshaft if the
drive plate and clutch assem bly are not installed.
11. Using a box-end wrench or socket and handle, rotate
the com pressor crankshaft or clutch drive plate on the
crankshaft several turns to ensure piston assembly to
cylinder wall lubrication.
12. Connect the charging station high pressure line or a
high pressure gage and J 5420 to J 9625-A high side
connector.
13. Attach J 5420 to the suction or low pressure port of
J 9625-A to open the Schrader-type valve.
Oil will drain out of the com pressor suction port
adapter if the com pressor is positioned with the suc
tion port downward.
14. Attach the com pressor to J 25008-A using metric
mounting screws. Clamp the com pressor holding fix
ture in a vise so that the com pressor can be m anually
turned with a wrench.
15. Using a wrench, rotate the com pressor crankshaft or
drive plate hub 10 com plete revolutions at a speed of
approxim ately one-revolution per second.
Turning the com pressor at less than one-revolution
per second can result in a lower pum p-up pressure
and disqualify a good pum ping com pressor.
16. Observe the reading on HIGH pressure gage at the
completion of the tenth revolution of the compressor.
The pressure reading for a good pum ping com pres
sor should be 344.75 kPa (50 psi) or above. A pres
sure reading of less than 310.275 kPa (45 psi) would
indicate one or more suction and/or discharge valves
leaking, an internal leak or an inoperative valve, and
th e c o m p re s s o r s h o u ld be d is a s s e m b le d and
checked for cause of leak. Repair as needed, re
assemble and repeat the pum p-up test. Externally
leak test.
17. W hen the p re ssure pum p-up te s t is co m p le te d ,
release the air pressure from the HIGH side and
remove J 5420 and J 9625-A.
18. On the R-4 compressor, tilt the com pressor so that
the com pressor suction and discharge ports are
down. Drain the oil from the compressor.
19. Allow the com pressor to drain for 10 minutes, then
charge with the proper am ount of oil. The oil may be
poured into the suction port.
If further assembly or processing is required, a ship
ping plate or J 9625-A should be installed to keep out
air, dirt and m oisture until the com pressor is installed.
Summary of Contents for 1989 Light Duty Truck
Page 1: ...vr V Light Duty Truck Unit Repair Manual...
Page 2: ......
Page 11: ...GENERAL INFORMATION OA 5 Figure 8 RV Models...
Page 13: ...GENERAL INFORMATION OA 7 Figure 11 ST Models...
Page 18: ......
Page 44: ......
Page 76: ...1B3 18 R 4 AIR CONDITIONING COMPRESSOR N...
Page 114: ......
Page 162: ......
Page 176: ...4B3 14 91 2 INCH RING GEAR...
Page 192: ...4B5 4 DANA REAR AXLES Figure 4 Spreading the Differential Case Figure 7 Removing the Ring Gear...
Page 218: ......
Page 220: ...4B6 2 12 INCH RING GEAR ROCKWELL F 04734 Figure 1 Rear Axle Components...
Page 229: ...12 INCH RING GEAR ROCKWELL 4B6 11 SPECIAL TOOLS Special Tools...
Page 230: ...4B6 12 12 INCH RING...
Page 240: ...4B7 10 LOCKING DIFFERENTIALS SPECIAL TOOLS Special Tools...
Page 260: ...4C2 6 93 4 INCH RING GEAR FRONT AXLE Figure 16 Removing the Pinion Inner Bearing...
Page 273: ...T TRUCK FRONT AXLE 4C3 3 F 05785 Figure 1 Axle Components...
Page 291: ...K TRUCK FRONT AXLE 4C4 3 Figure 1 Front Axle Com ponents K 15 25 Models...
Page 293: ...K TRUCK FRONT AXLE 4C4 5 Figure 3 Front Axle Com ponents K35 Models...
Page 318: ...C4 30 K TRUCK FBOHT AXLE...
Page 334: ......
Page 361: ...2 5 LITER L4 ENGINE 6A1 5 Figure 3 Cylinder Head Manifolds and Components...
Page 363: ...2 5 LITER L4 ENGINE 6A1 7 F 05715 Figure 5 Block and Components...
Page 395: ...2 8 LITER V 6 6A2 3 Figure 1 Engine Lubrication Diagram...
Page 396: ...6A2 4 2 8 LITER V 6 Figure 2 Engine Lubrication Diagram...
Page 424: ...6A2 32 2 8 LITER V 6...
Page 427: ...I 4 3 LITER V 6 6A3 3 Figure 1 Engine Lubrication Diagram B 07857...
Page 451: ...4 3 LITER V 6 6A3 27 SPECIFICATIONS ENGINE SPECIFICATIONS F 6344...
Page 457: ...4 8 LITER L6 6A4 3 Figure 2 Lubrication Diagram Front View...
Page 460: ...6A4 6 4 8 LITER L6 C 1 107 112 fK 108 3 109 165 129 B 05056 Figure 5 Block and Components...
Page 490: ...Ml...
Page 493: ...V8 ENGINE 6A5 3 Figure 1 Lubrication Diagram 5 0L and 5 7L Engines...
Page 494: ...6A5 4 V8 ENGINE Figure 2 Lubrication Diagram 5 0L and 5 7L Engines...
Page 530: ...6A5 40 V8 ENGINE Figure 81 Exhaust Manifold 7 4L Engines Figure 82 Water Pumps and Components...
Page 571: ...6 2 LITER DIESEL 6A7 35 Figure 58 Vacuum Pump Installed...
Page 576: ......
Page 582: ...6C1 6 MODEL 1MEF CARBURETOR Figure 9 Monojet Model 1MEF...
Page 604: ...6C2 6 MODEL M4MEF CARBURETOR Figure 9 Model M4MEF...
Page 640: ...6C4 8 MODEL 700 THROTTLE BODY...
Page 652: ...nmm...
Page 672: ......
Page 693: ...DISTRIBUTORS 6D5 13 Figure 27 Testing the Pickup Coil Figure 28 Testing the Ignition Coil...
Page 696: ......
Page 698: ...7A1 2 700 R4 AUTOMATIC TRANSMISSION Figure 1 Case and External Parts J H 0 0 5 3 7 0 0 R 4 R 2...
Page 745: ...700 R4 AUTOMATIC TRANSMISSION 7A1 49...
Page 762: ...7A2 2 400 475 AUTOMATIC TRANSMISSION Figure 1 Case and External Parts H H 0021 400 R 3...
Page 773: ...400 475 AUTOMATIC TRANSMISSION 7A2 13 Figure 29 Internal Parts H H 0 0 4 3 4 0 0 R 2...
Page 797: ...400 475 AUTOMATIC TRANSMISSION 7A2 37 Figure 93 Control Valve Assem bly...
Page 803: ...400 475 AUTOMATIC TRANSMISSION 7A2 43 Figure 104 Bushing Replacement Procedure...
Page 808: ...J c I i sal...
Page 838: ......
Page 840: ......
Page 842: ......
Page 850: ...7B1 12 HM 290 MANUAL TRANSMISSION J i t i a x V L...
Page 856: ...7B1 18 HM 290 MANUAL TRANSMISSION...
Page 892: ...7B1 54 HM 290 MANUAL TRANSMISSION Figure 93 Special Tools...
Page 897: ...HM 117 TRANSMISSION 7B2 5...
Page 901: ...HM 117 TRANSMISSION 7B2 9 B 05180 Figure 17 Installing the 1st and 2nd Synchronizer...
Page 912: ...20 HM...
Page 924: ...7B3 12 NEW PROCESS TRANSMISSION SPECIAL TOOLS...
Page 927: ...BORG WARNER TRANSMISSIONS 7B4 3 Figure 2 77 mm Transmission and Components...
Page 940: ...i ii iii m i in m i...
Page 944: ...7D1 4 TRANSFER CASE FO 5688 Figure 3 NP205 Transfer Case...
Page 952: ...7D1 12 TRANSFER CASE...
Page 963: ...NEW PROCESS 241 TRANSFER CASE 7D2 11 Figure 17 Oil Pump Pickup Screen Doweled Case Holes...
Page 964: ...7D2 12 NEW PROCESS 241 TRANSFER CASE Figure 18 NP 241 Transfer Case Cut Away...
Page 978: ......
Page 981: ...BORG WARNER 1370 TRANSFER CASE 7D4 3 J...
Page 992: ...7D4 14 BORG WARNER 1370 TRANSFER CASE Figure 26 Installing the Rear Output Yoke...
Page 993: ...BORG WARNER 1370 TRANSFER CASE 7D4 15 Figure 27 BW 1370 Transfer Case...
Page 997: ......
Page 998: ...X 8937...