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CONTROL SWITCHES
Figure 20
Remove or Disconnect
1.
R e c o v e r th e r e f r i g e r a n t .
2.
D i s c o n n e c t t h e e l e c t r i c a l c o n n e c t o r f r o m t h e s w i t c h in
t h e r e a r h e a d o f c o m p r e s s o r .
3.
R e m o v e t h e s w i t c h r e t a i n i n g r i n g u s i n g J 5 4 0 3 i n te r n a l
s n a p r i n g p lie rs .
4.
R e m o v e th e s w i t c h f r o m th e c o m p r e s s o r .
5.
R e m o v e o l d O - r i n g se al f r o m t h e s w i t c h c a v i t y u s i n g
J 9 5 5 3 - 0 1 O - r i n g r e m o v a l to o l.
I f e x i s t i n g c o n t r o l s w i t c h is r e i n s t a l l e d in t h e c o m p r e s s o r ,
a n e w O - r i n g se al m u s t b e u s e d a n d p r e f e r a b l y a n e w r e t a i n e r
r i n g s h o u l d a l s o b e u s e d . A n e w s w i t c h kit h a s th e O - r i n g a n d
r e t a i n e r r i n g i n c l u d e d .
2
.
3.
Install or Connect
C h e c k s w i t c h c a v i t y a n d O - r i n g g r o o v e in th e r e a r h e a d
f o r d irt o r f o r e i g n m a t e r i a l a n d c l e a n a s n e c e s s a r y . I n s ta ll
a n e w O - r i n g c o a t e d w i t h c l e a n r e f r i g e r a n t oil in to
g r o o v e in s w i t c h c av ity .
L u b r i c a t e
th e
c o n t r o l
s w i t c h
h o u s i n g
w i t h
c l e a n
r e f r i g e r a n t oil a n d c a r e f u l l y in s e r t s w i t c h i n to s w i t c h
c a v i t y un til s w i t c h b o t t o m s in cav ity .
U s i n g J 9 5 3 3 - 1 s n a p r i n g p l ie r s in stall s w i t c h r e t a i n i n g
r i n g w i t h h i g h p o i n t o f c u r v e d s i d e s a d j a c e n t to s w i t c h
h o u s i n g . Be s u r e r e t a i n i n g r i n g is p r o p e r l y s e a t e d in
s w i t c h c a v i t y r e t a i n i n g g r o o v e . L e a k tes t a c c o r d i n g to
b e n c h tes t p r o c e d u r e .
COMPRESSOR LEAK TESTING
(EXTERNAL AND INTERNAL)
Bench-Check Procedure
1.
I n s t a ll tes t p l a t e J 3 9 8 9 3 o n r e a r h e a d o f c o m p r e s s o r .
2.
U s i n g J 3 9 5 0 0 - G M R e f r i g e r a n t R e c o v e r y S y s t e m , a t t a c h
c e n t e r h o s e o f m a n i f o l d g a g e se t o n c h a r g i n g s t a t i o n to a
r e f r i g e r a n t d r u m s t a n d i n g in a n u p r i g h t d r u m .
3.
C o n n e c t c h a r g i n g s t a ti o n h i g h a n d l o w p r e s s u r e lin e s to
c o r r e s p o n d i n g f i tt i n g s o n tes t p l a t e J 3 9 8 9 3 . S u c t i o n p o r t
( l o w - s i d e ) o f c o m p r e s s o r h a s l a r g e in te r n a l o p e n i n g .
D i s c h a r g e p o r t ( h i g h - s i d e ) h a s s m a l l e r in te r n a l o p e n i n g
i n t o c o m p r e s s o r a n d d e e p e r r e c e s s .
4.
O p e n l o w p r e s s u r e c o n t r o l , h i g h p r e s s u r e c o n t r o l a n d
r e f r i g e r a n t
c o n t r o l
o n
c h a r g i n g
s t a ti o n
to
a l l o w
r e f r i g e r a n t v a p o r to H o w in to c o m p r e s s o r .
5.
U s i n g a l e a k d e t e c t o r , c h e c k f o r l e a k s at p r e s s u r e r e l i e f
v a l v e , r e a r h e a d s w i t c h l o c a t i o n , c o m p r e s s o r f r o n t a n d
r e a r h e a d s e a ls , c e n t e r c y l i n d e r se a l, t h r o u g h b o lt h e a d
g a s k e t s a n d c o m p r e s s o r s h a f t se a l. A f t e r c h e c k i n g , s h u t
o f f l o w p r e s s u r e c o n t r o l a n d h i g h - p r e s s u r e c o n t r o l o n
c h a r g i n g s t a tio n .
6.
If an e x te r n a l lea k is p r e s e n t , p e r f o r m th e n e c e s s a r y
c o r r e c t i v e m e a s u r e s a n d r e c h e c k f o r l e a k s t o m a k e
c e r t a i n th e leak h a s b e e n c o r r e c t e d .
7.
R e c o v e r th e r e f r i g e r a n t .
8.
D i s c o n n e c t b o th h o s e s f r o m t h e tes t p l a t e J 3 9 8 9 3 .
9.
A d d 9 0 m l (3 o z .) n e w P A G l u b r i c a n t to t h e c o m p r e s s o r
a s s e m b ly . R o t a t e t h e c o m p l e t e c o m p r e s s o r a s s e m b l y
(n o t th e c r a n k s h a f t o r d r i v e p l a t e h u b ) s l o w l y s e v e r a l
tu r n s to d i s t r ib u t e oil to all c y l i n d e r a n d p i s t o n a r e a s .
10.
Install a M 9 x 1.25 t h r e a d e d n u t o n t h e c o m p r e s s o r
c r a n k s h a f t if th e d r i v e p l a t e a n d c l u t c h a s s e m b l y a r e n o t
i n stalled .
11.
U s i n g a b o x - e n d w r e n c h o r s o c k e t a n d h a n d l e , r o t a t e th e
c o m p r e s s o r c r a n k s h a f t o r c l u t c h d r i v e p l a t e o n th e
c r a n k s h a f t s e v e r a l t u r n s to i n s u r e p i s t o n a s s e m b l y to
c y l i n d e r wall l u b r ic a t i o n .
12.
U s in g J
3 9 5 0 0 - G M
R e f r i g e r a n t
R e c o v e r y S y s t e m ,
c o n n e c t th e c h a r g i n g s t a ti o n h i g h - p r e s s u r e lin e to th e
h i g h - s i d e p r e s s u r e p o r t o f th e tes t p l a t e J 3 9 8 9 3 .
13.
U s in g
J 3 9 5 0 0 - G M
R e f r i g e r a n t
R e c o v e r y
S y s t e m ,
c o n n e c t th e c h a r g i n g s t a ti o n l o w - p r e s s u r e lin e to t h e l o w
p r e s s u r e p o rt o f t h e tes t p l a t e J 3 9 8 9 3 . O il w ill d r a i n o u t
o f th e c o m p r e s s o r s u c t i o n p o r t if t h e c o m p r e s s o r is
p o s i t i o n e d w ith th e s u c t i o n p o r t d o w n w a r d .
14.
A t t a c h th e c o m p r e s s o r to t h e J 3 3 0 2 6 h o l d i n g f i x tu r e a n d
m o u n t th e c o m p r e s s o r in a v is e s o t h a t t h e c o m p r e s s o r
w ill b e in a h o r i z o n t a l p o s i t i o n a n d t h e s h a f t c a n b e
t u r n e d w i t h a w r e n c h .
15.
U s in g a w r e n c h , r o t a t e th e c o m p r e s s o r c r a n k s h a f t o r
d r i v e p late h u b te n c o m p l e t e r e v o l u t i o n s at a s p e e d o f
a p p r o x i m a t e l y o n e - r e v o l u t i o n p e r s e c o n d . T u r n i n g th e
c o m p r e s s o r at les s t h a n o n e - r e v o l u t i o n p e r s e c o n d c a n
re su lt in a l o w e r p u m p - u p p r e s s u r e a n d d i s q u a l i f y a g o o d
p u m p i n g c o m p r e s s o r .
16.
O b s e r v e th e r e a d i n g o n h i g h - p r e s s u r e g a g e at th e
c o m p l e t i o n o f th e t e n t h r e v o l u t i o n o f th e c o m p r e s s o r .
T h e p r e s s u r e r e a d i n g f o r a g o o d p u m p i n g c o m p r e s s o r
s h o u l d be 6 9 0 k P a ( 1 0 0 p s i) o r a b o v e . A p r e s s u r e r e a d i n g
o f less t h a n 6 2 0 k P a ( 9 0 p s i) w o u l d i n d i c a t e o n e o r m o r e
s u c t io n a n d / o r d i s c h a r g e v a l v e s l e a k i n g a n i n t e r n a l lea k ,
o r an i n o p e r a t i v e v a l v e , a n d t h e r e f r i g e r a n t m u s t b e
r e c o v e r e d
a n d
t h e
c o m p r e s s o r
d i s a s s e m b l e d
a n d
c h e c k e d fo r c a u s e o f lea k . R e p a i r a s n e e d e d , r e a s s e m b l e
a n d re p e a t the p u m p - u p te st. E x t e r n a l l y le a k te st.
17.
W h e n th e p r e s s u r e p u m p - u p t e s t is c o m p l e t e d , r e c o v e r
the r e f r i g e r a n t f r o m th e h i g h - s i d e a n d r e m o v e t h e tes t
p late J 3 9 8 9 3 .
18.
Tilt th e c o m p r e s s o r s o th a t t h e c o m p r e s s o r s u c t i o n a n d
d i s c h a r g e p o r t s a r e d o w n . D r a i n t h e P A G l u b r i c a n t f r o m
th e c o m p r e s s o r .
19.
A l l o w th e c o m p r e s s o r to d r a i n f o r 10 m i n u t e s , t h e n refill
w ith th e p r o p e r a m o u n t o f P A G l u b r i c a n t , p e r oil b a l a n c e
p r o c e d u r e in s e c ti o n 1 B o f t h e s e r v i c e m a n u a l . T h e P A G
lu b r ic a n t m a y be p o u r e d in to t h e s u c t i o n p o rt. I f f u r t h e r
a s s e m b l y o r p r o c e s s i n g is r e q u i r e d , a s h i p p i n g p l a t e o r
tes t p late J 3 9 8 9 3 s h o u l d b e i n s t a l l e d to k e e p o u t air, dirt
a n d m o i s t u r e until th e c o m p r e s s o r is in s t a l l e d .
Summary of Contents for S Series 1994
Page 1: ......
Page 11: ...VIEW A p n n n j VIEW C F7554 Figure 10 Hydra Matic 4L60 E Transmission I D Location...
Page 24: ...NOTES...
Page 26: ......
Page 69: ...NOTES...
Page 71: ...3 2 STEERING...
Page 73: ......
Page 84: ......
Page 102: ...40...
Page 130: ...NOTES...
Page 146: ...NOTES...
Page 162: ...NOTES...
Page 166: ...Figure 5 Removing the Pinion Flange Figure 6 Pressing the Drive Pinion from the Cage...
Page 178: ...Figure 3 Spreading the Differential Case Figure 4 Removing the Differential...
Page 190: ...NOTES...
Page 202: ...NOTES...
Page 206: ...F5785...
Page 212: ...B Button Moved Out of Bearing Bore F5791...
Page 228: ...NOTES...
Page 232: ......
Page 234: ......
Page 236: ...Adjuster 63 Bolt 64 Lock Figure 10 Turning the Adjuster Plug K3 Models...
Page 237: ...Figure 13 Removing the Pinion Seal 39 Bearing Cup Figure 16 Removing the Inner Bearing Cap...
Page 261: ...F7475...
Page 267: ...B Button Moved Out of Bearing Bore F5791...
Page 294: ...NOTES...
Page 300: ...NOTES...
Page 318: ...NOTES...
Page 322: ...SR207LN2 EDS...
Page 324: ......
Page 326: ...OVERHEAD OILING AND RETURN MAIN OIL GALLERY N30005 6A2 J EDS...
Page 368: ...103 153 127 V1200...
Page 370: ......
Page 372: ......
Page 374: ...F9375 Figure 7 Engine Lubrication Diagram Engines Without Balance Shaft...
Page 376: ...Figure 9 Engine Lubrication Diagram Engines With Balance Shaft...
Page 399: ...V2974...
Page 410: ......
Page 412: ...195 196 201 174 252 163 165 164 244 3706r3924...
Page 452: ......
Page 454: ...163 164 V1202...
Page 456: ...20 21x 302 210 4 0 41 2 5 2 5 1 2 51 4 2 e3 54 3 9 252 252 S 255 255 25 6 256 209 V1196...
Page 458: ...100 1 8 4 185 183 177 v 75 201 3706r1204...
Page 460: ......
Page 510: ......
Page 512: ...V2131...
Page 514: ...110 106 106 103 90 93 89 88 87 86 v 7 7 7 7 j A _ 111 f t 2 a a s 53 49 L 47 46 3706r4751...
Page 516: ...259 260 150 237 S lM 180 167180 J 1 82 183 170 169 1 1 78 1 7 9 213212 2 0 7 205 r i 3706r4752...
Page 566: ...NOTES...
Page 574: ...NOTES...
Page 618: ...SPECIAL TOOLS...
Page 620: ...NOTES...
Page 672: ......
Page 682: ......
Page 686: ......
Page 694: ...RH0213 4L60 E...
Page 695: ...657 659 m i J 8092 H J 34196 4 3 34196 5 657 658 665 J 23907 J 7004 1 J 8092 RH0214 4L60 E...
Page 696: ...J 8092 J 34196 4 33 31 J 8092 RH0215 4L60 E...
Page 697: ...SPECIAL TOOLS...
Page 698: ...SPECIAL TOOLS...
Page 758: ...RH0194 4L80 E...
Page 764: ......
Page 770: ...SPECIAL TOOLS...
Page 771: ...SPECIAL TOOLS CONT...
Page 772: ......
Page 775: ......
Page 776: ......
Page 785: ......
Page 804: ...NOTES...
Page 806: ......
Page 808: ......
Page 822: ...3707r5079...
Page 840: ......
Page 848: ...NOTES...
Page 852: ......
Page 860: ...F5435...
Page 866: ......
Page 878: ...F9167...
Page 882: ...16 FrontOutputShaft 18 DrivtQNr 19 DrivenGm t 20 DriveChain 22 FrontOutputBearing V2836...
Page 890: ...F9168...
Page 908: ......
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