PONTIAC FIERO 1988 Service Manual Online

1 Dl-2 R-4 AIR CONDITIONING COMP
4 POLE CLUTCH-
SHORT SHAFT
1. COMPRESSOR SHELL 2. ROLL PINS 3. THRUST AND BELLEVILLE WASHER 4. MAlN BEARING-FRONT 5. CLUTCH COlL TERMINALS 6. PULLEY RIM 7. PULLEY RIM MOUNTING SCREW
AND LOCKWASHER
8. RmOR BEARING 9. ROTOR BEARING RETAINER
10. SEAL SEAT RETAINER
11. SHAFT KEY 12. SHAFT NUT 13. SHAFT SEAL 14. CLUTCH DRIVE ASSEMBLY 15. ROTOR AND HUB ASSEMBLY 16. CLUTCH COlL AND HOUSING
ASSEMBLY
17. SEAL SEAT O-RING 18. FRONT HEAD 19. VALVE PLATE ASEMBLY
20. VALVE PLATE RETAINING RING
21. SHELL RETAINER 22. PISTON ASSEMBLY 23. MAlN BEARING - REAR 24. SUCTION PORT
25. DISCHARGE PORT
Fig. 4 R-4 Compressor With Six-Pole Clutch
should then be discarded and the same
amount of new
525 viscosity refrigerant oil
added to the compressor (See Refrigerant Oil
Distribution" in
the Air Conditioning Section
1 B).
Fig. 2 R-4 Compressor Cross Section Shaft Design

R-4 AIR CONDITIONING COMPRESSOR OVERHAUL 101-3
1-RETAINER RlNG
2-SHAFT SEAL
4-O-RING, SEAL SEAT
%-SHAFT SEAL KIT
6-SCREW AND WASHER
ASSEMBLY FRONT
HEAD MOUNTING
7-FRONT HEAD
8-MAIN BEARING
9-RING SEAL, FRONT
HEAD TO CYLINDER
11-O-RING, CYLINDER
TO SHELL
12-TH RUST WASHER
13-BELLEVILLE WASHER
14-THRUST WASHER KIT
15-CYLINDER AND SHAFT
ASSEMBLY
16-RETAINER RlNG
17-VALVE PLATE
18-SHIPPING PLATE
19-SCREW
20-O-RING
SUCTION-
DISCHARGE PORTS
21-PRESSURE RELIEF
VALVE
22-O-RING, PRESSURE
RELIEF VALVE
23-SHAFT NUT
24-CLUTCH HUB KEY
25-CLUTCH DRIVE
ASSEMBLY
26-RETAINER RlNG
27-ROTOR
28-ROTOR BEARING
29-ROTOR AND BEARING
ASSEMBLY
*
30-COIL AND HOUSING
ASSEMBLY
31-PULLEY RIM MOUNT-
ING SCREW
32-PULLEY RIM
I
Fig. 5 8-4 Compressor Disassembled View

181-4 R-4 ABR CONDITIONING COMPRESSOR OVERHAUL
SERVICE PROCEDURES
MINOR REPAIR PROCEDURES
THE FOLLOWING OPERATIONS TO THE
R-4 COMPRESSOR CLUTCH PLATE AND 1 -SUCTION
HUB, ROTOR AND BEARING, AND COIL &
PULLEY RIM ARE COVERED AS 'WINOR" 3-DISCHARGE
BECAUSE THEY MAY BE PERFORMED
WITHOUT FIRST DISCHARGING THE
SYSTEM OR REMOVING THE
COMPRESSOR FROM THE VEHICLE. 5-~-25008-~
The two types of drive systems used on the R-4
Compressor (\I-groove type and poly-groove type)
affect only minor repair procedures and are so noted
where required. Major repair procedures are not
Fig. 6 Compressor In Holding Fixture affected by the type of drive system.
The Shaft and 2. Keep the clutch hub from turning with the
Pressure Relief Valve may also be serviced WITHOUT
REMOVING THE COMPRESSOR from the vehicle Clutch
Hub Holding Tool 5-25030/J-33027
remove, and discard the shaft nut, using Thin
but these operations are covered later in this section as
MAJOR REPAIR PROCEDURES because the Wall Socket
5-9399.
system must be discharged, evacuated and recharged
to complete service.
Illustrations used in describing these operations
show the compressor removed from the vehicle only to
more clearly illustrate the various operations.
CLUTCH HUB
When servicing the compressor, remove only the
necessary components that preliminary diagnosis
indicates are in need of service. Refer to the AIR
CONDITIONING section and Fig.
4 and Fig. 5 for
information relative to parts nomenclature and
location.
Removal and installation of external compressor
components and disassembly and assembly of internal
components must be performed on a clean workbench.
The work area, tools and parts must be kept clean at
all times.
CLUTCH PLATE AND HUB ASSEMBLY Fig. 7 Removing Shaft Nut Fig. 6 thru 10
CLUTCH PLATE AND HUB ASSEMBLY 3. Thread the Clutch Plate and Hub Assembly INSTALLATION AND REMOVAL Remover 5-33013-I3 into the hub. Hold the body
PROCEDURES FOR THE SIX-POLE of the Remover with a wrench and turn the center
CLUTCH ARE THE SAME AS THE screw into the Remover body to remove the
FOUR-POLE CLUTCH WITH THE Clutch Plate and Hub assembly.
EXCEPTION OF THE CLUTCH HUB
HOLDING TOOL. FOR FOUR-POLE 4. Shaft key
CLUTCH USE J-25030. FOR SIX-POLE
CLUTCH USE J-33027. Install or Connect
a Remove or Disconnect 1. Shaft key in hub key groove. Allow the key to
project approximately
4.8mm (3/16") out of
1. If compressor is on the car, loosen compressor keyway.
mounting brackets, disconnect the compressor
The shaft key is curved slightly to provide an
drive belt and reposition the compressor for
interference fit in the shaft key groove of the hub.
access, if necessary. If compressor has been
removed from the car, attach the compressor to 2. Be Sure the frictional surface of the clutch plate
Holding Fixture
J-'25008-8 and clamp the and
the clutch rotor are clean before installing the
Holding Fixture
in a vise. Clutch
Plate and Hub assembly.
Compressor mounting holes are metric. Use 3.
Align the shaft key with the shaft keyway and
proper metric bolts with holding fixture place the Clutch Plate and Hub assembly onto the
J-25008-A. compressor shaft.

R-4 AIR CONDITIONING COMPRESSOR - OVERHAUL 1 Dl-5
J-33013-8 HUB AND CLUTCH PLATE AND
CLUTCH DRIVE PLATE HUB ASSEMBLY
ASSEMBLY REMOVER
H60070-1 Dl-D
Fig. 8 Clutch Plate And Hub Assembly Removal
1-CLUTCH PLATE AND HUB
ASSEMBLY
2-CLUTCH ROTOR
3-SHAFT KEY
Fig.
9 Installing Shaft Key
NOTICE: To avoid internal damage to the
compressor, do not drive or pound on the clutch
hub or shaft.
4. Install the Clutch Plate and Hub Installer
J-9480-B.
5. Hold the hex portion of the Installer Body
J-9480-B with a wrench and tighten the center
screw to press the, hub onto the shaft until there
is
a .5mm - l.Omm (.020"-.040") inch air gap
between the frictional surfaces of the clutch plate
and clutch rotor.
6. Install a new shaft nut with the small diameter
boss of the nut against the crankshaft shoulder,
using Thin Wall Socket J-9399. Hold the Clutch
Plate and Hub assembly with Clutch Hub
Holding Tool
J-25030/J-33027 and tighten to 14
N-m (10 lb. ft.) torque, using a 0-60 N-m (0-25
1b.ft.) torque wrench.
7. If operation is performed with compressor on car,
connect drive belt, tighten mounting brackets and
adjust belt tension.
1-DRIVE PLATE
INSTALLER
J-9480-B
2-DRIVE PLATE
INSTALLER
BEARING
3-AIR GAP
(.02OU-.040")
4-CLUTCH PLATE
AND HUB ASM.
Fig.
10 Installing Clutch Plate & Hub Asm.
CLUTCH ROTOR AND BEARING:FOUR POLE
CLUTCH
Fig. 11 thru 28
Remove or Disconnect
1. Clutch Plate and Hub assembly
2. Rotor and Bearing assembly retaining ring, using
Snap Ring Pliers J-6083. Mark the location of the
clutch coil terminals.
Fig. 11 Removing Rotor & Bearing Asm. Retainer Ring
If only the Clutch Rotor and/or Rotor Bearing
are to be replaced, bend the lockwashers away
from the pulley rim mounting screws, andremove
the six mounting screws and special lock washers
before proceeding with Step 3. Discard the lock
washers.
3. Install Rotor and Bearing Puller
5-25031 down
into the rotor until the Puller arms engage the
recessed edge of the rotor hub. Hold the Puller
and arms in place and tighten the Puller screw
against the Puller Guide to remove the Clutch

1 D1-6 R-4 AIR CONDITIONING COMPRESSOR OVERHAUL
I-J 25031
ROTOR AND
BEARING
PULLER
GUIDE
2-PULLEY ARM
3-PULLEY RIM SCREW AND
LOCKWASHER
(6) LOCATIONS
Fig.
12 Installing Rotor & Bearing Puller Guide
Rotor and Bearing assembly, being careful not to
drop the Puller Guide.
1 -J-2503 1 ROTOR
AND BEARING
PULLER
2-J-25031 GUIDE
Fig.
13 Removing Clutch Rotor Asm.
4. If
the pulley rim mounting screws and washers
were removed in Step 2, only the Clutch Rotor
and Bearing assembly will be removed for
replacement. The Clutch Coil and Housing
assembly is pressed onto the Front Head of the
compressor and will not be removed unless the
pulley rim mounting screws are left securely in
place and the pulley rim pulls the Coil and
Housing assembly off with the total Clutch Rotor
and Pulley Rim Assembly.
5. Place the Rotor and Bearing assembly on blocks.
Drive the bearing out of the rotor hub with Rotor
Bearing Remover
J-9398-A.
It is not necessary to remove the staking at the
rear of the rotor hub to remove the bearing. However,
it will be necessary to file away the old stake metal for
proper clearance for the new bearing to be installed
into the rotor bore, or the bearing may be damaged.
1 -J-29886
2-J-9398-8
REMOVER
Fig.
14 Clutch Rotor Bearing Removal
Fig.
15 Rotor & Bearing Asm.
Install or Connect
1. Place the Rotor and Hub assembly face down on
a clean, flat and firm surface.
2. Align
the new bearing squarely with the hub bore
and using Pulley and Bearing Installer
5-9481-A
with Universal Handle 5-29886, drive the bearing
fully into the hub. The Installer will apply force
to the outer race of the bearing if used as shown.
3. Using
a center punch with
a 45" angle point, stake
1.1
- 1.4mm (.045"-.055" deep) the bearing in
three places 120" apart, but do not stake too
deeply to avoid distorting the outer race of the
bearing.
4. Replace
rotor and bearing assembly.
On Car
A. Position the Rotor and Bearing assembly on
the front head.
B. With Rotor
& Bearing Installer J-26271-A
(without driver handle) in position and
Rotor and Bearing assembly aligned with
the Front Head, drive the assembly part
way onto the head.
C. Plug clutch coil connector onto Clutch Coil.
D. Position the Clutch Coil so the three
locating tabs will
align with the holes in the
head and continue to drive the Rotor and
Bearing assembly onto the front head.

R-4 AIR CONDITIONING COMPRESSOR OVERHAUL 1B1-7
I
1-J-29886 DRIVER
HANDLE
2-J-9481 -A PULLEY BEARING AND
PULLEY INSTALLER
3-ROTOR BEARING
I
4-ROTOR AND
HUB ASM.
Fig.
16 Installing Clutch Rotor Bearing
Fig.
17 Installing Rotor and Bearing Asrn. (On Car)
E. Install the retainer ring.
F. Reassemble the Clutch Plate and Hub with
the shaft key onto the shaft with Installer
J-9480-B until .5 to l.Omm (.020" to ,040")
air gap is obtained.
G. Install shaft lock nut. Torque to 14 N-m (10
lb. ft.).
On Bench
Reassemble the Rotor and Bearing assembly to
the front head of the compressor using Rotor
&
Bearing Installer J-26271-A. With Installer
assembled to the Universal Handle, J-29886,
force will be applied to the inner race of the
bearing and the face of the rotor when installing
the assembly onto the front head of the
compressor. 8.
Tighten pulley rim mounting screws to
11 N.m
(100 inch-pounds) torque and lock screw heads in
place by bending special lock washers, similar to
original crimp and lock bends on washers.
9. Reinstall Clutch Plate and Hub assembly as
described in "Clutch Plate and Hub"
Replacement procedures.
1 -J.25031
GUIDE
2-J-25031
ROTOR 81
BEARING
PULLER
3-POLY GROOVE
PULLEY
ROTOR
5. Install rotor and bearing assemblv retainer ring,
Fig. 19 Removing Clutch Rotor Asrn. - Poly-Groove
Drive
CLUTCH ROTOR AND EBEARING:SIX POLE
CLUTCH
Fig. 2 1 thru 28
I Remove or Disconnect -. using Snap Ring Pliers j-6083. I
1. Clutch plate hub assembly 6. Apply sealer (Loctite RC-75, Loctite 601 or 2. Rotor and bearing assembly retaining ring using equivalent) to threads of pulley rim mounting
Snap Ring Pliers 5-6083 screws. Instal1 screws and new 'pecial lock 3.
Install Pulley Rotor and Puller Guide J-2503 1 to
washers but do not torque the screws.
the front head and install
5-33020 Pulley Rotor
7. Rotate the pulley rim and rotor to insure that and Bearing Puller down into the inner circle of
pulley rim is rotating "in-line." If pulley rim is slots in the rotor. Turn the J-33020 puller
distorted (does not rotate in-line), adjust or clockwise in the slots to engage the puller tangs
replace pulley rim.
with the segments between the slots in the rotor.

1 -J-29886 DRIVER
HANDLE
2-J-26271-A ROTOR
& BEARING
ASSEMBLY
INSTALLER
Fig. 20 Installing Rotor
& Bearing Assembly,
Poly-Groove Type (On Bench)
4. Hold the J-33020 Puller in place and tighten the
puller screw against the Puller Guide to remove
the pulley rotor and bearing assembly.
5. To prevent damage to the pulley rotor during
bearing removal, the rotor hub must be properly
supported.
Remove the forcing screw from J-33020 Puller
and with the puller tangs still engage in the rotor
slots, invert the assembly onto a solid flat surface
or blocks.
Fig. 22 Pulley Rotor and Bearing Puller Installation
I 1-LATCH ASM 3-SPRING I 1 2-25 N-rn (18 LB.FT.1 4-HOOD ASM I
Fig. 23 Pulley Rotor and Bearing Removal
1 -CLUTCH
COl L
2-PULLEY BEARING
3-POLY GROOVE
PULLEY ROTOR
4-RETAINER 5-CLUTCH DRIVE
6-SHAFT KEY
7-SHAFT NUT

R-4 AIR CONDITIONING COMPRESSOR OVERHAUL 1D1-9
6. Drive the bearing out of the rotor hub with Rotor
Bearing Remover
J-9398-A and J-29886
Universal Handle.
It is not necessary to remove the staking in front
of the bearing, however, it will be necessary to file
away the old stake metal for proper clearance for
the new bearing to be installed into the rotor bore
or the bearing may be damaged.
DRIVER HANDLE
BEARING REMOVER
(LESS FORCING
SCREW) INVERT-
ED AND USED TO
SUPPORT HUB OF
ROTOR FOR BEAR-
ING REMOVAL
PULLER TANGS ENGAGED IN
ROTOR SLOTS.
Fig. 24 Bearing Removal
Install or Connect
1. Place the Pulley Rotor on the 5-2 1352-A Support
Block to fully support the rotor hub during
bearing installation.
Do not support the rotor by
resting the pulley rim on a flat surface during the
bearing installation or the rotor face will be bent.
2. Align the new bearing squarely with the hub bore
and using Puller and Bearing Installer
J-9481-A
with with Universal Handle 5-29886, drive the
bearing fully into the hub. The Installer will apply
force to the outer race of the bearing is used as
shown.
1 -J-9481 -A BEARING
INSTALLER
2-PULLEY ROTOR
3-J-29886 DRIVER
HANDLE
4-J-2
1352-8
SUPPORT BRACKET Fig.
26 Bearing Staking
3. Place Bearing Staking Guide J-33019-1 and
Bearing Staking Pin
5-33019-2 in the hub bore.
Shift the rotor and bearing assembly on the
J-21352-A Support Block to give full support of
the hub under the staking pin location. A heavy
duty rubber band may be used to hold the stake
pin in the guide, and the stake pin should be
properly position in the guide after each impact
on the pin.
STAKE THREE
(3) LOCATIONS
Fig. 27 Staking Location
4. Using care to prevent personal injury, strike the
staking pin with a hammer until a metal stake,
similar to the original, is formed down to, but not
touching, the bearing. Stake three places
120
degrees apart.
NOTICE: The stake metal should not contact the
outer race of the bearing to prevent the possibility
of distorting the outer race.
5. With the compressor mounted to the J-25008-A
Holding Fixture, position the Rotor and Bearing
Assembly on the front head. Using Rotor and
Bearing Installer
5-948 1-A and Universal Handle
J-29886 drive the rotor and bearing assembly
onto the front head. With the Installer assembled
to the Handle, force will be applied to the inner
race of the bearing when installing the assembly
onto the front head of the compressor.
6. Install rotor and bearing assembly retainer ring,
Fig. 25 Bearing Installation using Snap Ring Pliers J-6083.
7. Reinstall clutch plate and hub assembly as
described previously.

1191-"1 8-4 AIR CONDITIONING COMPRESSOR OVERHAL
CLUTCH COIL AND PULLEY RIM
Fig. 29 thru 34
Clutch coil and pulley rim installation
and removal procedures for the six-pole
clutch are the same as the four-pole clutch
with the exception of Steps
1 through 4 of
the
clutch rotor and/or bearing - Six-Pole
Clutch, removal or disconnect must
be used.
V-Groove Drive
Remove
or Disconnect
1. Perform Steps I through 4 of CLUTCH ROTOR
AND BEARING removal procedure but do not
loosen or remove the pulley rim mounting screws
until the Clutch Rotor, Coil and Pulley Rim
assembly have been removed from the Front
Head. Be careful not to drop the Puller Guide
5-2503 1 when removing the assembly.
2. Remove the pulley rim mounting screws and
special lock washers. Discard the lock washers
and screws.
3. Slide the pulley rim off the Rotor and Hub
assembly. The Pulley Rim and the Clutch Coil
are replaceable at this point.
FRONT SURFACE
Fig. 29 Clutch Coil Asm.
Poly-Groove Drive
Remove
or Disconnect
1. Clutch plate and hub assembly
2. Pulley rotor and bearing assemblyusly. Mark the
location of the clutch coil terminals on the
compressor.
3. Install Rotor and Bearing Puller Guide J-25031
to the front head and install Puller J-8433 with
Poly-V-Belt Puller Leg Set
5-24092 and remove
the clutch coil from the front head. Clutch coil
may also be removed by using rotor and bearing
puller guide
J-25031 with puller tool J-25287.
1 -J-24092 PULLER LEGS
2-J-8433 PULLER
3-J-25031 GUIDE
4-CLUTCH
COl L
Fig.
30 Removing Poly-Groove Clutch Coil
V-Groove Drive
Install or Connect
1. Assemble the Clutch Coil, Pulley Rim and the
Clutch Rotor and Bearing assembly. Use new
screws and special lock washers and apply sealer
(Loctite RC-75, Loctite
601, or equivalent) to
screw threads but do not lock the screws in place.
2. Place the assembly on the neck of the Front Head
and seat into place using Rotor
& Bearing
Installer
J-2627 1-A.
Before fully seating the assembly on the Front
Head, be sure the clutch coil terminals are in the
proper location in relation to the compressor and
that the three protrusions on the rear of the
clutch coil align with the locator holes in the
Front Head.

R-4 AIR 60NDlVlONBNG COMPRESSOR OVERHAUL l Dl-1 l
1-J-25287 CLUTCH COIL PULLER
2-5-25031 GUIDE
3-J-25Q88-A HOLDING F IXVUWE
4-CLUTCH COl b 520023.1 DI
Fig. 3 1 Removing Poly-Groove Clutch Coil (Optional
Method)
1-CLUTCH COIL AND HOUSING
ASM.
2-PULLEY
RIM
Fig. 32 Assembling Clutch Coil, Pulley Rim, Rotor & Bearing
3. Install the rotor and bearing assembly retaining
ring and reassemble the Clutch Plate and Hub
assenibly as described in "Clutch Plate and Hub
Assembly"
Repllacement procedure. Check to see
that the clutch plate to clutch rotor air gap is
.5
to l.Omm (.020 to .040 inches).
Rotate the Pulley Rim and Rotor to be sure the
Pulley Rim is rotating "in-line" and adjust or
replace as required.
4. Tighten the pulley rim mounting screws to 11
Nom (100 inch-pounds) torque and lock the
screw heads in place by bending lock washers
similar to original
crimp and lock bends on
washers.
Fig. 33 Pulley Rim Mounting Location Detail
Ill
1- MOUNTING NOTCHES
2- MOUNTING SLOTS
Fig.
34 Pulley Rim Mounting Location Detail - Optional
Design
Poly-Groove Drive
1. Place
the clutch coil assembly on the neck of the
front head with clutch coil terminals in line with
mark scribed in Step
2 of the removal procedure.
2. Place the pulley rotor and bearing assembly on
the neck of the front head and seat the clutch coil
and pulley rotor in place using Rotor and Bearing
Installer
J-2627 1 -A.
Before fully seating the assembly on the front
head, be sure the clutch coil terminals are in
proper location in relation to the compressor and
that the three protrusions on the rear of the
clutch coil housing align with the locator holes in
the front head.
3. Install the pulley-rotor and bearing assembly
retaining ring and reassemble the clutch plate and
hub assembly as described in "Clutch Plate and
Hub Assembly
- Replace."
Install or Gsns~eet 4. Check
to see that the clutch plate to clutch rotor
air gap is 0.5
- f.Omm (0.020" - 0.040").