A/c Compressor Servicing Chevrolet Chevy Van G10

HARRISON A-6 6-CYL CLUTCH R & I

Removal

1. Using Compressor Fixture (J-9396), mount compressor in a vise. Using Clutch Plate Spanner (J-25030), hold crankshaft and remove crankshaft nut. Using Clutch Plate Remover (J-9401), remove clutch plate. Remove clutch plate key. (Scheme 12)
2. Remove pulley assembly snap ring. Using Shaft Protector (J-9395) and commercial puller (if necessary), remove pulley assembly. Remove snap ring and disconnect electrical wiring at clutch coil.
3. Place reference marks on clutch coil and shell for reassembly reference. Using large screwdriver, pry clutch coil from shell. Use care as clutch coil is retained on shell with adhesive.

Installation

1. Ensure all adhesive is removed from shell and clutch coil. Apply trim detail adhesive on back of clutch coil around the coil locator protrusions.
2. Install clutch coil and snap ring. Ensure reference marks are aligned. Install pulley assembly and snap ring. Install clutch plate key in clutch plate, allowing key to protrude about 3/16" from rear of clutch plate.
3. Install clutch plate on compressor crankshaft. Using Clutch Plate Installer (J-9480-B), press clutch plate on compressor to achieve a clutch assembly clearance of .022-.057" (.56-1.34 mm). Using spanner, install nut and tighten to 20 ft. lbs. (27 N.m). Ensure components rotate freely.

Scheme 12

1. Remove clutch plate and shaft key. Pry out dust seal (if equipped). Remove seal seat snap ring.
2. Using Seal Seat Remover/Installer (J-23128-A) for ceramic type or (J-9393-A) for steel type, remove seal seat. Using Seal Remover (J-9553-01), remove "O" ring seal.
3. Using Shaft Seal Remover/Installer (J-9392-01), remove shaft seal by turning remover/installer slightly clockwise to disengage tangs and pull out shaft seal. Clean all surface areas.

1. Coat new shaft seal with refrigerant oil and install shaft seal on remover/installer. Align compressor shaft machine surface with shaft seal and install. Rotate shaft seal remover/installer slightly counterclockwise to secure shaft seal tangs.
2. Using Seal Installer (J-33011), install "O" ring and coat with refrigerant oil. Coat seal seat with refrigerant oil and install using seal seat remover/installer. Install snap ring. Install dust seal (if supplied in seal kit). To complete installation, reverse removal procedure.

1. Using Clutch Plate Spanner (J-33027), hold clutch plate and remove nut. Thread Clutch Plate Remover/Installer (J-33013-B) into clutch plate and remove clutch plate. (Scheme 15)and 5.
2. Remove clutch plate key. Remove snap ring and remove pulley assembly. Disconnect clutch coil electrical wiring. Scribe marks on compressor and clutch coil for reassembly reference. Using Puller Adapter (J-33023-A) and 2-jaw puller, remove clutch coil. Inspect all parts for damage and replace as necessary.

1. Align scribe marks. Using Puller Adapter (J-33024), Puller Bar (J-8433-1) and Compressor Fixture (J-34992), Compressor Fixture (J-33026) on HR-6, press clutch coil on compressor. Restake clutch coil inner ring in 3 places. Install pulley assembly and snap ring. Install clutch plate key in clutch plate, allowing key to protrude approximately 1/8" from rear of clutch plate.
2. Install clutch plate on compressor crankshaft. Using remover/installer, press clutch plate on compressor to achieve a clutch assembly clearance of .015-.025" (.38-.64 mm). Using spanner, install crankshaft nut and tighten to 12 ft. lbs. (17 N.m). Turn pulley and clutch plate by hand to check for free rotation.

Scheme 13

Scheme 14

Discharge system using approved refrigerant recovery/recycling equipment. Remove clutch plate. Using Snap Ring Pliers (J-5403), remove shaft seal snap ring. Install Shaft Seal Protector (J-34614) on crankshaft. Insert Shaft Seal Remover/Installer (J-23128-A) into shaft seal. Tighten handle and remove shaft seal. Using "O" Ring Remover (J-9553-01), remove "O" ring. Clean and inspect all parts.

1. With shaft seal protector in place, lubricate new "O" ring with refrigerant oil and install "O" ring on "O" Ring Installer (J-33011). Insert "O" ring installer in compressor until it bottoms. Move slide on "O" ring installer downward until "O" ring is released into groove. Rotate installer to seat "O" ring.
2. Lubricate shaft seal with refrigerant oil. Expand seal using shaft seal remover/installer and install seal on Seal Protector (J-34614). Place seal protector over shaft and push shaft seal into compressor with a rotary motion until seal bottoms.
3. Install NEW snap ring with flat side against lip seal. To complete installation, reverse removal procedure. Evacuate and recharge system.

1. Mount compressor on Holding Fixture (J-25008-A) and secure in a vise. Using Clutch Plate Spanner (J-33027), remove crankshaft nut. Thread Clutch Plate Remover (J-33013-B) into the clutch plate. Hold body of clutch plate remover and tighten center bolt to remove clutch plate. Remove pulley retaining snap ring. (Scheme 15)
2. On "V" groove drive, remove pulley rim mounting bolts and washers. Install Puller Guide (J-25031) on compressor. Using internal-jaw puller, remove pulley assembly from compressor.
3. On poly-groove drive, install Clutch Plate Puller (J-33021) over Puller Guide (J-25031). Pull clutch plate from compressor. Using internal-jaw puller, remove pulley assembly from compressor.
4. Remove clutch coil electrical wiring. Scribe marks on compressor and clutch coil for installation reference. Using Puller Guide (J-25031) and 2-jaw puller, remove clutch coil. Inspect all parts for damage and replace as necessary.

1. Using Puller Adapter (J-33024), Puller Bar (J-8433-1) and Compressor Fixture (J-25008-A), press clutch coil on compressor. Restake clutch coil inner ring in 3 places and connect electrical wiring.
2. Use Pulley Assembly Installer (J-26271-A), Installer Handle (J-29886) and hammer to drive pulley assembly on compressor. On "V" groove drive, use thread sealant on pulley rim mounting bolts. On all models, ensure clutch coil terminals are aligned correctly and locating tabs are aligned with front head locator holes. Install retaining ring.
3. Install clutch plate key in clutch plate, allowing key to protrude approximately 3/16" from rear of clutch plate. Install clutch plate on compressor crankshaft. Using Clutch Plate Installer (J-9480-B), press clutch plate on compressor to achieve a clutch assembly clearance of .020-.040" (.50-1.00 mm). Using spanner, install crankshaft nut and tighten to 10 ft. lbs. (14 N.m). Turn pulley and clutch plate by hand to check for free rotation.

Discharge system using approved refrigerant recovery/recycling equipment. Remove clutch plate. Using Snap Ring Pliers (J-5403-A), remove shaft seal snap ring. Insert Shaft Seal Remover/Installer (J-23128-A) into shaft seal. Tighten handle and remove shaft seal. Using "O" Ring Remover (J-9553-01), remove "O" ring. Clean and inspect all parts.

1. Lubricate new "O" ring with refrigerant oil and install "O" ring on "O" Ring Installer (J-33011). Insert installer in compressor until it bottoms. Move slide on "O" ring installer downward until "O" ring is released into groove. Rotate installer to seat "O" ring.
2. Coat shaft seal with refrigerant oil and install on shaft seal remover/installer. Expand seal using shaft seal remover/installer and install Shaft Seal Protector (J-34614) through the seal. Seal must be installed on shaft seal protector so seal lip will be installed toward the compressor. Remove shaft seal remover/installer.
3. Install shaft seal protector over end of compressor shaft. Push shaft seal into compressor until it bottoms. Install NEW shaft seal retaining snap ring with flat side against lip seal.
4. To complete installation, reverse removal procedure. Evacuate and recharge system.

Scheme 15

1. Using Clutch Plate Spanner (J-33027) and a thin-wall socket, remove crankshaft bolt. Using Clutch Plate Remover (J-37252), remove clutch plate. Remove clutch plate shims.
2. Remove pulley assembly snap ring. Using a plastic hammer, tap pulley assembly from compressor. Remove snap ring and remove clutch coil. Inspect all parts for damage.

Install clutch coil and snap ring. Install pulley assembly and snap ring. Install clutch plate shims. Install clutch plate and bolt. Hold clutch plate with spanner and tighten bolt to 10 ft. lbs. (14 N.m). Using a feeler gauge, check clearance between pulley and clutch plate. Proper clearance is .014-.026" (.36-.66 mm). If clearance is not correct, remove or add shims.

1. Discharge system using approved refrigerant recovery/recycling equipment and drain oil from compressor. Note amount of oil drained. Remove clutch plate, pulley assembly and clutch coil. Using a 6 mm Allen wrench, remove compressor through bolts. Pull front head from compressor. Use care not to scratch sealing surface.
2. Reach down inside front head and remove felt seal and retainer. Remove "O" ring. Remove shaft seal snap ring. Push shaft seal from head. Inspect front head for damage to sealing surface. Replace if necessary.

1. Lubricate new "O" ring with refrigerant oil. Press seal into front head and install snap ring. Install felt seal and retainer.
2. Lubricate Shaft Seal Protector (J-34614) with refrigerant oil and install on crankshaft. Install a new front head "O" ring on compressor housing.
3. Position front head on compressor. Ensure dowel pins are aligned. Use care when guiding shaft seal protector through seal opening. Remove shaft seal protector.
4. Install compressor through bolts using NEW brass washers. Diagonally tighten bolts to 18 ft. lbs. (24 N.m). Fill compressor with the same amount of oil that was drained from compressor. To complete installation, reverse removal procedure. Evacuate and recharge system. Perform leak test.