A/c Compressor Servicing Dodge Shadow I

CHRYSLER C-171 6-CYL CLUTCH R & I

Removal

1. Disconnect negative battery cable. Loosen and remove belt. Disconnect A/C compressor electrical connector. With refrigerant lines attached, remove compressor mounting bolts and position compressor for service.
2. Using a 13 mm socket and Clutch Spanner (C-4563), remove compressor shaft nut and washer. Thread Clutch Puller (C-4771) into clutch plate. Tighten center screw in puller and remove clutch plate.
3. Using snap ring pliers, remove pulley retaining snap ring and remove pulley. Remove snap ring and remove clutch coil assembly. Inspect hub and pulley clutch surfaces. Replace if scoring is excessive.

Note. Clutch hub and pulley must be replaced as a set. Clutch slipping will result if only one piece is replaced.

Installation

1. Align hole in back of clutch coil with pin in compressor housing. Ensure clutch coil electrical wiring is properly routed.
2. Install clutch coil retaining snap ring with beveled side away from compressor and eyelets located to right or left of clutch coil pin. Ensure snap ring is fully seated.
3. If original front plate and pulley are to be reused, the old shims can be used. If new components are used, install several shims so thickness is .10" (2.5 mm) thick. Install front plate and hold tightly against the shims.
4. Using feeler gauge, measure air gap between front plate and pulley surface. Proper clearance is .020-.035" (.05-.89 mm). Adjust shim thickness to obtain correct clearance. Tighten compressor shaft nut to 13 ft. lbs. (18 N.m). Install compressor.

Note. After installing new clutch, ensure voltage is correct and cycle clutch with 5 seconds on and 5 seconds off. Repeat cycle for approximately 20 times with A/C on, blower fan on "HIGH", and engine RPM at 1500-2000. This will provide better clutch torque capability.

CHRYSLER C-171 6-CYL SHAFT SEAL R & I

Note. Information not available from manufacturer for seal removal without compressor disassembly.

Removal & Installation

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect refrigerant lines and electrical wiring at compressor. Remove compressor. Remove suction port and drain oil. Record amount of oil drained. Remove compressor clutch assembly.
2. Remove compressor crankshaft key. Remove felt packing from nose of front head. Remove seal retaining snap ring. Use a 6 mm Allen wrench, remove compressor through bolts. Using a plastic hammer, tap on outside of front head and remove. Remove "O" ring seal from front head and discard.
3. Place front head on a flat surface with nose upward. Using a plastic hammer and drift, tap shaft seal seat assembly from front head. Remove shaft seal assembly from compressor crankshaft.
4. Lubricate shaft seal assembly and shaft seal seat assembly and "O" ring with refrigerant oil. Install shaft seal assembly on crankshaft. Install "O" ring on shaft seat assembly.
5. Using a socket, tap new shaft seal seat assembly in the front head. Install compressor front and rear heads using NEW "O" rings lubricated with refrigerant oil. Ensure heads are aligned with dowel pins. Tighten through bolts to 19 ft. lbs. (26 N.m).
6. Install felt seal in front head. To complete installation, reverse removal procedure. Use new "O" rings. Verify proper refrigerant oil level. See R-12 & REFRIGERANT OIL SPECIFICATIONS table in this section. Evacuate and recharge system. Perform leak test.

Exploded View of Chrysler & Nippondenso 6-Cyl Compressors. Scheme 12

1. Disconnect negative battery cable. Loosen and remove belt. Disconnect A/C compressor electrical connector. With refrigerant lines attached, remove compressor mounting bolts and position compressor for service.
2. Using Clutch Hub Holder (6355), remove compressor shaft nut. Using Clutch Hub Puller (6354), remove clutch hub and hub clearance shims.
3. Using snap ring pliers, remove pulley retaining snap ring and pulley. Remove snap ring and remove clutch coil assembly. Inspect hub and pulley clutch surfaces. Replace if scoring is excessive.

1. Align hole in back of clutch coil with pin in compressor housing. Ensure clutch coil electrical wiring is properly routed. To complete installation, reverse removal procedure.
2. Tighten compressor shaft nut to 13 ft. lbs. (17.5 N.m). Using a feeler gauge, check hub-to-pulley clutch clearance. Clearance should be .035" (.89 mm). If clearance is incorrect, add or remove shims behind clutch hub as necessary.

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect refrigerant lines and electrical wiring at compressor. Remove compressor. Remove suction port and drain oil. Remove compressor clutch assembly.
2. Remove compressor crankshaft key. Remove felt packing from nose of front cover. Remove seal retaining snap ring. Using Seal Remover/Installer (6429), remove seal from compressor.
3. To install seal, lubricate shaft with refrigerant oil. Install Seal Protector (6231) over the shaft. Using flat end of seal/remover installer, install seal until seal seats in the housing. To install remaining components, reverse removal procedure. Adjust oil level. Evacuate and recharge system. Perform leak test.

1. Remove clutch plate retaining bolt and discard. Using 8 mm bolt, thread bolt into crankshaft and remove clutch plate. Remove clutch plate shims.
2. Remove pulley assembly snap ring. Remove pulley assembly. Remove snap ring and disconnect clutch coil electrical wiring. Remove clutch coil.

1. Install clutch coil over locating tab. Install snap ring. Install pulley assembly and install snap ring. Apply a thin coat of White grease to compressor shaft splines.
2. Install clutch plate spacer shims. Slide compressor clutch on crankshaft and install NEW retaining bolt. Tighten bolt to 96-120 INCH lbs. (11-14 N.m). Using a feeler gauge, rotate clutch assembly and check clearance between pulley and clutch plate in 3 places. Proper clearance is .014-.026" (.36-.66 mm). If clearance is not correct, add or remove shims.

Scheme 13

NIPPONDENSO 10PA17 & 10PA17A 10-CYL SHAFT SEAL R & I

Note. Information not available from manufacturer for seal removal without compressor disassembly.

1. Remove compressor and drain refrigerant oil. Install compressor in Holding Fixture (T89P-19623-D) and clamp fixture in a vise. Remove clutch plate, pulley assembly and clutch coil. Using a 6 mm Allen wrench, remove 5 compressor through bolts. Pull front head from compressor using care not to scratch sealing surface. (Scheme 13)
2. Using "O" Ring Remover (T71P-19703-C), remove felt dust seal and retainer from front head. Remove shaft seal retaining snap ring. Position front head (nose up) on cardboard place on a flat surface. Using Shaft Seal Remover (T89P-19623-E), push shaft seal from head. Inspect front head for damage to sealing surface. Replace if necessary.

1. Lubricate new shaft seal with refrigerant oil. DO NOT touch sealing surfaces. Using Shaft Seal Installer (T89P-19623-F), press seal into front head and install snap ring. Install felt dust seal and retainer.
2. Lubricate Shaft Seal Protector (T89D-19623-C) with refrigerant oil and install on crankshaft. Install a new front head "O" ring on cylinder assembly and coat with refrigerant oil.
3. Install front head on cylinder assembly. Ensure dowel pins are aligned. Use care when guiding shaft seal protector through seal opening. Remove shaft seal protector. Install through bolts with NEW brass washers. Diagonally tighten bolts to 19 ft. lbs. (26 N.m). Add amount of refrigerant oil that was drained to the compressor. To complete installation, reverse removal procedure.

1. Using Spanner (J8924-17), hold clutch hub stationary and remove shaft nut. Using Puller (J-8924-1B), remove clutch plate. Remove external front housing snap ring and internal bearing snap ring (SD-508 only). (Scheme 14)
2. Install puller and remove pulley assembly. Remove snap ring and clutch coil.

1. Install clutch coil and snap ring on compressor. Support compressor on rear mounting ears. Using Pulley Installer Set (J-8924-21), install pulley assembly. After pulley assembly is seated, install internal bearing snap ring (SD-508 only) and external front housing snap ring.
2. Using Clutch Plate Installer (J-8924-27), install clutch plate on the shaft. Tighten shaft nut to 25-30 ft. lbs. (34-41 N.m). Using feeler gauge, measure clearance between clutch plate and pulley in several areas. Clearance should be.016-.031" (.41-.79 mm).
3. If clearance is not within specification, adjust shim thickness to obtain correct clearance. (Scheme 14)

1. With compressor removed, remove clutch assembly. If oil is drained from compressor, note amount drained. Remove key from the shaft. Remove felt ring metal retainer and felt ring. Using small screwdriver, remove shims for the clutch plate. (Scheme 14)
2. Remove shaft seat retaining snap ring. Using Shaft Seat Remover/Installer (J-8924-32), remove shaft seat. Install Shaft Seal Remover/Installer (J-8924-31) into shaft seal. Press downward on shaft seal remover/installer and rotate to engage tangs with slots of shaft seal. Pull shaft seal from compressor.

1. Install Seal Sleeve Protector (J-8924-34) over compressor shaft. Coat seal sleeve protector, new shaft seal and shaft seal seat with refrigerant oil. DO NOT touch the sealing surfaces of the seal.
2. Place seal on shaft seal remover/installer. Install seal in compressor and twist seal remover/installer opposite direction and remove. Using shaft seat remover/installer, install shaft seat.
3. Install snap ring with beveled edge away from compressor. It may be necessary to tap on snap ring to ensure it seats in the groove. Install shims and NEW felt. To install remaining components, reverse removal procedure. Fill compressor with the amount of oil that was drained. Evacuate and recharge system. Perform leak test.

Scheme 14