A/c Compressor Servicing: Removal & Installation Eagle Vision I

Removal

1. Remove and discard compressor shaft bolt. Remove clutch plate and shims. Tap on clutch plate using a soft-faced hammer (if necessary).
2. Remove pulley assembly snap ring. Remove pulley assembly. Remove snap ring, and disconnect clutch coil lead. Remove clutch coil.

Installation

Note. Ensure voltage is correct after installing new clutch. Cycle clutch on for 5 seconds and off for 5 seconds. Repeat cycle 20 times with A/C on, blower fan on high speed and engine speed at 1500-2000 RPM.

1. Install clutch coil so pin in back of coil aligns with hole in front housing. Install snap ring with beveled side away from compressor.
2. Install pulley assembly. Install snap ring with beveled side away from compressor. If reusing original clutch plate and pulley, old shims can be used.
3. If using new components, install several shims so shim pack thickness is .10" (2.5 mm). Install clutch plate and hold it tightly against shims.
4. Using feeler gauge, measure air gap between clutch plate and pulley surface. On Laser and Talon, clearance should be .014-.026" (.36-.66 mm). On all other models, clearance should be .020-.035" (.51-.89 mm). Adjust shim thickness to obtain correct clearance. Install new compressor shaft bolt, and tighten it to 13 ft. lbs. (18 N.m).
5. Once compressor shaft bolt is tightened, recheck clearance between clutch plate and pulley surface in 4 places. Readjust clearance if necessary.

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove compressor. Drain oil from compressor, and measure amount drained. Remove clutch assembly.
2. Remove felt dust seal and dust seal retainer from front head. (Scheme 1) Remove shaft seal snap ring. Position front head (nose up) on cardboard placed on a flat surface. Using brass drift, press shaft seal from front head.

1. Lubricate new shaft seal with refrigerant oil. DO NOT touch sealing surfaces. Press seal into front head, and install snap ring. Install felt dust seal and dust seal retainer.
2. Lubricate Shaft Seal Protector (J-34614) and front head "O" ring with refrigerant oil. Install shaft seal protector on crankshaft. Install a new front head "O" ring on cylinder assembly.
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.
4. Install through-bolts and new brass washers. Diagonally tighten bolts to 19 ft. lbs. (26 N.m). Using INCH-lb. torque wrench, check compressor shaft rotating torque. Rotating torque should be 43 INCH lbs. (5 N.m) or less. Install clutch assembly.
5. Using new refrigerant oil, add same amount of oil to compressor as was drained from it. Install compressor. Evacuate and recharge system. Perform leak test. See LEAK TESTING in the «A/C SYSTEM GENERAL SERVICING»(ref-39221) article in the AIR CONDITIONING & HEAT section.

Scheme 1

1. Using Spanner (J-37872), hold clutch and remove compressor shaft nut. Using Puller (J-37825), remove clutch plate. Remove key from compressor shaft.
2. Remove pulley snap ring. Install jaws of Puller (J37828) in snap ring groove on pulley. Place Shaft Protector (J-29640) on compressor shaft.
3. Install puller plate on jaws. Thread 2 bolts through puller plate into jaws. Remove pulley from compressor. Remove snap ring and clutch coil.

1. Install clutch coil and snap ring on compressor. Support compressor on rear mounting ears.
2. Using hammer, Handle (J-29886) and Driver (J-38467), install pulley assembly. Ensure driver rests on inner race of bearing when installing pulley assembly. Install snap ring.
3. Install shims. Install key in compressor shaft. Using hammer and Shaft Protector (J-29640), install clutch plate on compressor shaft. Tighten compressor shaft nut to 25-30 ft. lbs. (34-41 N.m).
4. Using feeler gauge, measure clearance between clutch plate and pulley assembly in several areas. Clearance should be .016-.031" (.41-.79 mm). If clearance is not within specification, adjust shim thickness to obtain correct clearance.

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove compressor. Drain oil from compressor, and measure amount drained. Remove clutch assembly.
2. Remove key from shaft. Remove felt ring metal retainer and felt ring. Using small screwdriver, remove shims for clutch plate.
3. Ensure area around seal is clean. Remove shaft seal snap ring. Using Shaft Seal Remover/Installer (J-33011), remove shaft seal.
4. Install Shaft Seal Remover/Installer (J-23128-A) into shaft seal. Press downward on shaft seal remover/installer and rotate it to engage tangs with slots of shaft seal. Pull shaft seal from compressor.

1. Install Shaft Protector (J-29640) over compressor shaft. Coat shaft protector, new shaft seal and shaft seal seat with refrigerant oil. DO NOT touch sealing surfaces of seal.
2. Place seal on seal remover/installer, and twist tool to hold seal. Install seal in compressor, and twist tool in opposite direction to release seal. Remove seal remover/installer. Using shaft seat remover/installer, install shaft seat.
3. Install snap ring. Tap on snap ring to ensure it seats in groove (if necessary). Install shims and new felt. To install remaining components, reverse removal procedure. Using new refrigerant oil, fill compressor with the same amount of oil drained from it. Install compressor. Evacuate and recharge system. Perform leak test. See LEAK TESTING in the «A/C SYSTEM GENERAL SERVICING»(ref-39221) article in the AIR CONDITIONING & HEAT section.

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove compressor. Install two6-mm bolts in holes of clutch plate. Hold 6-mm bolts while removing nut from end of compressor shaft.
2. Remove clutch plate and shims. Tap clutch plate from compressor (if necessary). DO NOT pry between clutch plate and pulley to remove clutch plate.
3. Remove pulley assembly snap ring. Remove pulley assembly. Disconnect clutch coil lead. Scribe marks on clutch coil and compressor for installation reference. Remove snap ring and clutch coil.

1. Install clutch coil on compressor so locating pin engages hole in clutch coil. Install snap ring with beveled side away from compressor.
2. Install pulley assembly. Install snap ring with beveled side away from compressor. If reusing original clutch plate and pulley, old shims can be used.
3. If new components are used, install several shims so shim pack thickness is .10" (2.5 mm). Install clutch plate and hold it tightly against shims.
4. Using feeler gauge, measure air gap between clutch plate and pulley surface. Proper clearance is .013-.025" (.33-.64 mm). Adjust shim thickness to obtain correct clearance. Tighten compressor shaft nut to 13 ft. lbs. (18 N.m).
5. Once compressor shaft nut is tightened, recheck clearance between clutch plate and pulley surface in 4 places. Readjust clearance if necessary. Install compressor. Evacuate and recharge system. Perform leak test. See LEAK TESTING in the «A/C SYSTEM GENERAL SERVICING»(ref-39221) article in the AIR CONDITIONING & HEAT section.

Note. After installing new clutch, ensure voltage is correct. Cycle clutch on for 5 seconds and off for 5 seconds. Repeat cycle 20 times with A/C on, blower fan on high speed and engine speed at 1500-2000 RPM.

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove compressor. Install two 6-mm bolts in holes of clutch plate. Hold 6-mm bolts while removing nut from end of compressor shaft.
2. Remove clutch plate and shims. Tap clutch plate from compressor (if necessary). DO NOT pry between clutch plate and pulley to remove clutch plate.
3. Insert 2 jaws of Bearing Remover/Installer (6533) into bearing groove. Install retainer over jaws of bearing remover/installer.
4. Tighten pressure screw of bearing remover/installer against compressor shaft until bearing is removed.
5. Remove felt washer from compressor. Remove shaft seal snap ring. Engage Seal Remover/Installer (6551) in slots of seal case. Lift seal from compressor.

1. Place Seal Sleeve Protector (6552) over compressor shaft. Coat seal sleeve protector and seal lip with refrigerant oil. Using seal remover/installer, install seal. Remove seal sleeve protector.
2. Install shaft seal snap ring. Install felt washer. Install bearing in pulley. Using hammer with jaws and retainer of bearing remover/installer, drive bearing into pulley.
3. If reusing original clutch plate and pulley, old shims can be used. If using new components, install several shims so shim pack thickness is .10" (2.5 mm). Install clutch plate and hold it tightly against shims.
4. Using feeler gauge, measure air gap between clutch plate and pulley surface. Proper clearance is .013-.025" (.33-.64 mm). Adjust shim thickness to obtain correct clearance. Tighten compressor shaft nut to 13 ft. lbs. (18 N.m).
5. Once compressor shaft nut is tightened, recheck clearance between clutch plate and pulley surface in 4 places. Readjust clearance if necessary.