A/c Compressor Overhaul - r-4 GMC Pickup R1500

INTRODUCTION

Note. This article covers seal, pulley bearing, and clutch coil replacement procedures for Harrison R-4 4-cylinder compressor with 6-pole clutch. R-4 compressors with "V" or Poly-Groove drives are covered in a separate article.

HARRISON R-4 4-CYL OIL CHECKING

1. Operate system for several minutes to stabilize system before performing repairs. Turn off engine, discharge system using approved refrigerant recovery/recycling equipment and remove compressor. Drain and measure oil.
2. If more than one ounce is drained, replace it with the same amount of new oil. If less than one ounce is drained, replace it with that amount plus an additional 2 ounces.

Removal

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 1)
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.

Installation

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.

Scheme 1

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 1)

STEP 1 - REMOVE SHAFT NUT

Hold clutch hub stationary using clutch holder wrench. Remove shaft nut with thin-wall deep socket.

1. Tool Reference No. 18 - Clutch Holder Wrench

Removing Shaft Nut. Scheme 2

STEP 2 - REMOVE CLUTCH HUB

Thread the clutch plate and hub remover into the hub. Hold body of tool with a wrench. Turn center screw into remover body to remove the clutch plate and hub assembly. Remove shaft key.

1. Tool Reference No. 19 - Clutch Plate and Hub Remover

Removing Clutch Hub. Scheme 3

STEP 3 - REMOVE RETAINING RING

Remove shaft seal seat retaining ring using snap ring pliers. Place seal protector over the end of the shaft to prevent chipping the ceramic seat.

1. Tool Reference No. 8 - Internal Snap Ring Pliers
2. Tool Reference No. 5 - Shaft Seal Protector

Removing Retaining Ring. Scheme 4

STEP 3 - REMOVE SEAL SEAT

Remove ceramic seal seat by inserting seal seat remover tool into compressor neck. Tighten tool by turning handle clockwise to engage knurled tangs into seal. Remove seal seat with a twist and pulling motion.

1. Tool Reference No. 4 - Seal Seat Remover

Removing Seal Seat. Scheme 5

STEP 4 - REMOVE SEAL

Remove seal by inserting seal remover tool into compressor neck. Engage the shaft seal by pressing downward on tool to overcome the seal spring pressure. Turn the tool clockwise to engage seal assembly tangs with tangs of tool. Remove seal by pulling tool straight out from compressor. Remove seal seat "O" ring using "O" ring remover.

1. Tool Reference No. 6 - Seal Remover
2. Tool Reference No. 20 - "O" Ring Remover

Removing Seal. Scheme 6

STEP 5 - INSTALLING SEAL SEAT "O" RING

Be sure inside of compressor neck is perfectly clean. Install "O" ring on installer tool and dip "O" ring in clean refrigerant oil. Insert installer tool into compressor neck until it bottoms. Lower movable slide to place "O" ring in lower groove. Rotate the installer to seat the "O" ring and remove.

1. Tool Reference No. 7 - "O" Ring Installer

Installing Seal Seat "O" Ring. Scheme 7

STEP 6 - INSTALLING SHAFT SEAL

Dip "O" ring and shaft seal in clean refrigerant oil. Engage shaft seal with locking tangs of seal remover. DO NOT touch the carbon area of seal with fingers. Install shaft seal protector over shaft, and slide shaft seal into compressor. While applying light pressure, slowly turn seal installer clockwise until the seal engages flats on compressor shaft and can be seated into place. Rotate installer counterclockwise to disengage.

1. Tool Reference No. 5 - Shaft Seal Protector
2. Tool Reference No. 6 - Seal Installer

Installing Shaft Seal. Scheme 8

STEP 7 - INSTALLING SEAL SEAT

Attach ceramic seal seat to seal seat installer. Dip seat in clean refrigerant oil. Install seal seat over compressor shaft and seal protector, and push into place with a rotating motion. Take care not to dislodge seat "O" ring. Remove seal seat installer and seal protector.

1. Tool Reference No. 5 - Shaft Seal Protector
2. Tool Reference No. 4 - Seal Seat Installer

Installing Seal Seat. Scheme 9

STEP 8 - INSTALLING SEAL SEAT RETAINING RING

Install new seal seat retaining ring with flat side against seal seat using snap ring pliers. Use the sleeve from the seal seat installer to press in on the seal seat retainer ring so that it snaps into its groove.

1. Tool Reference No. 4 - Seal Seat Installer
2. Tool Reference No. 8 - Internal Snap Ring Pliers

Installing Seal Seat Retaining Ring. Scheme 10

STEP 9 - INSTALLING CLUTCH PLATE

Install shaft key into hub key groove. Allow the key to project approximately 3/16" out of the keyway. Be sure the frictional surfaces are clean and install clutch plate and clutch rotor. Align the shaft key with the shaft keyway and place the clutch plate and hub assembly onto the compressor shaft. Install clutch plate and hub installer.

1. Tool Reference No. 15 - Clutch Plate and Hub Installer

Installing Clutch Plate. Scheme 11

STEP 10 - INSTALLING CLUTCH PLATE (CON'T)

Hold the center screw with a wrench. Tighten the hex portion of the installer to press the hub onto the shaft. Tighten the body several turns, remove installer and check to see that shaft keyway is still in place before installing clutch plate and hub to final position. Air gap between clutch plate and rotor should be .015-.025" (.38-.64 mm).

1. Tool Reference No. 15 - Clutch Plate and Hub Installer

Installing Clutch Plate (Con't). Scheme 12

STEP 11 - INSTALLING SHAFT NUT

Remove installer and check that shaft key is even with or slightly above clutch hub. Install the shaft nut with the small diameter boss of the nut against crankshaft shoulder with thin-wall deep socket. Hold clutch plate and hub assembly with clutch holder wrench and tighten to 10 ft. lbs.

1. Tool Reference No. 15 - Clutch Plate and Hub Installer
2. Tool Reference No. 18 - Clutch Holder Wrench

Installing Shaft Nut. Scheme 13

Hold clutch hub stationary using clutch holder wrench. Remove shaft nut with thin-wall deep socket.

1. Tool Reference No. 18 - Clutch Holder Wrench

Removing Shaft Nut. Scheme 14

Thread the clutch plate and hub remover into the hub. Hold body of tool with wrench. Turn center screw into remover body to remove the clutch plate and hub assembly. Remove shaft key.

1. Tool Reference No. 19 - Clutch Plate and Hub Remover

Removing Clutch Hub. Scheme 15

STEP 3 - REMOVE SNAP RING

Remove rotor and bearing assembly retaining ring using snap ring pliers. Mark Location of clutch coil terminals.

1. Tool Reference No. 9 - External Snap Ring Pliers

Removing Snap Ring. Scheme 16

STEP 4 - INSTALL PULLER GUIDE

Install pulley rotor and puller guide to front head. Install bearing puller down into the inner circle of slots in the rotor.

1. Tool Reference No. 10 - Rotor and Bearing Puller Guide
2. Tool Reference No. 21 - Bearing Puller

Installing Puller Guide. Scheme 17

STEP 5 - REMOVE ROTOR

Turn puller clockwise in slots to engage puller tangs between slots in rotor. Hold puller in place and tighten puller screw against puller guide to remove pulley rotor and bearing assembly. Take care to properly support rotor hub during bearing removal.

1. Tool Reference No. 10 - Rotor and Bearing Puller Guide
2. Tool Reference No. 21 - Bearing Puller

Removing Rotor. Scheme 18

STEP 6 - REMOVE BEARING

Remove the forcing screw from the puller and with the tangs still engaged in the rotor slots, invert the assembly onto a solid flat surface. Drive the bearing out of the rotor hub with rotor and bearing remover.

1. Tool Reference No. 23 - Rotor and Bearing Remover
2. Tool Reference No. 21 - Bearing Puller

Note. It is not necessary to remove staking to remove bearing. However, it will be necessary to file away old stake metal for proper clearance for the new bearing to be installed.

Removing Bearing. Scheme 19

STEP 7 - INSTALL BEARING

Place the pulley rotor on the support block to fully support rotor hub. Align new bearing squarely with hub bore and using rotor and bearing installer and universal handle drive the bearing into hub.

1. Tool Reference No. 23 - Rotor and Bearing Installer
2. Tool Reference No. 22 - Universal Handle

Installing Bearing. Scheme 20

STEP 8 - STAKE BEARING

Place bearing staking guide and bearing staking pin into hub bore. Shift rotor and bearing to support block to give full support of hub under staking pin location. A heavy rubber band may be used to hold stake pin in place. Strike the staking pin with a hammer until a metal stake is formed down to but not touching the bearing. Stake 3 places 120° apart.

1. Tool Reference 25 - Bearing Staking Tool

Stake Bearing. Scheme 21

STEP 9 - INSTALL ROTOR

With compressor mounted to holding fixture, position rotor and bearing assembly on front head. Using rotor and bearing installer, drive rotor and bearing onto front head. Install rotor and bearing retaining ring with snap ring pliers.

1. Tool Reference No. 9 - External Snap Ring Pliers
2. Tool Reference No. 24 - Rotor and Bearing Installer

Installing Rotor. Scheme 22

STEP 10 - INSTALL CLUTCH PLATE

Install shaft key into hub key groove. Key should project approximately 3/16" out of keyway. Frictional surface of clutch plate and clutch plate and clutch rotor should be clean before installing clutch plate and rotor assembly. Align shaft key with shaft keyway and place clutch plate and hub assembly onto compressor shaft. Install clutch plate and hub installer.

1. Tool Reference No. 15 - Clutch Plate and Hub Installer

Installing Clutch Plate. Scheme 23

STEP 11 - INSTALL CLUTCH PLATE (CON'T)

Hold center screw with a wrench. Tighten hex portion of installer to press hub onto shaft. Tighten body several turns, remove installer and check to see that shaft keyway is still in place before installing clutch plate and hub to final position. Air gap between clutch plate and rotor should be .015-.025".

1. Tool Reference 15 - Clutch Plate and Hub Installer

Installing Clutch Plate (Con't). Scheme 24

STEP 12 - INSTALL SHAFT NUT

Remove installer and check that shaft key is even with or slightly above clutch hub. Install the shaft nut with the small diameter boss of the nut against crankshaft shoulder with thin-wall deep socket. Hold clutch plate and hub assembly with clutch holder wrench and tighten to 10 ft. lbs.

1. Tool Reference No. 15 - Clutch Plate and Hub Installer
2. Tool Reference No. 18 - Clutch Holder Wrench

Installing Shaft Nut. Scheme 25

STEP 1 - REMOVE CLUTCH

Perform steps 1 through 5 of Clutch Bearing Replacement. Mark clutch coil terminal locations on compressor front head. Install puller guide on front head of compressor and install clutch coil puller. Tighten forcing screw of puller against puller guide to remove clutch coil.

1. Tool Reference No. 10 - Rotor and Bearing Puller Guide
2. Tool Reference No. 16 - Clutch Coil Puller

Removing Clutch. Scheme 26

STEP 2 - REPLACE COIL

Place the clutch coil assembly on the front head with the terminals positioned at marked location. Place the clutch coil installer over the internal opening of the clutch coil housing and align the installer and clutch coil with compressor front head.

1. Tool Reference No. 26 - Clutch Coil Installer

Replace Coil. Scheme 27

STEP 3 - INSTALL CLUTCH COIL

Tap clutch coil installer with a hammer to start clutch coil onto front head. When fully seated on front head, use a l/8" diameter drift punch to stake front head at 3 places 120° apart. Stake size should be only the area of the punch tip and .010-.015" deep. Install rotor and bearing assembly and clutch plate and hub assembly as described in steps 7 through 12 of Pulley Bearing Replacement.

1. Tool Reference No. 26 - Clutch Coil Installer

Installing Clutch Coil. Scheme 28