A/c Compressor Overhaul GMC Sonoma Syclone

HARRISON HR-6 & V5 CLUTCH ASSEMBLY R & I

REMOVAL

1. Using Clutch Plate Spanner (J-25030 for HR-6 or J-33027-A for V5), hold clutch plate and remove crankshaft nut. Use Clutch Plate Remover/Installer (J-33013-B) to remove clutch plate. (Scheme 12)and (Scheme 13). CAUTION: DO NOT drive on compressor shaft to remove clutch plate or compressor damage will result.
2. Remove key from shaft. Remove snap ring. Install Guide (J-33023-A) on front head. Position Puller (J-33020) in slots on pulley assembly. Tighten puller and remove pulley assembly.
3. Use hammer and Bearing Remover (J-9398-A) to drive bearing from pulley. Disconnect clutch coil electrical wiring.
4. Scribe reference marks on compressor and clutch coil for reassembly reference. Remove clutch coil using Puller Adapter (J-33023-A) and 2-jaw puller.

INSTALLATION

1. Align reference marks. Using Puller Adapter (J-33024) and Puller Bar (J-8433-1), press clutch coil on compressor. Restake clutch coil inner ring in 3 places, 120 degrees apart.
2. If bearing was removed from pulley, place pulley on Support (J-21352-A). DO NOT support on flat surface or pulley will be damaged. Install bearing in pulley using hammer, Handle (J-29886) and Bearing Installer (J-948-1).
3. With pulley on support, stake pulley in 3 places, 120 degrees apart. Position pulley on compressor.
4. Place Bearing Installer (J-33017) and Puller Guide (J-33023-A) over inner race of bearing. Using puller, press pulley assembly on compressor. Install snap ring. Install key in clutch plate, allowing key to protrude approximately 1/8" from rear of clutch plate.
5. Install clutch plate on compressor crankshaft. Using clutch plate remover/installer, press clutch plate on compressor to achieve a clutch assembly clearance of .020-.030" (.51-.76 mm) on HR-6 compressors or .015-.025" (.38-.64 mm) on V5 compressors.
6. Using spanner, install crankshaft nut and tighten to 12 ft. lbs. (17 N.m). Check components for proper rotation.

1. Discharge system using approved refrigerant recovery/recycling equipment. Using Clutch Plate Spanner (J-25030) for HR-6 or (J-33027-A) for V5, hold clutch plate and remove crankshaft nut. Thread Clutch Plate Remover/Installer (J-33013-B) into clutch plate and remove clutch plate. (Scheme 12)and (Scheme 13).
2. Remove shaft seal retaining snap ring. Ensure all surfaces around seal are clean. Install Shaft Seal Protector (J-34614) over compressor shaft. Insert Shaft Seal Remover/Installer (J-23128-A) into shaft seal.
3. Rotate handle clockwise to seat seal remover/installer in seal. Remove shaft seal. Using "O" Ring Remover (J-9553-01), remove "O" ring.

1. With shaft seal protector in place, lubricate new "O" ring with refrigerant oil and install "O" ring on "O" Ring Installer (J-33011).
2. 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. Remove "O" ring installer.
3. Lubricate shaft seal with refrigerant oil. Expand seal using shaft seal remover/installer. Install seal on Seal Protector (J-34614). Place seal protector over shaft. Push shaft seal into compressor with a rotary motion until seal bottoms.
4. Install NEW snap ring with flat side against seal. Install clutch plate on compressor crankshaft.
5. Using clutch plate remover/installer, press clutch plate on compressor to achieve a clutch assembly clearance of .020-.030" (.51-.76 mm) on HR-6 compressors or .015-.025" (.38-.64 mm) on V5 compressors.
6. Using spanner, install crankshaft nut and tighten to 12 ft. lbs. (17 N.m). Evacuate and recharge system. Check for leaks.

Scheme 12

Scheme 13

REMOVAL (POLY GROOVE-TYPE BELT DRIVE)

1. Discharge system using approved refrigerant recovery/recycling equipment and remove compressor. Drain oil from compressor and record amount for reassembly. Mount compressor on Holding Fixture (J-25008-A) and secure in a vise. Using Clutch Plate Spanner (J-33027-A), remove crankshaft nut.
2. Thread Clutch Plate Remover (J-33013-B) into clutch plate. Hold body of clutch plate remover. Tighten center bolt to remove clutch plate. Remove crankshaft key. (Scheme 14) Remove rotor retaining snap ring.
3. Install Puller Guide (J-25031) on compressor shaft. Using Puller (J-33020), pull rotor from compressor.
4. If bearing is to be removed, remove center screw from puller. Invert assembly on solid surface. Using hammer, Handle (J-29886) and Bearing Remover (J-9398-A), drive bearing from rotor.
5. Scribe reference marks on compressor and clutch coil for reassembly reference.
6. Install puller guide on compressor shaft. Using Puller (J-25287), pull clutch coil from compressor.

1. Using hammer, Handle (J-29886) and Rotor/Bearing Installer (J-26271-A), install clutch coil. Ensure reference marks are aligned. CAUTION: Ensure protrusions on rear of clutch coil align with holes in front head.
2. If bearing was removed, place rotor on Support (J-21352-A). DO NOT support on flat surface or assembly will be damaged. Using hammer, Handle (J-29886) and Rotor/Bearing Installer (J-26271-A), install bearing in rotor. Stake rotor in 3 places, 120 degrees apart.
3. Install rotor assembly on front head. Drive rotor on front head using hammer, Handle (J-29886) and Rotor/Bearing Installer (J-26271-A). Install snap ring.
4. Install crankshaft key, allowing key to protrude approximately 3/16" from rear of clutch plate. Install clutch plate on compressor crankshaft.
5. Using Clutch Plate Installer (J-9401-B), press clutch plate on compressor to achieve a clearance between clutch plate and rotor of .020-.040" (.50-1.00 mm).
6. Using spanner, install NEW crankshaft nut and tighten to 10 ft. lbs. (14 N.m). Check components for proper rotation. Add same amount of new refrigerant oil to compressor as was drained. Install compressor. Evacuate and recharge system. Check for leaks.

REMOVAL ("V" GROOVE-TYPE BELT DRIVE)

1. Discharge system using approved refrigerant recovery/recycling equipment and remove compressor. Drain oil from compressor and record amount for reassembly. Mount compressor on Holding Fixture (J-25008-A) and secure in a vise. Remove crankshaft nut using Clutch Plate Spanner (J-33027-A).
2. Thread Clutch Plate Remover (J-33013-B) into clutch plate. Hold body of clutch plate remover. Tighten center bolt to remove clutch plate. Remove crankshaft key. (Scheme 14) Remove rotor retaining snap ring.
3. If removing rotor and bearing only, remove pulley rim bolts. If replacing clutch coil, DO NOT loosen or remove pulley rim mounting bolts. Pulley rim bolts will pull clutch coil off when rotor is removed.
4. If clutch coil is being removed, scribe reference marks on compressor and clutch coil for reassembly reference. Install Puller Guide (J-25031) on compressor shaft. Using internal-jaw puller, remove rotor assembly from compressor.
5. If removing clutch coil, remove pulley rim bolts. Separate clutch coil from pulley rim. If removing bearing, place clutch assembly on wooden block. Using hammer, Handle (J-29886) and Bearing Remover (J-9398-A), drive bearing from rotor.

1. If bearing was removed, install bearing in rotor using Bearing Installer (J-9481-A). Stake rotor in 3 places, 120 degrees apart.
2. If clutch coil was removed, install coil in pulley rim. Coat pulley rim bolts with Loctite and install. DO NOT tighten at this time.
3. On all applications, install rotor assembly on front head. Using hammer, Handle (J-29886) and Rotor/Bearing Installer (J-26271-A), install rotor assembly. Ensure reference marks are aligned. CAUTION: Ensure protrusions on rear of clutch coil align with holes in front head.
4. Install snap ring. Tighten pulley rim bolts to 100 INCH lbs. (11 N.m). Install crankshaft key, allowing key to protrude approximately 3/16" from rear of clutch plate. Install clutch plate on compressor crankshaft.
5. Using Clutch Plate Installer (J-9401-B), press clutch plate on compressor to achieve a clearance between clutch plate and rotor of .020-.040" (.50-1.00 mm).
6. Using spanner, install NEW crankshaft nut and tighten to 10 ft. lbs. (14 N.m). Check components for proper rotation. Add same amount of new refrigerant oil to compressor as was drained. Install compressor. Evacuate and recharge system. Check for leaks.

1. Discharge system using approved refrigerant recovery/recycling equipment. Using Clutch Plate Spanner (J-33027-A), remove crankshaft nut. Thread Clutch Plate Remover (J-33013-B) into clutch plate. Hold body of clutch plate remover. Tighten center bolt to remove clutch plate. Remove crankshaft key. (Scheme 14)
2. Remove shaft seal snap ring. Ensure seal area on compressor is clean. Insert Shaft Seal Remover/Installer (J-23128-A) into shaft seal.
3. Rotate handle clockwise and remove shaft seal. Using "O" Ring Remover (J-9553-01), remove "O" ring.

1. 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.
2. Move slide on "O" ring installer downward until "O" ring is released into groove. Rotate installer to seat "O" ring.
3. Coat shaft seal with refrigerant oil. Install seal on shaft seal remover/installer. Expand seal using shaft seal remover/installer.
4. Install Shaft Seal Protector (J-34614) through seal. Seal must be installed on shaft seal protector so seal lip will be installed toward compressor. Remove shaft seal remover/installer.
5. 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 seal.
6. Install crankshaft key, allowing key to protrude approximately 3/16" from rear of clutch plate. Install clutch plate on compressor crankshaft.
7. Using Clutch Plate Installer (J-9401-B), press clutch plate on compressor to achieve a clearance between clutch plate and rotor of .020-.040" (.50-1.00 mm).
8. Using spanner, install NEW crankshaft nut and tighten to 10 ft. lbs. (14 N.m). Check components for proper rotation. Install compressor. Evacuate and recharge system. Check for leaks.

Scheme 14

1. Using Clutch Holder (J-33027-A), hold clutch. Remove compressor shaft bolt. Remove clutch plate and shims.
2. Remove pulley assembly retaining snap ring. Remove pulley assembly. Remove snap ring and disconnect clutch coil electrical wiring. Remove clutch coil.

1. Install clutch coil so pin in back of coil aligns with hole in front housing. Install snap ring.
2. Install pulley assembly and snap ring. Install clutch plate and shims. Tighten compressor shaft bolt to 10 ft. lbs. (14 N.m). DO NOT use air tools to tighten bolt.
3. Using feeler gauge, measure air gap between clutch plate and pulley surface in 3 areas. Proper clearance is .014-.026" (.35-.66 mm). Adjust shim thickness to obtain correct clearance.
4. Once compressor shaft bolt is tightened, recheck clearance between clutch plate and pulley surface in 4 places. Readjust clearance if necessary.

1. Discharge system using approved refrigerant recovery/recycling equipment and remove compressor. Drain oil from compressor and record amount for reassembly.
2. Remove clutch assembly. See NIPPONDENSO 10PA17 & 10PA17A CLUTCH ASSEMBLY R & I. Remove front head retaining bolts. Separate front head and "O" ring from compressor. (Scheme 15)
3. Remove felt dust seal and dust seal retainer from front head. Remove shaft seal retaining snap ring. Press seal from front head.

1. Lubricate new shaft seal and seal cavity of front head with refrigerant oil. Press seal into front head and install snap ring.
2. Lubricate front head "O" ring with refrigerant oil. Install front head "O" ring on cylinder assembly. Install Shaft Protector (J-34614) on compressor shaft. Install front head on cylinder assembly. Ensure dowel pins are aligned.
3. Install all through bolts with NEW washers. Tighten through bolts to 18 ft. lbs. (24 N.m). Remove shaft protector. Install felt dust seal and dust seal retainer.
4. Using INCH lb. torque wrench, check compressor shaft rotating torque. Rotating torque should be 26 INCH lbs. (3 N.m). Install clutch assembly.
5. Add amount of refrigerant oil that was drained to compressor. Install compressor. Evacuate and recharge system. Perform leak test.

Scheme 15

1. Hold clutch using Clutch Holder (J-33027-A). Remove compressor shaft bolt. Remove clutch plate and shims.
2. Remove pulley assembly retaining snap ring. Remove pulley assembly. Remove snap ring and disconnect clutch coil electrical wiring. Remove clutch coil.

1. Install clutch coil so pin in back of coil aligns with hole in front housing. Install snap ring.
2. Install pulley assembly and snap ring. Install clutch plate and shims. Tighten compressor shaft bolt to 10 ft. lbs. (18 N.m). DO NOT use air tools to tighten bolt.
3. Using feeler gauge, measure air gap between clutch plate and pulley surface in 3 areas. Proper clearance is .014-.026" (.35-.66 mm). Adjust shim thickness to obtain correct clearance.
4. Once compressor shaft bolt is tightened, recheck clearance between clutch plate and pulley surface in 4 places. Readjust clearance if necessary.

1. Discharge system using approved refrigerant recovery/recycling equipment and remove compressor. Drain oil from compressor and record amount for reassembly.
2. Remove clutch assembly. See NIPPONDENSO 10PA20 CLUTCH ASSEMBLY R & I. Remove front head retaining bolts. Separate front head and "O" ring from compressor. (Scheme 15)
3. Remove felt dust seal and dust seal retainer from front head. Remove shaft seal retaining snap ring. Press seal from front head.

1. Lubricate new shaft seal and seal cavity of front head with refrigerant oil. Press seal into front head and install snap ring.
2. Lubricate front head "O" ring with refrigerant oil. Install front head "O" ring on cylinder assembly. Install Shaft Protector (J-34614) on compressor shaft. Install front head on cylinder assembly. Ensure dowel pins align.
3. Install all through bolts with NEW washers. Tighten through bolts to 18 ft. lbs. (24 N.m). Remove shaft protector. Install felt dust seal and dust seal retainer.
4. Using INCH-pound torque wrench, check compressor shaft rotating torque. Rotating torque should be 26 INCH lbs. (3 N.m). Install clutch assembly. Add amount of refrigerant oil that was drained to compressor. Install compressor. Evacuate and recharge system. Perform leak test.