A/c Compressor Servicing GMC Suburban I

CAPACITIES

Note. Due to late changes, always refer to underhood A/C specification label in engine compartment or A/C compressor label while servicing A/C system. If A/C specification label and specifications listed here differ, use label specifications.

REFRIGERANT OIL & R-134a REFRIGERANT CAPACITY (CARS)

REFRIGERANT OIL & R-134a REFRIGERANT CAPACITY LIGHT TRUCKS & VANS)

COMPRESSOR APPLICATIONS

COMPRESSOR APPLICATIONS (CARS)

COMPRESSOR APPLICATIONS (LIGHT TRUCKS & VANS)

BODY DESIGNATIONS

BODY DESIGNATIONS (CARS)

BODY DESIGNATIONS (LIGHT TRUCKS & VANS)

CLUTCH ASSEMBLY

Removal

1. Remove compressor from vehicle and support using Holding Fixture (J-33026 for HD6/HR6-HE compressor or J-34992 for V5 compressor). Using Clutch Plate Spanner (J-25030 for HD6/HR6-HE compressor or J-33027-A for V5 compressor), hold clutch plate and remove compressor shaft nut.
2. Use Clutch Plate Remover/Installer (J-33013-B) to remove clutch plate. (Scheme 1)or (Scheme 2). Remove key from shaft. Remove snap ring. Install Guide (J-33022) 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 lead.
4. Scribe marks on compressor and clutch coil for installation reference. Remove clutch coil using Puller Adapter (J-33023-A) and 2-jaw puller.

Scheme 1

Scheme 2

Installation

1. Align reference marks made during removal. Using Puller Adapter (J-33023-A) and Puller Bar (J-8433-1), press clutch coil onto compressor. Stake 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 pulley on flat surface, or pulley will be damaged. Install bearing in pulley using hammer, Handle (J-29886) and Bearing Installer (J-9481-A).
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 onto compressor. Install snap ring. Install key in clutch plate, allowing key to protrude about 1/8" from rear of clutch plate.
5. Install clutch plate on compressor shaft. Using clutch plate remover/installer, press clutch plate onto compressor. Clutch assembly clearance for HD6/HR6-HE compressor is .020-.030" (.51-.76 mm) and for V5 compressor is .015-.020" (.38-.51 mm).
6. Using spanner, install compressor shaft nut. Tighten shaft nut to 12.5 ft. lbs. (17 N.m). Check components for proper rotation.

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Using Clutch Plate Spanner (J-25030 for HD6/HR6-HE compressor or J-33027-A for V5 compressor), hold clutch plate and remove compressor shaft nut. Thread Clutch Plate Remover/Installer (J-33013-B) into clutch plate, and remove clutch plate. (Scheme 1)or (Scheme 2).
2. Remove shaft seal 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 it 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.
4. Push shaft seal into compressor using a rotary motion until seal bottoms. Install new snap ring with flat side against seal. Install clutch plate on compressor shaft.
5. Using clutch plate remover/installer, press clutch plate onto compressor until a clutch assembly. Clutch assembly clearance for HD6/HR6-HE compressor is .020-.030" (.51-.76 mm) and for V5 compressor is .015-.020" (.38-.51 mm).
6. Using spanner, install compressor shaft nut and tighten it to 12.5 ft. lbs. (17 N.m). Evacuate and recharge system. Check for leaks.

1. If compressor is on vehicle, loosen mounting brackets, disconnect drive belt and position compressor for easy access. Using a spanner wrench, remove shaft nut (if equipped). It is not necessary to discharge system. If compressor has been removed from vehicle, use Holding Fixture (J-25008-A) and vise to support compressor.
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 compressor shaft key. (Scheme 3)

1. Install compressor shaft key, allowing key to protrude about 3/16" from rear of clutch plate. Install clutch plate onto compressor shaft.
2. Using Clutch Plate Installer (J-9401-B), press clutch plate onto compressor until clearance between clutch plate and pulley assembly is .015-.020" (.38-.51 mm). To complete installation, reverse removal procedure.

Removal (Serpentine Belt Pulley)

1. Remove clutch plate. See CLUTCH PLATE. Remove pulley assembly snap ring. Install Pulley Rotor and Puller Guide (J-25031) to pulley assembly. Install Pulley Rotor and Bearing Puller (J-33020) down into inner circle of slots in pulley assembly.
2. Turn puller clockwise to engage puller tangs with segments between pulley assembly slots. Tighten puller center screw against puller guide to remove pulley assembly from compressor.
3. If removing bearing, remove center screw from puller. Do not remove puller from pulley assembly slots. Invert assembly and use puller for support on a solid surface.
4. Using hammer, Handle (J-29886) and Bearing Remover (J-9398-A), drive bearing from pulley assembly hub. Using a file, remove old stake metal from pulley assembly to provide clearance for new bearing.
5. Scribe reference marks on compressor and clutch coil for installation reference. 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 align.
2. If bearing was removed, use Support Block (J-21352-A) and support pulley assembly. DO NOT support pulley assembly on a flat surface during bearing installation, or assembly will be damaged.
3. Using hammer, Handle (J-29886) and Bearing Installer (J-9481-A), install bearing fully into pulley hub. Using Bearing Staking Guide (J-33019-1) and Bearing Staking Pin (J-33019-2), stake rotor in 3 places, 120 degrees apart. Create metal stake down to, but not touching bearing.
4. 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. Install clutch plate. See CLUTCH PLATE.
5. Check components for proper rotation. If compressor was removed from vehicle, ensure compressor contains proper amount of oil. Install compressor. Evacuate and recharge system. Check for leaks.

Removal ("V" Groove Belt Pulley)

1. Remove clutch plate. See CLUTCH PLATE. Remove pulley assembly snap ring. Install Pulley Rotor and Puller Guide (J-25031) to pulley assembly. Install Pulley Rotor and Bearing Puller (J-33020) down into inner circle of slots in pulley assembly.
2. Turn puller clockwise to engage puller tangs with segments between pulley assembly slots. Tighten puller center screw against puller guide to remove pulley assembly from compressor.
3. Scribe reference marks on compressor and clutch coil for installation reference. Install Pulley Rotor and Puller Guide (J-25031) to pulley assembly. Using a 2-jaw puller, remove clutch coil from front head of compressor.

1. Install clutch coil on compressor neck. Use reference marks to ensure clutch coil terminals are in correct position. Place pulley assembly on neck of compressor front head. Using a hammer and Rotor And Bearing Installer (J-26271-A), install clutch coil and pulley assembly.
2. Before fully seating clutch coil and pulley assembly, ensure protrusions on rear of clutch coil align with holes in front compressor head. Install snap ring and install clutch plate. See CLUTCH PLATE.
3. Using spanner wrench, install new compressor shaft nut (if equipped) and tighten it to 10 ft. lbs. (14 N.m). Check components for proper rotation. If compressor was removed from vehicle, ensure compressor contains proper amount of oil. Install compressor. Evacuate and recharge system. Check for leaks.

Scheme 3

1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Use Clutch Plate Spanner (J-33027-A) to remove compressor shaft 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 compressor shaft key. (Scheme 3)
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 it on "O" Ring Installer (J-33011). Insert "O" ring installer in compressor until installer bottoms.
2. Move slide on "O" ring installer downward until "O" ring is released into lower groove. The top groove is for snap ring. 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. Install seal on shaft seal protector so seal lip is 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 snap ring with flat side against seal.
6. Install compressor shaft key, allowing key to protrude about 3/16" (4.8 mm) from rear of clutch plate. Install clutch plate on compressor shaft.
7. Using Clutch Plate Installer (J-9401-B), press clutch plate onto compressor until clearance between clutch plate and rotor is .020-.030" (.51-.76 mm).
8. Using spanner, install new compressor shaft nut (if equipped) and tighten it to 10 ft. lbs. (14 N.m). Check components for proper rotation. Install compressor. Evacuate and recharge system. Check for leaks.

1. Hold clutch using Clutch Holder (J-33027-A). Remove compressor shaft bolt. Remove clutch plate and shims.
2. Remove pulley assembly snap ring. Remove pulley assembly and snap ring. Disconnect clutch coil lead. Remove clutch coil. (Scheme 4)

Scheme 4

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 a feeler gauge, measure air gap between clutch plate and pulley surface in 3 areas. Proper clearance is .014-.026" (.36-.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 A/C system using approved refrigerant recovery/recycling equipment. Remove compressor. Drain oil from compressor, and measure amount drained.
2. Using Spanner (J-37872), hold clutch and remove compressor shaft nut. Using Puller (J-37825), remove clutch plate. Remove key from compressor shaft.
3. Remove pulley external snap ring. Install jaws of Puller (J-37828) in snap ring groove on pulley.
4. Install puller plate on jaws. Thread 2 bolts through puller plate into jaws finger tight. Tighten pulley center bolt and remove pulley from compressor. Remove clutch coil snap ring and clutch coil.

1. Install clutch coil and clutch coil snap ring on compressor. Support compressor on rear mounting ears.
2. Use a hammer, Handle (J-29886) and Driver (J-38467), install pulley assembly. Ensure driver rests on inner race of bearing when installing pulley assembly. Install external snap ring.
3. Install original shims. Use a hammer and Shaft Protector (J-29640) to install clutch plate on compressor shaft. Tighten compressor shaft nut to 124 INCH lbs. (14 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.

Note. Removing compressor is not necessary to service clutch assembly.

1. Loosen tensioner and remove drive belt from pulley. Remove coolant/washer reservoir screws. Disconnect electrical harness from coolant reservoir. Release heater return pipe clips. Lift coolant/washer reservoir out of the way.
2. Using Clutch Holder (SA9149AC-4) and 10-mm deep socket, remove clutch drive plate center bolt. Insert drive plate holder sleeve into drive plate. Install remover bolt. While holding clutch remover handle, tighten remover bolt to remove drive plate. DO NOT lose shims.
3. Remove pulley snap ring. Position puller Center Adapter (SA9149AC-2) over end of compressor shaft. Attach 3-jaw puller to back of pulley. Tighten puller bolt against center adapter. Remove pulley. Remove clutch coil screws. Disconnect clutch coil wire. Remove clutch coil.

1. Install coil in original position. Tighten screws to 35-52 INCH lbs. (3.9-5.9 N.m). Install drive bolt, Drive Plate Installer (SA9149AC-3) and thrust bearing assembly through center of pulley. Finger tighten pulley installation bolt into compressor shaft.
2. Finger tighten nut on installation bolt to align pulley to compressor. Tighten nut until pulley bottoms in compressor. Loosen nut and remove installation bolt. Install snap ring with tapered side out.
3. Install drive plate on holder. Place thrust bearing on installation bolt. Insert installation bolt through drive plate. Place shims on installation bolt. Thread bolt into compressor shaft. Slide drive plate over splines of compressor shaft.
4. While holding end of installation bolt, tighten nut until drive plate bottoms. Loosen nut and remove installation bolt. Install center bolt. Tighten center bolt to 104-130 INCH lbs. (11.8-14.7 N.m).
5. Using a feeler gauge, measure clearance between drive plate and pulley. Clearance should be .01"-.02" (.3-.5 mm). If clearance is not as specified, add or remove shims as necessary.