A/c Compressor Overhaul - dav5 GMC Vandura I

DESCRIPTION

The 5-cylinder Harrison DA V5 compressor is an infinitely, variable displacement compressor, matching vehicle A/C demand under all conditions without cycling on and off. Using the DA-6 6-pole clutch, the DA V5 features a variable angle swashplate and 5 axially located piston-cylinder assemblies.

Compressor displacement is controlled by a bellows-actuated control valve in the compressor's rear head. This valve senses compressor suction pressure. The swashplate angle and compressor displacement are controlled by crankcase-suction pressure differential.

When A/C capacity demand is lower and suction pressure will be above the control point, the valve will bleed discharge gas into the crankcase. The valve also closes a passage from the crankcase to the suction plenum, providing smaller displacement.

The swashplate angle is controlled by the force balance on the 5 pistons. A slight increase of crank-suction pressure differential creates a total force on the pistons. This causes a movement about the swashplate pivot pin, reducing the swashplate angle.

The compressor is self-lubricating, collecting up to 4 ounces of oil in the crankcase. The crankcase-suction bleed is routed through the rotating swashplate. Rotation separates and removes some of the oil from the bleed, re-routing it to the crankcase for component lubrication.

Exploded View of Harrison DA V5 5-Cylinder Compressor. Scheme 29

Harrison DA V5 Compressor Tools Number Cross-References. Scheme 30

Note. Tariffed numbers in Fig. (Scheme 30) refer to the following: 1 - Part number is for kit. 2 - Kits needed are 41064 and 41075. 3 - Used with J-8433-1 Puller Bar & J-9433-3 Puller Screw.

Expansion Tube/Orifice Tube Tool Number Cross-References. Scheme 31

Mounting Compressor, Tool Reference No. 1, Holding Fixture. Scheme 32

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

1. Mounting Compressor - Do not replace shaft seal due to small oil seepage, as this permits proper lubrication. If serious leaks exist, discharge refrigerant using approved refrigerant recovery/recycling equipment and remove compressor. Mount compressor in holding fixture, second in a vise. (Scheme 33): Removing Shaft Nut - Tool No. 2, Clutch Holder Wrench; No. 3, Shaft Nut Socket
2. Remove Shaft Nut - While holding clutch assembly with clutch holder wrench, remove shaft nut using shaft nut socket. (Scheme 34): Removing Clutch Assembly - Tool No. 4, Hub & Drive Plate Remover/Installer
3. Remove Clutch Assembly - With center screw tip against end of shaft, thread hub and drive plate remover into hub. Holding body of remover with wrench, turn center screw. Lift off clutch plate and hub. (Scheme 35): Removing Key
4. Remove Key - Using side cutters, remove shaft key and save it for later reassembly. (Scheme 36): Removing Snap Ring - Tool No. 5, Internal Snap Ring Pliers
5. Remove Snap Ring - Using internal snap ring pliers, remove snap ring type seal retaining ring. (Scheme 37): Cleaning Shaft Area
6. Clean Shaft Area - Thoroughly clean compressor neck area around shaft to prevent entrance of dirt or other foreign material. (Scheme 38): Removing Seal - Tool No. 8, Seal Remover/Installer
7. Remove Seal - Fully engage tangs of seal remover into recessed portion of seal by turning handle clockwise. Remove seal with a twisting, pulling motion. Discard seal. CAUTION: Tighten tool securely by hand. Never use wrench or pliers. (Scheme 39): Removing "O" Ring - Tool No. 10, Seal "O" Ring Remover
8. Remove "O" Ring - Using an "O" ring remover, remove and discard "O" ring from compressor neck. Clean compressor neck area thoroughly before installing new parts. (Scheme 40): Installing "O" Ring - Tool No. 11, Seal "O" Ring Installer
9. Install "O" Ring - Dip new seal seat "O" ring in clean refrigerant oil and place on "O" ring installer. Insert installer into compressor neck until it bottoms. Lower installers movable slide to release "O" ring into lower groove. The top groove is for the shaft seal retainer ring. Rotate installer to seat "O" ring. Remove installer. (Scheme 41): Lubricating Seal - Tool Reference No. 8, Seal Remover/ Installer
10. Lubricate Seal - Install one piece seal on seal installer. Seal has a steel shell around its Teflon lip seal. Dip face of seal into clean refrigerant oil. Be sure seal is not scratched and is free of dirt and lint. (Scheme 42): Installing Seal - Tool Reference No. 7, Shaft Seal Protector
11. Install Seal - Place seal protector inside seal and place over end of shaft. With a twisting motion, push new seal downward into place. (Scheme 43): Installing Snap Ring - Tool No. 5, Internal Snap Ring Pliers
12. Install Snap Ring - Using internal snap ring pliers, install seal retaining ring in compressor neck, with its flat side toward seal. Use sleeve from seal installer to press snap ring into its groove. (Scheme 44): Leak Testing Compressor - Tool No. 20, Leak Test Fixture
13. Leak Test Compressor - Install compressor leak test fixture on rear head. Connect manifold gauge charging lines. Pressurize low and high sides with vaporous R-12 to drum pressure. Temporarily install shaft nut. With compressor in horizontal position, turn compressor shaft by hand several turns in normal direction. Check for leaks and remove shaft nut. (Scheme 45): Installing Key
14. Install Key - Clean shaft and compressor neck of excess oil and install shaft key. Allow key to project 1/8" from keyway. Key is curved slightly to provide an interference fit with hub keyway. (Scheme 46): Installing Clutch Assembly - Tool No. 4, Hub & Drive Plate Remover/Installer
15. Install Clutch Assembly - Clean frictional clutch surfaces. Place clutch drive plate and hub assembly on shaft. Do not drive or pound on clutch hub or shaft, as internal compressor damage will result. Remove installer center screw and reverse body direction on center screw. Install drive plate installer with bearing. Back off installer body to allow center screw to be threaded fully onto the end of the shaft. (Scheme 47): Completing Clutch Installation - Tool No. 4, Hub & Drive Plate Remover/Installer
16. Complete Clutch Installation - Failure to follow directions in this step exactly can cause key to break the clutch hub. Hold center screw (not body) with wrench. Tighten hex portion of installer body (not center screw) to press hub onto shaft. Tighten body several turns. Remove installer. Be sure shaft key is still in place before installing clutch assembly to its final position. (Scheme 48): Checking Air Gap
17. Using feeler gauge, check air gap between clutch plate and pulley surfaces. Gap should be.015-.025". Remove hub and drive plate remover/installer tool. Check that shaft key is even or slightly above clutch plate and hub assembly. (Scheme 49): Installing Shaft Nut Tool Reference No. 2, Clutch Holder Wrench; No. 3, Shaft Nut Socket
18. Hold clutch assembly with clutch holding tool. Tighten shaft nut against shaft shoulder, using shaft nut socket. Tighten to 8-16 ft. lbs. Spin pulley by hand to be sure pulley and clutch drive plate are not rubbing. Install compressor, evacuate and charge.

Removing Snap Ring - Tool No. 6, External Snap Ring Pliers. Scheme 50

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Scheme 59

1. Remove Snap Ring - Perform steps 1-4 of SEAL REPLACEMENT. Using external snap ring pliers, remove retaining ring securing pulley and bearing assembly. (Scheme 51): Installing Puller Pilot - Tool No. 14, Puller Pilot
2. Install Puller Pilot - Install puller pilot to front head. (Scheme 52): Removing Pulley & Bearing - Tool No. 12, Pulley Puller
3. Remove Pulley & Bearing - Install pulley rotor and bearing puller down into inner circle of slots in pulley. Turn puller clockwise to engage puller tangs in segments of pulley between slots. Hold puller in place and tighten puller screw against puller pilot. Remove pulley and bearing assembly from compressor head. (Scheme 53): Removing Bearing - Tool No. 21, Bearing Remover; No. 18, Driver Handle
4. Remove Bearing - Remove forcing screw from puller. Without removing puller from pulley, turn assembly over, and rest pulley on puller. Place puller on wooden support blocks. Drive out bearing with bearing remover and a driver handle. NOTE: It is not necessary to remove staking to remove bearing, but staking should be filed away before installing new bearing. (Scheme 54): Installing Bearing - Tool No. 17, Support Block; No. 22, Bearing Installer; No. 18, Driver Handle
5. Install Bearing - Place pulley on support block. Be sure to fully support pulley hub, not rim. Align new bearing squarely with pulley hub bore. Using bearing installer and driver handle, drive bearing into hub. Installer should apply force to bearing outer race. (Scheme 55): Staking Bearing - Tool No. 17, Support Block; No. 19, Staking Tool
6. Stake Bearing - Place bearing staking guide and pin assembly in pulley hub bore. Place support block under staking pin. Reposition staking pin after each impact. Stake should be formed down to but not touching bearing. Stake at 3 equally-spaced points around bearing. (Scheme 56): Installing Pulley & Bearing - Installer Tool No. 1, Holding Fixture; No. 13, Pulley and Bearing Installer; No. 14, Puller Pilot
7. Install Pulley & Bearing Installer - With compressor still mounted in holding fixture, place pulley and bearing assembly on front head. Position the pulley and bearing installer and puller pilot directly over inner race of bearing. Install a puller as shown. (Scheme 57): Installing Pulley & Bearing
8. Install Pulley & Bearing - Be sure puller through bolt threads engage the full thickness of the holding fixture. Tighten puller center screw to force pulley and bearing assembly onto compressor head. Be sure proper alignment is maintained throughout installation. (Scheme 58): Installing Snap Ring - Tool No. 6, External Snap Ring Pliers
9. Install Snap Ring - Using external snap ring pliers, install snap ring which retains pulley and bearing. (Scheme 59): Installing Key
10. Install Key - Clean shaft. Install shaft key. Allow key to project 1/8" from keyway. Key is curved slightly, providing an interference fit with keyway. Perform steps 15-18 of SEAL REPLACEMENT.

Removing Clutch Coil - Tool No. 9, Puller Bar & Screw; No. 14, Puller Pilot; No. 16, Puller Legs. Scheme 60

Scheme 61

Scheme 62

Scheme 63

1. Remove Clutch Coil - Perform steps 1-3 of PULLEY BEARING REPLACEMENT. Mark clutch coil terminal location on compressor front head. Install puller pilot on front head. Install puller and puller legs as shown. Tighten forcing screw against puller pilot. Lift off clutch coil. (Scheme 61): Aligning Clutch Coil
2. Align Clutch Coil - Align clutch coil terminals with alignment marks made earlier on the compressor head. (Scheme 62): Installing Clutch Coil - Tool No. 9, Puller Bar & Screw; No. 15, Clutch Coil Installer
3. Install Clutch Coil - Place coil installer over internal opening of clutch coil housing. Align installer, coil and front head. Install puller as shown, with crossbar center screw in countersunk center hole of clutch coil installer. Be sure puller through bolts extend through full width of holding fixture. Turn center forcing screw, while keeping clutch coil properly aligned. (Scheme 63): Staking Clutch Coil
4. Stake Clutch Coil - When clutch coil is properly seated on front head, use a 1/8" drift punch to stake front head at 3 equally-spaced locations. Stake size should be half the area of drift tip and.010-.015" deep. Perform steps 7-10 of PULLEY BEARING REPLACEMENT.