A/c Compressor Servicing: Removal & Installation Isuzu Amigo II

Removal

1. Remove compressor from vehicle. Place compressor in Holding Fixture (J-33026). Using Clutch Plate/Hub Remover/Installer (J-33013-B), remove compressor clutch plate and hub. (Scheme 1) Position remover/installer center screw forcing tip flat against compressor shaft and thread remover/installer into hub. End of shaft will be damaged if forcing tip is not flat. Hold remover/installer body and turn center screw into remover/installer body and remove clutch plate and hub. Remove shaft key from compressor shaft.
2. Remove snap ring. Install Pulley/Bearing Puller Guide (J-33023-A) on front head. Position Pulley/Bearing Puller (J-41552) into inner circle of slots on pulley. Turn puller clockwise until engaged in pulley slots. Tighten puller screw against puller guide until pulley is removed.
3. Disconnect clutch coil connector. Scribe match marks on compressor and clutch coil connector for installation reference. Install Puller Pilot Adapter (J-33023-A) on front head of compressor. Install Puller Crossbar (J-8433-1), Puller Legs (J-33025) and Forcing Screw (J-8433-3). Tighten puller forcing screw against pilot adapter and remove clutch coil. (Scheme 1)

Installation

1. Align clutch reference marks made during removal. Position Clutch Coil Installer (J-33024) over internal opening of clutch coil housing and align with front head of compressor. Position Puller Crossbar (J-8433-1) and Through-Bolts (J-33026) so Forcing Screw (J-8433-3) is centered in clutch coil installer center hole. Ensure through-bolts are fully threaded into holding fixture.
2. Tighten forcing screw against installer to press clutch coil onto compressor front head. Ensure clutch coil and installer stay aligned during installation. When clutch coil is fully seated on front head, stake front head and clutch coil. Using a 1/8" punch, stake clutch coil inner ring in 3 places, 120 degrees apart. Stake size should be 1/2 the area of punch tip and 0.010-0.015" (0.28-0.38 mm) deep.
3. Position Pulley/Bearing Installer (J-33017) and Pulley/Bearing Puller Guide (J-33023-A) over inner race of pulley bearing. Position Puller Crossbar (J-8433-1) and Through-Bolts (J-33026) so Forcing Screw (J-8433-3) is centered over puller guide. Ensure through-bolts are fully threaded into holding fixture.
4. Tighten forcing screw against puller guide to press pulley and bearing assembly onto front head of compressor. Ensure puller guide and front head of compressor stay aligned during installation. Install snap ring.
5. Install shaft key into clutch plate and hub. Ensure shaft key protrudes about 1/8" (3.2 mm) out of keyway. Ensure friction surfaces of clutch plate and pulley are clean. Ensure shaft key and keyway in hub are aligned and position clutch plate and hub onto compressor shaft.
6. Install Clutch Plate/Hub Remover/Installer (J-33013-B) with forcing screw in installation position. Body of remover/installer should be backed off from hub enough to allow forcing screw to be threaded onto compressor shaft.
7. Hold forcing screw and tighten installer body to press hub onto compressor shaft. Before pressing clutch plate and hub to final position, remove installer and ensure shaft key is still in keyway. Continue pressing clutch plate and hub until air gap between friction surfaces is 0.020-0.030" (0.51-0.76 mm).

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Loosen and reposition compressor in mounting bracket. Remove clutch plate and hub assembly. See procedures in «CLUTCH COIL & BEARING ASSEMBLY»(ref-37815-S01018337882001101200000). (Scheme 1)
2. Remove shaft seal snap ring. Thoroughly clean all surfaces around seal including inside of compressor neck and exposed parts of seal, snap ring groove and compressor shaft. Insert shaft Seal Remover/Installer (J-23128-A) into shaft seal. Hand-tighten seal remover/installer handle clockwise to seat inside seal. Remove shaft seal by turning and pulling seal remover/installer.
3. Using "O" Ring Remover (J-9553-01), remove "O" ring. Ensure shaft and inside of compressor neck are clean and free of foreign material. Thoroughly clean "O" ring groove in front head.

1. Lubricate NEW "O" ring with refrigerant oil and install using "O" Ring Installer (J-33011). Expand seal using shaft "O" ring installer. Insert installer into compressor until it bottoms. Move slide on installer downward until "O" ring is released into lower groove. Rotate installer to seat "O" ring and remove installer.
2. Lubricate shaft seal with refrigerant oil. Install shaft seal onto Seal Remover/Installer (J-23128-A). Install shaft seal so flared side of lip seal is installed toward compressor. Install Seal Protector (J-34614) into shaft seal lip and position seal protector over compressor shaft.
3. Push shaft seal into compressor using a rotary motion until seal bottoms. Use care to not move "O" ring. Remove installer. Install NEW snap ring with flat side against seal. Using seal remover/installer, push snap ring into snap ring groove. Clean excess refrigerant oil from compressor shaft and neck. Install clutch plate and hub assembly onto compressor shaft. See «CLUTCH COIL & BEARING ASSEMBLY»(ref-37815-S01018337882001101200000) .

Scheme 1

1. Remove compressor from vehicle. Place compressor in Holding Fixture (J-41790). Use Clutch Plate Spanner (J-33027) to hold clutch plate. Remove compressor shaft nut.
2. Use Clutch Plate Remover/Installer (J-33013-B) to remove compressor clutch plate and hub. (Scheme 2) Hold remover body and turn center screw into remover body to remove clutch plate and hub. Ensure forcing tip on remover/installer center screw is flat or end of shaft/axial plate will be damaged. Remove key from compressor shaft.
3. Remove snap ring. Install Puller Pilot/Guide (J-33023-A) on front head. Position Pulley and Bearing Puller (J-41552) into inner circle of slots on pulley. Turn puller clockwise in slots to engage puller tangs with pulley. Tighten puller forcing screw against puller pilot/guide and remove pulley.
4. Disconnect clutch coil lead. Scribe marks on compressor and clutch coil for installation reference. Install Puller Pilot/Guide (J-33023-A) on front head. Remove clutch coil using puller pilot/guide and 2-jaw puller. Position puller jaws under edge of clutch coil.

Scheme 2

1. Align reference marks made during removal. Using Puller Adapter (J-33024) and 2-jaw puller, press clutch coil onto compressor. Position puller jaws under compressor mounting bosses. Ensure clutch coil and installer stay lined up during installation.
2. Position pulley on compressor. Place Bearing Installer (J-33017) and Clutch Plate Remover/Installer (J-33013-B) over inner race of bearing. Place Adapter (J-42126) onto remover/installer and reposition center forcing screw into the opposite end of the remover/installer.
3. Back body of remover/installer off enough to allow center forcing screw to be threaded onto end of compressor shaft several turns. Hold center forcing screw while turning hex portion of remover/installer several turns. DO NOT allow center forcing screw to turn. Continue turning remover/installer until pulley bearing is pressed onto compressor enough to clear snap ring groove. Install snap ring with chamfer side facing up. Install key in clutch plate, allowing key to protrude about 1/8" from rear of clutch plate.
4. Install clutch plate on compressor shaft. Hold center forcing screw and turn hex portion of remover/installer several turns to press clutch plate onto compressor. Remove remover/installer and ensure key is still in keyway. Reinstall remover/installer and check air gap before installing clutch plate to its final position. Air gap between friction surfaces should be 0.015" (0.38 mm). Using spanner, install compressor shaft nut. Tighten shaft nut to 13 ft. lbs. (18 N.m). Check components for proper rotation.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove compressor from vehicle. Remove clutch plate and hub assembly. See «CLUTCH COIL & BEARING ASSEMBLY»(ref-37815-S01018337882001101200000). (Scheme 2)
2. Remove shaft seal snap ring. Ensure all surfaces around seal are clean. Insert Shaft Seal Remover/Installer (J-42136) into shaft seal. Rotate handle clockwise to seat seal remover/installer in seal. Remove shaft seal. Ensure shaft and inside of compressor neck are clean and free of foreign material. Thoroughly clean "O" ring groove in front head.

1. Install Shaft Seal Protector (J-34614) over compressor shaft. With shaft seal protector in place, lubricate NEW shaft seal with refrigerant oil and install on to Shaft Seal Remover/Installer (J-34614).
2. Push shaft seal into compressor using a rotary motion until seal bottoms. Install new snap ring with flat side against seal. Install clutch plate and hub assembly onto compressor shaft. See «CLUTCH COIL & BEARING ASSEMBLY»(ref-37815-S01018337882001101200000) .

Using Clutch Plate Holder (J-37872), hold clutch plate stationary and remove compressor shaft bolt. Remove clutch plate and shims. Remove snap ring and pulley. Remove clutch coil wiring harness from compressor. Remove snap ring and clutch coil. (Scheme 2)

1. To install, reverse removal procedure. Use NEW snap rings. Ensure snap rings are installed with beveled side facing out and fully seated in snap ring groove. Install clutch coil with wire facing downward. Apply thread lock to compressor shaft bolt. Tighten shaft bolt to 117 INCH lbs. (13 N.m).
2. Ensure air gap between clutch plate and pulley is 0.014-0.026" (0.36-0.66 mm). If air gap is incorrect, add or remove shim(s) as necessary.

Scheme 3

Scheme 4

Scheme 5

1. Using clutch disc/plate holder, remove clutch disc/plate bolt. Using puller and forcing screw, remove clutch disc/plate. (Scheme 6)
2. Remove shim(s) and snap ring. On DKV-14D compressor, use pulley puller pilot to protect compressor shaft. Use a puller to remove pulley. Remove screw for clutch coil lead. Remove 3 clutch coil screws and clutch coil.

1. To install, reverse removal procedure. Align clutch coil pin with hole in front head of compressor and install clutch coil. Tighten clutch coil screws to 44 INCH lbs. (5 N.m). Using pulley installer and drive handle, tap pulley onto compressor. Install new snap ring.
2. On DKV-14D compressor, tighten clutch plate bolt to 113 INCH lbs. (13 N.m) Using feeler gauge, ensure air gap between clutch plate and pulley is 0.012-0.024" (0.30-0.60 mm). If air gap is incorrect, add or remove shim(s) as necessary.

Scheme 6