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

Removal

1. Remove compressor from vehicle. Place compressor in Holding Fixture (J-41790). Use Clutch Plate Spanner (J-33027-A) 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 1) 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 shaft.
3. Remove snap ring. Install Guide (J-33023-A) on front head. Position Pulley and Bearing Puller (J-33020) into inner circle of slots on pulley. Turn puller clockwise in slots. Tighten puller and remove pulley.
4. If bearing is to be removed, remove forcing screw from puller. With puller still engaged in pulley slots, invert assembly onto a solid flat surface. Use a hammer and Bearing Remover (J-9398-A) to drive bearing from pulley. (Scheme 1) NOTE: It is not necessary to remove staking in front of bearing before removing bearing.
5. Disconnect clutch coil lead. 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

Installation

1. Align reference marks made during removal. Using Puller Adapter (J-33024) and Puller Bar (J-8433-1), press clutch coil onto compressor. Ensure clutch coil and installer stay lined up during installation. 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 .010-.015" (.28-.38 mm). NOTE: To ensure proper clearance, it is necessary to remove old stake metal before installing a new bearing.
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, use Bearing Staking Guide (J-33019-1) and Bearing Staking Pin (J-33019-2) to stake pulley in 3 places, 120 degrees apart. Reposition pulley on support to ensure full support under staking pin. Metal stake should be similar to original stake (down to, but not touching bearing). 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 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. Ensure key is still in keyway before installing clutch coil and bearing assembly to its final position. Air gap between friction surfaces should be .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. Loosen and reposition compressor in mounting bracket. Remove clutch plate and hub assembly. See «CLUTCH COIL & BEARING»(ref-37684-S29318959272001101200000). (Scheme 1)
2. Remove shaft seal snap ring. Ensure all surfaces around seal are clean. Insert Shaft Seal Remover/Installer (J-23128-A) into shaft seal. Rotate handle clockwise to seat seal remover/installer in seal. Remove shaft seal. 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. Install Shaft Seal Protector (J-34614) over compressor shaft. 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. Install shaft seal onto Seal Installer (J-23128-A). Install shaft seal so flared side of lip seal is installed toward compressor. Expand seal using shaft seal remover/installer. Install shaft 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 and hub assembly onto compressor shaft. See «CLUTCH COIL & BEARING»(ref-37684-S29318959272001101200000) .

1. Remove nut and clutch plate using Clutch Plate Holder/Remover (J-41384).
2. Remove snap ring and shim(s) from shaft. Tap pulley off shaft with plastic hammer. If pulley cannot be removed by hand, use a puller. Remove snap ring, bearing, and seal (if equipped) from pulley. (Scheme 2) Remove screw for clutch coil lead. Remove snap ring and clutch coil.

To install, reverse removal procedure. Ensure snap rings are installed with beveled side facing out. Tighten shaft bolt (or nut) to 11-15 ft. lbs. (15-20 N.m). Ensure air gap between clutch plate and pulley is .016-.028" (.41-.71 mm). If air gap is incorrect, add or remove shim(s) as necessary.

Note. On some compressors, it is necessary to use a dial indicator on clutch plate to check air gap. Energize clutch coil and zero dial indicator. De-energize clutch coil and measure air gap. Ensure air gap is as specified.

Scheme 2

1. Remove clutch plate and pulley. Remove shim(s) from shaft. Remove clutch coil if necessary. Remove felt and felt retainer (if equipped). (Scheme 2) Place shaft key remover on shaft and turn to remove key.
2. Remove seal plate snap ring. Engage plate remover on seal plate, and pull up to remove seal plate. Engage shaft seal remover/installer to shaft seal, and pull up to remove shaft seal from front housing.

1. Apply clean refrigerant oil to compressor housing bore. Lubricate shaft seal with refrigerant oil and install in front housing. Lubricate seal plate and install in front housing.
2. Install shaft key, snap ring, felt retainer and felt. With clutch plate installed, ensure air gap between clutch plate and pulley is .016-.028" (.41-.71 mm). If air gap is incorrect, add or remove shim(s) as necessary.

1. Using clutch plate holder, remove clutch plate bolt. Using puller and forcing screw, remove clutch plate. (Scheme 3)
2. Remove shim(s) and snap ring. Use pulley puller pilot. Use a puller to remove pulley. Remove screw for clutch coil lead. Remove 3 screws and clutch coil.

1. To install, reverse removal procedure. Align 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. Tighten clutch plate bolt to 113 INCH lbs. (13 N.m) Using feeler gauge, ensure clearance between clutch plate and pulley is .012-.024" (.30-.60 mm). If clearance is incorrect, add or remove shim(s) as necessary.

Scheme 3

1. Using Clutch Plate Holder (J-33939), remove clutch plate bolt. Using Puller (J-33944-A) and Forcing Screw (J-33944-4), remove clutch plate. (Scheme 4)
2. Remove shim(s), snap ring, and cover. Using Pulley Puller Pilot (J-38324), Pulley Puller (J-8433), and Pulley Puller Legs (J-24092), remove pulley. Remove screw for clutch coil lead. Remove 3 screws and clutch coil.

1. To install, reverse removal procedure. Using Pulley Installer and Handle (J-8092), tap pulley onto compressor. Install snap ring with bevel side facing out.
2. Tighten clutch plate bolt to 11 ft. lbs. (15 N.m). Using feeler gauge, ensure clearance between clutch plate and pulley is .012-.024" (.30-.60 mm). If clearance is incorrect, add or remove shim(s) as necessary.

Scheme 4

1. Using Clutch Plate Holder (J-33939), remove clutch plate bolt. Using Puller (J-33944-A) and Forcing Screw (J-33944-4), remove clutch plate. Remove shim(s) and felt.
2. Using Shaft Seal Remover/Installer (J-33942-B), remove shaft seal cover. Remove shaft seal snap ring. Using shaft seal remover/installer, remove shaft seal.

1. Place Shaft Seal Guide (J-34614) over compressor shaft. (Scheme 5) Lubricate shaft seal guide and shaft seal with refrigerant oil. Using shaft seal remover/installer, install shaft seal. Install shaft seal cover, felt, and shim(s).
2. Tighten clutch plate bolt to 11 ft. lbs. (15 N.m). Using feeler gauge, ensure clearance between clutch plate and pulley is.012-.024" (.30-.60 mm). If clearance is incorrect, add or remove shim(s) as necessary.

Note. Shaft seal servicing procedure not available at time of publication

Scheme 5