A/c Compressor Servicing: Removal & Installation Mazda MX-6 I

Removal

1. Using Clutch Holder (000 41 0812 05), remove clutch plate bolt. Using an 8-mm bolt threaded into clutch plate, remove clutch plate and shim(s).
2. Remove snap ring and pulley assembly. Install Shaft Protector (49 UN01 047) over shaft seal opening. Use a 2-jaw puller to remove clutch coil from compressor.

Installation

1. Ensure clutch coil mounting surface is clean. Use Coil Installer (49 UN01 046) and 2-jaw puller engaged to rear side of compressor front mounts to press coil into place.
2. Install pulley assembly. Install pulley assembly snap ring with bevel side of snap ring facing out. Install shim(s) and clutch plate. Install a new clutch plate bolt and tighten to 97-115 INCH lbs. (11-13 N.m).
3. Use a feeler gauge to check clearance between clutch plate and pulley assembly. Clearance should be .018-.030" (.46-.76 mm). If clearance is incorrect, add or remove shims as necessary.

1. Using Clutch Holder (000 41 0812 05), remove clutch plate bolt. Using an 8-mm bolt threaded into clutch plate, remove clutch plate and shim(s).
2. Remove shaft felt seal. Thoroughly clean seal area of compressor. Remove shaft seal snap ring. Position Shaft Seal Remover (49 UN01 044) over compressor shaft.
3. Push shaft seal remover downward against seal. Ensure end of shaft seal remover is engaged with inside of seal. Rotate shaft seal remover clockwise to expand remover tip inside seal. Pull shaft seal from compressor.

1. Lubricate shaft seal protector and shaft seal with refrigerant oil. Install shaft seal on shaft seal protector so lip seal is toward compressor (large end of shaft seal protector).
2. Install shaft seal protector on compressor shaft. Using Shaft Seal Installer (49 UN01 043), push shaft seal down seal protector until seal is seated.
3. Remove shaft seal installer and protector. Install a new shaft seal retaining snap ring and shaft seal felt. Install shim(s) and clutch plate. Install a new clutch plate bolt and tighten to 97-115 INCH lbs. (11-13 N.m).
4. Use a feeler gauge to check clearance between clutch plate and pulley assembly. Clearance should be .018-.030" (.46-.76 mm). If clearance is incorrect, add or remove shims as necessary.

1. Hold clutch plate with Clutch Holder (00007-10331) and remove shaft nut. Install Clutch Disc Remover (4992-02-020) and remove clutch plate and shims. (Scheme 1)
2. Remove pulley snap ring and tap pulley (with bearing) off of compressor with plastic hammer. Remove screw for clutch coil lead. Remove snap ring and clutch coil.

To install, reverse removal procedure. Ensure pulley-to-clutch plate clearance is .016-.024" (.40-.60 mm). If clearance is incorrect, add or remove shim(s) as necessary.

1. Drain and measure compressor oil in compressor. Remove discharge valve body through-bolts. Remove discharge valve body bolts and body. Remove discharge valve plate and discharge valve.
2. Remove compressor through-bolts. Remove front and rear housing (oil separator case). Remove pins and gaskets. Remove shaft seal from shaft. Press shaft seal plate off of front housing (head cover).

To install components, reverse removal procedure. Tighten compressor through-bolts to 19 ft. lbs. (26 N.m). Tighten discharge valve bolts to 41 INCH lbs. (4.6 N.m). Tighten discharge valve body and body through-bolts to 96 INCH lbs. (10.8 N.m).

Scheme 1

1. Hold clutch plate stationary and remove shaft bolt (or nut). Remove clutch plate using puller.
2. Remove shim(s) from shaft and snap ring. Tap pulley off shaft with plastic hammer. If pulley cannot be removed by hand, use a puller.
3. Remove snap ring, bearing, and seal (if equipped) from pulley. 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 10-13 ft. lbs. (14-17 N.m). Ensure air gap between clutch plate and pulley is .014-.026" (.36-.66 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. Apply voltage to clutch coil. Ensure air gap is as specified.

1. Remove clutch plate and pulley. Remove shim(s) from shaft. Remove clutch coil if necessary. Remove felt and felt retainer (if equipped). 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 .014-.026" (.36-.66 mm). If air gap is incorrect, add or remove shim(s) as necessary.

Hold clutch disc stationary and remove shaft bolt. Remove clutch disc and shim(s) from shaft. Remove snap ring. Using a puller, remove pulley. Remove screw from clutch coil lead. Remove screws and field coil.

To install, reverse removal procedure. Ensure pulley-to-armature gap is .016-.020" (.40-.50 mm). If air gap is incorrect, add or remove shim(s) as necessary. Tighten shaft bolt to 11 ft. lbs. (15 N.m).

Removal & Installation

Remove compressor head cover. Remove discharge valve stopper and discharge valve. (Scheme 2) Install replacement discharge valve and stopper, reversing removal procedure. Tighten discharge valve bolts to 35-56 INCH lbs. (4.0-6.3 N.m). Tighten compressor head cover bolts to 79-104 INCH lbs. (8.9-11.7 N.m).

Scheme 2

Remove compressor rear cover. Remove oil control valve. Remove springs, valve, and rear cover seal. To install components, reverse removal procedure. Tighten oil control valve bolts to 96-104 INCH lbs. (10.8-11.7 N.m). Tighten rear cover nuts to 22-25 ft. lbs. (30-34 N.m) and bolts to 113-156 INCH lbs. (12.8-17.6 N.m).

Remove clutch disc and shim(s). Remove felt seal and snap ring. Using Seal Plate Remover (49 B061 005), engage and remove shaft seal plate. Remove shaft seal with Seal Remover/Installer (49 B061 006). To install, reverse removal procedure. Coat new seal plate and seal with clean refrigerant oil. DO NOT touch seal surfaces with fingers.