A/c Compressor Servicing Nissan Pulsar N13

HITACHI 6-CYLINDER

Removal

1. Using Clutch Holder (KV99412302), hold clutch hub. Remove shaft nut from shaft. Using Clutch Hub Remover (KV994C5780), remove clutch hub. Thread tool into bore of clutch hub. Hold remover with wrench and thread in center bolt.
2. Pry inner snap ring off. Remove pulley and bearing assembly. If assembly cannot be removed by hand, use Pulley and Bearing Removers (KV994C5781 and KV994C5782).
3. Remove clamping screws that secure coil assembly leads. Remove inner snap ring from coil assembly. Remove coil assembly from front cover. (Scheme 1)

Inspection

Check friction surfaces of clutch for damage due to excessive heat, or excessive grooving due to slippage. Replace compresssor components as necessary. Oil or dirt on friction surfaces should be cleaned with a solvent and a dry rag. Check coil for binding, shorted or open leads.

Installation

1. Install coil assembly on compressor. Properly position terminals. Using snap ring pliers, install snap ring. Using a plastic mallet, drive pulley and bearing assembly onto neck of front cover. Turn pulley, making sure that there is no noise and that rotation is free. Ensure there is no pulley play.
2. Using snap ring pliers, install inner snap ring. Remove all oil from clutch pulley. Fit key and clutch hub to shaft. Select adjusting spacer which gives the correct clearance between pulley and clutch hub.
3. Coat shaft nut with Loctite and install. Using a feeler gauge, measure clutch hub-to-pulley clearance. Clearance should be 020-.031" (.5-.8 mm). If specified clearance is not obtained, replace adjusting spacer and readjust.
4. When replacing compressor clutch assembly, DO NOT forget break-in operation. This is accomplished by engaging and disengaging clutch 30 times.

Hitachi 6-Cylinder Compressor. Scheme 1

SHAFT SEAL

Note. Check compressor refrigerant oil level when replacing seals. See COMPRESSOR REFRIGERANT OIL CHECKING article in this section.

1. Drain oil from suction port, measure oil drained and discard oil. Remove clutch hub, pulley, bearing assembly and coil assembly. See «CLUTCH & COIL»(/nissan/pulsar/n13-1986-1990/remont/general-servicing-all-makes/#ac-compressor-servicing) removal in this article.
2. Using snap ring pliers, remove retainer ring. Remove key and plug low and high pressure openings of compressor with Plugs (KV994C4531, KV994C4532 and KV994C4559).
3. Insert Adapter (KV994C1552) into hole in middle of blind cover at low pressure side of compressor. Connect Pressurizer (KV994C1552) to can of R-12 refrigerant. Wrap a rag around compressor shaft. Apply pressure of 28-71 psi (2-5 kg/cm 2 ) at low pressure (suction) service valve of compressor. Catch shaft seal seat in rag. (Scheme 2) NOTE: If shaft seal cannot be pulled out, reset to its original position, and pressurize again.
4. Insert shaft seal Remover and Installer (KV994C1143) through the open end of front cover. Depress carbon seal and hook tool at case projection of shaft seal. Slowly pull out tool, removing shaft seal. (Scheme 3)

Hitachi 6-Cylinder Compressor Shaft Seal Seat Removal. Scheme 2

Hitachi 6-Cylinder Compressor Shaft Seal Removal. Scheme 3

Check carbon seal surface of shaft seal for damage. Check "O" ring and carbon seal contact surface of shaft seal seat for damage. Make sure that "O" ring contact surface on front cover is not damaged. Make sure refrigerant oil is applied to oil seal in shaft seal seat.

1. To install, reverse removal procedure. Ensure shaft seal contact surface is free of dirt. Lubricate with refrigerant oil. Cap end of compressor shaft.
2. Using Guard (KV994C1143), insert shaft seal. Be sure shaft seal case is aligned with shaft. Apply force to turn seal to left and right. Ensure shaft seal seats properly in shaft cut-out.
3. Fit "O" ring to outside groove of shaft seal seat. Ensure O" ring seats properly. Apply refrigerant oil on contact surfaces and around shaft seal seat. Lightly coat surface of shaft with refrigerant oil.
4. Install key on compressor shaft. Using snap ring pliers, compress retainer ring and fit retainer ring into front cover. Seat retainer ring firmly in groove. Throughly wipe grease or oil from shaft surface.
5. Connect Installer (KV99412329) to shaft of compressor, and turn shaft 5 or 6 times in a clockwise direction to seat seal. See «REFRIGERANT OIL & R-12 CAPACITY TABLE»(/nissan/pulsar/n13-1986-1990/remont/general-servicing-all-makes/#ac-compressor-servicing) for system capacities.

1. Turn compressor upside-down. Drain oil from suction port, measure oil drained and discard oil. Using Remover (KV99412330), remove rear cover mounting bolts. Starting at top, loosen all bolts one turn in an alternating pattern and remove bolts.
2. Grasp rear cover and carefully separate it from compressor. Tap flange lightly with a plastic mallet. Remove flange and discard 3 "O" rings. Remove rear cylinder head, suction valve plate, 2 pins and "O" ring. Carefully remove suction valve plate.

Ensure cylinder surface which comes into contact with suction valve plate is not scratched. Check suction valve plate and cylinder head valve for signs of damage.

1. Using clean refrigerant oil, remove dirt and other matter from rear cover, cylinder head and suction valve plate.
2. Using blocks, position compressor with front face downward and rear upward. Install 2 pins and gas pipe "O" ring in rear of cylinder. Coat "O" ring with refrigerant oil.
3. Apply a coat of refrigerant oil to cylinder surface. Install suction valve plate, making sure that 3 valves properly align with cylinders. Assemble cylinder head and install 3 "O" rings in their respective positions. Coat "O" rings with refrigerant oil before installation.
4. Carefully fit rear cover to rear of compressor. Using hex socket, tighten 5 bolts in an alternating pattern, starting at the top. DO NOT forget lock washers. See «REFRIGERANT OIL & R-12 CAPACITY TABLE»(/nissan/pulsar/n13-1986-1990/remont/general-servicing-all-makes/#ac-compressor-servicing) for system capacities.

1. Turn compressor upside-down. Drain oil from suction valve, measure oil drained and discard oil. Remove compressor clutch assembly. See «CLUTCH & COIL»(/nissan/pulsar/n13-1986-1990/remont/general-servicing-all-makes/#ac-compressor-servicing) removal in this article.
2. Using snap ring pliers, remove shaft seal retainer ring. Remove shaft seal seat. Shaft seal may be removed when cylinder assembly is removed from front cover.
3. Remove rear cover "O" rings, cylinder head, suction valve plate, 2 pins and "O" ring in order. With front facing downward, support compressor shell. Using a plastic mallet, tap at rear end of shell flange, driving shell straight downward. Discard front cover gasket. Detach front cover from cylinder assembly. Discard old "O" rings. DO NOT deform suction valve plate when removing. (Scheme 4)

Hitachi 6-Cylinder Compressor Front Cover Removal. Scheme 4

1. Using blocks, face cylinder assembly upward. Install 2 "O" rings before assembly. Position suction valve plate, making sure that 3 valves of suction valve plate are aligned with cylinder.
2. Apply refrigerant oil on both suction plate surfaces before assembling. Align shaft seal with shaft cut-out. Firmly seat shaft seal at shaft land.
3. Attempt to turn shaft seal back and forth, confirming that shaft seal is seated properly. Install "O" rings on cylinder head. Coat "O" rings with refrigerant oil.
4. Front cover must be installed in such a manner that clutch terminal can be positioned in cut portion of shell. Install front cover on cylinder head so angle is about 60 degrees between threaded hole in front cover and low pressure side of refrigerant passage.
5. Install gasket on front cover. Adjust position of compressor case so suction inlet of case opens in same direction as suction slot of cylinder assembly. Make sure swashplate is visible in suction inlet by removing suction valve.
6. Turn over assembled compressor case and cylinder (with front downward). Install shaft seal seat. Install and adjust compressor clutch. NOTE: Hold compressor case and cylinder assembly firmly to prevent possible mismatching of "O" rings.
7. Ensure clutch terminal is in cut portion provided on top of case. Perform leak test. Fill compressor with specified amount of refrigerant oil. See «REFRIGERANT OIL & R-12 CAPACITY TABLE»(/nissan/pulsar/n13-1986-1990/remont/general-servicing-all-makes/#ac-compressor-servicing) for system capacities.

REFRIGERANT OIL & R-12 CAPACITY

See also:
• CLUTCH & COIL