Air Conditioning System: Removal & Installation Suzuki Forenza I

O-ring Replacement

Install new SUZUKI-approved service replacement air conditioning (A/C) O-rings whenever a joint or a fitting is disassembled, except when the O-rings are provided on new components.

When replacing O-rings on an A/C component or a joint connection, the fitting design should be identified to ensure installation of the correct air conditioning service replacement O-ring. Some joint connections and components will implement a "captured" O-ring design fitting that uses a groove to retain the O-ring. Others do not have a groove and use a "non-captured" or "standard" O-ring. Assembly and tightening procedures are the same for both designs, but the O-rings are different.

Installation

1. Align the relay terminal contacts with the base receptacle.
2. Push the relay into the base until it is seated.
3. Connect the negative battery cable.

Scheme 34

1. Remove the glove box. Refer to «GLOVE BOX REMOVAL AND INSTALLATION»(ref-257070-S28189178932007062900000) .
2. Remove the screws and the air filter.
3. Remove the air filter.

Scheme 35

1. Install the air filter.
2. Install the air filter cover and the screws.
3. Install the glove box. Refer to «GLOVE BOX REMOVAL AND INSTALLATION»(ref-257070-S28189178932007062900000) .

Scheme 36

Scheme 37

1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .
3. Remove the suction hose/liquid pipe block retaining nuts at the fire wall.
4. Remove the expansion valve connector block retaining stud bolts.
5. Remove the expansion valve.
6. Discard the O-rings.

1. Clean the grooves that fit the O-rings of any dirt or contamination.
2. Install new O-rings on the evaporator tubes.
3. Install a expansion valve onto the evaporator tubes.
4. Insert the expansion valve connector block retaining stud bolts. Tighten: Tighten the expansion valve retaining stud bolts to 8 N.m (71 lb-in).
5. Install the suction hose/liquid pipe block retaining nuts. Tighten: Tighten the suction hose/liquid pipe block-to-expansion valve retaining nuts to 14 N.m (10 lb-ft).
6. Connect the negative battery cable.
7. Evacuate and recharge the A/C system. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .

Scheme 38

Scheme 39

Scheme 40

Scheme 41

1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .
3. Remove the nut at the discharge hose block connected to compressor.
4. Remove the headlamp housing at the left-hand side. Refer to «HEADLAMP ASSEMBLY REMOVAL AND INSTALLATION (FOR NOTCHBACK AND STATION WAGON MODEL)»(ref-257071-S02617451482007062900000) and «HEADLAMP ASSEMBLY REMOVAL AND INSTALLATION (FOR HATCHBACK MODEL)»(ref-257071-S40823131952007062900000) .
5. Remove the nut at the condenser connecting block.
6. Remove the refrigerant discharge hose.
7. Remove the air cleaner housing bolts and the air filter housing assembly.
8. Disconnect the electrical connector at the pressure transducer.
9. Remove the liquid pipe block-to-expansion valve retaining nut at the fire wall.
10. Remove the headlamp housing at the right-hand side. Refer to «HEADLAMP ASSEMBLY REMOVAL AND INSTALLATION (FOR NOTCHBACK AND STATION WAGON MODEL)»(ref-257071-S02617451482007062900000) and «HEADLAMP ASSEMBLY REMOVAL AND INSTALLATION (FOR HATCHBACK MODEL)»(ref-257071-S40823131952007062900000) .
11. Remove the liquid pipe block-to-receiver dryer retaining nut.
12. Remove the bolts which secure the support clamps that hold the liquid pipe to the vehicle.
13. Remove the liquid pipe from the vehicle.
14. Cap the opening at the receiver-dryer to prevent contamination.

1. Position the liquid pipe into the vehicle.
2. Install the liquid pipe support clamp bolts. Tighten: Tighten the liquid pipe support clamp bolts to 4 N.m (35 lb-in).
3. Install a new O-ring on the pipe at the receiver dryer.
4. Install the liquid pipe block-to-receiver-dryer retaining nut. Tighten: Tighten the liquid pipe block-to-receiver-dryer retaining nut to 14 N.m (10 lb-ft).
5. Install the headlamp housing at the right-hand side. Refer to «HEADLAMP ASSEMBLY REMOVAL AND INSTALLATION (FOR NOTCHBACK AND STATION WAGON MODEL)»(ref-257071-S02617451482007062900000) and «HEADLAMP ASSEMBLY REMOVAL AND INSTALLATION (FOR HATCHBACK MODEL)»(ref-257071-S40823131952007062900000) .
6. Install the liquid evaporator pipe block retaining nut to the fire wall. Tighten: Tighten the liquid pipe block-to-expansion valve retaining nut to 14 N.m (10 lb-ft).
7. Connect the electrical connector at the pressure transducer.
8. Install the air cleaner housing bolts and the air filter housing assembly.
9. Position the refrigerant discharge hose into the vehicle.
10. Install the nut at the condenser connecting block. Tighten: Tighten the refrigerant discharge hose block-to-condenser retaining nut to 16 N.m (12 lb-ft).
11. Install the headlamp housing at the left-hand side. Refer to «HEADLAMP ASSEMBLY REMOVAL AND INSTALLATION (FOR NOTCHBACK AND STATION WAGON MODEL)»(ref-257071-S02617451482007062900000) and «HEADLAMP ASSEMBLY REMOVAL AND INSTALLATION (FOR HATCHBACK MODEL)»(ref-257071-S40823131952007062900000) .
12. Install the nut at the discharge hose block connected to compressor. Tighten: Tighten the refrigerant discharge hose block-to-compressor retaining nut to 33 N.m (24 lb-ft).
13. Connect the negative battery cable.
14. Evacuate and recharge the A/C system. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .

Scheme 42

Scheme 43

1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .
3. Remove the heater/air distributor case assembly. Refer to «HEATER / AIR DISTRIBUTOR CASE ASSEMBLY REMOVAL AND INSTALLATION»(ref-257101-S41142829912007062900000) .
4. Remove A/C expansion valve. Refer to «A/C Expansion Valve Removal and Installation»(ref-257102-S23986489572007062900000) .
5. Remove the wiring harness and electrical connectors from the heater/air distributor case assembly.
6. Remove the screws that connect the heater core housing and the evaporator housing.
7. Remove evaporator core cover screws from the evaporator core housing.
8. Remove the evaporator core.

Scheme 44

Scheme 45

1. Install the evaporator core into the case.
2. Install the screws on the evaporator core housing. Tighten: Tighten the evaporator core cover screws to 1.2 N.m (11 lb-in).
3. Install the screws that connect the heater core housing and the evaporator housing. Tighten: Tighten the heater core housing-to-evaporator housing retaining screws to 1.2 N.m (11 lb-in).
4. Connect the wiring harness and electrical connectors to the heater/air distributor case assembly.
5. Install A/C expansion valve. Refer to «A/C Expansion Valve Removal and Installation»(ref-257102-S23986489572007062900000) .
6. Install the heater/air distributor case assembly. Refer to «HEATER / AIR DISTRIBUTOR CASE ASSEMBLY REMOVAL AND INSTALLATION»(ref-257101-S41142829912007062900000) .
7. Evacuate and recharge the A/C system. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .
8. Connect the negative battery cable.

Scheme 46

Scheme 47

1. Disconnect the negative battery cable.
2. Discharge and recover the refrigerant. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .
3. Remove the air cleaner housing bolts and the air filter housing assembly.
4. Disconnect the electrical connector at the pressure transducer.
5. Remove the suction hose block retaining nut at the fire wall.
6. Cap the openings to the expansion valve to prevent contamination.
7. Remove the suction hose support clamp bolts.
8. Remove the retaining nut from the hose connecting block and disconnect the air conditioning hose assembly connector block from the compressor.
9. Remove the A/C suction hose assembly.
10. Cap the openings to the compressor to prevent contamination.

Scheme 48

Scheme 49

Scheme 50

1. Position the A/C suction hose into the vehicle.
2. Insert the suction hose block-to-compressor to the compressor. Tighten: Tighten the suction hose block-to-compressor retaining nut to 33 N.m (24 lb-ft).
3. Install the suction hose support clamp-to-longitudinal member. Tighten: Tighten the suction hose support clamp-to-longitudinal member bolt to 4 N.m (35 lb-in).
4. Install the suction hose support clamp-to-engine bracket. Tighten: Tighten the suction hose support clamp-to-engine bracket bolt to 14 N.m (10 lb-ft).
5. Install the suction hose block-to-expansion valve retaining nut at the fire wall. Tighten: Tighten the suction hose block-to-expansion valve retaining nut to 14 N.m (10 lb-ft).
6. Connect the electrical connector at the pressure transducer.
7. Install the air cleaner housing bolts and the air filter housing assembly.
8. Connect the negative battery cable.
9. Evacuate and recharge the A/C system. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .

Removal

1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .
3. Remove the nut at the discharge hose block connected to compressor.
4. Remove the headlamp housing at the left-hand side. Refer to «HEADLAMP ASSEMBLY REMOVAL AND INSTALLATION (FOR NOTCHBACK AND STATION WAGON MODEL)»(ref-257071-S02617451482007062900000) and «HEADLAMP ASSEMBLY REMOVAL AND INSTALLATION (FOR HATCHBACK MODEL)»(ref-257071-S40823131952007062900000) .
5. Remove the nut at the condenser connecting block.
6. Remove the refrigerant discharge hose.

1. Install new sealing washers at the compressor connecting block end and a new O-ring at the condenser connecting block end.
2. Position the hose into the vehicle, and install the nut at the condenser connecting block. Tighten: Tighten the refrigerant discharge hose block-to-condenser retaining nut to 16 N.m (12 lb-ft).
3. Make the hose connecting the connecting block to the compressor, and install the retaining nut. Tighten: Tighten the refrigerant discharge hose block-to-compressor retaining nut to 33 N.m (24 lb-ft).
4. Connect the negative battery cable.
5. Evacuate and recharge the A/C system. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .

Scheme 51

1. Disconnect the negative battery cable.
2. Discharge and recover the refrigerant. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .
3. Remove the condenser. Refer to «Condenser Removal and Installation»(ref-257102-S19134011802007062900000) .
4. Remove the receiver-dryer-to-condenser pipe block bolt.
5. Loosen the bolt that secures the receiver-dryer band clamp.
6. Remove the receiver-dryer by sliding it up and out of the band clamp.
7. Cap all open connections to prevent contamination.
8. Drain the oil from the receiver-dryer into a graduated container. Record the amount of oil drained.
9. Discard the used oil.

Scheme 52

1. Add the new oil to the new receiver-dryer. Use the exact amount of oil that you drained from the old receiver-dryer.
2. Install new O-rings onto the two pipes that connect to the receiver-dryer.
3. Install the receiver-dryer into the band clamp. Support the receiver-dryer-to-condenser pipe while pushing the receiver-dryer downward until the pipe is fully installed.
4. Tighten the bolt on the band clamp. Tighten: Tighten the band clamp bolt to 5 N.m (44 lb-in).
5. Install the receiver dryer-to-condenser pipe block bolt. Tighten: Tighten the receiver-dryer-to-condenser pipe block bolt to 5 N.m (44 lb-in).
6. Install the condenser. Refer to «Condenser Removal and Installation»(ref-257102-S19134011802007062900000) .
7. Evacuate and recharge the A/C system. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .

Scheme 53

Scheme 54

1. Disconnect the negative battery cable.
2. Discharge and recover the refrigerant. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .
3. Remove the front bumper. Refer to «FRONT BUMPER FASCIA REMOVAL AND INSTALLATION»(ref-257114-S33603472852007062900000) .
4. Remove the discharge hose block-to-condenser retaining nut.
5. Remove the discharge hose from the condenser.
6. Remove the liquid pipe block-to-receiver-dryer retaining nut.
7. Remove the liquid pipe from the receiver-dryer.
8. Remove the condenser mount bolts.
9. Remove the condenser.
10. Cap all the open lines and the fittings to prevent contamination.

Scheme 55

1. Position the condenser into the vehicle.
2. Install the condenser mount bolts. Tighten: Tighten the condenser mount bolts to 4 N.m (35 lb-in).
3. Install a new O-ring onto the high-pressure pipe mounting block fitting on the receiver-dryer.
4. Install the liquid pipe into the receiver-dryer.
5. Install the liquid pipe block-to-receiver-dryer retaining nut. Tighten: Tighten the liquid pipe block-to-receiver-dryer retaining nut to 14 N.m (10 lb-ft).
6. Install a new O-ring onto the discharge hose connecting block fitting.
7. Install the discharge hose fitting into the condenser.
8. Install the discharge hose connecting block-to-condenser retaining nut at the condenser connecting block. Tighten: Tighten the refrigerant discharge hose block-to-condenser retaining nut to 16 N.m (12 lb-ft).
9. Install the front bumper. Refer to «FRONT BUMPER FASCIA REMOVAL AND INSTALLATION»(ref-257114-S33603472852007062900000) .
10. Connect the negative battery cable.
11. Evacuate and recharge the A/C system. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .
12. Operate the HVAC control to verify the proper function of the heating and cooling systems.

Scheme 56

Scheme 57

1. Disconnect the negative battery cable.
2. Discharge and recover the refrigerant. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .
3. Remove the discharge hose mounting nut.
4. Lift the discharge hose mounting block and the suction hose from the compressor.
5. Raise and suitably support the vehicle.
6. Remove the engine under cover. Refer to «ENGINE UNDER COVERS REMOVAL AND INSTALLATION»(ref-257119-S09566346512007062900000) .
7. Remove the accessory drive belt.
8. Disconnect electrical connector at the compressor.
9. Remove the compressor bolts and nuts.
10. Remove the compressor.
11. Drain the oil from the compressor into a container. Measure the amount of the oil that is drained. Then discard the used oil.

1. Add oil to the new compressor. Use the exact amount of oil that you drained from the old compressor.
2. Install the compressor.
3. Install the compressor mounting bolts and nuts. Tighten: Tighten the compressor mounting bolts and nuts to 25 N.m (18.5 lb-ft).
4. Install new sealing washers to the suction hose and the discharge hose mounting.
5. Connect the electrical connector at the compressor.
6. Install the accessory drive belt.
7. Install the engine under cover. Refer to «ENGINE UNDER COVERS REMOVAL AND INSTALLATION»(ref-257119-S09566346512007062900000) .
8. Lower the vehicle.
9. Place the suction hose into its cavity in the compressor and install the discharge hose mounting block to clamp it into place. Hold this all together while tightening the retaining nut. Tighten: Tighten the refrigerant discharge hose block-to-compressor retaining nut to 33 N.m (24 lb-ft).
10. Connect the negative battery cable.
11. Evacuate and recharge the A/C system. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .

Scheme 58

Clutch Rotor and Bearing Disassembly and Installation

Tools Required

J-6083 Snap Ring Pliers

J-9398-A Bearing Remover

J-9481 Bearing Installer

J-33020 Pulley Puller

J-33023-A Puller Pilot

J-33019 Bearing Staking Tool Set

Includes: J-33019-1 Bearing Staking Guide

Includes: J-33019-2 Bearing Staking Pin

J-33017 Pulley Rotor and Bearing Installer

J-8433-1 Puller Crossbar

J-34992 Compressor Holding Fixture

J-8092 Driver Handle

J-8433-3 Forcing Screw

Scheme 59

Scheme 60

1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .
3. Remove the compressor. Refer to «Condenser Removal and Installation»(ref-257102-S19134011802007062900000) .
4. Remove the clutch drive plate and hub assembly. Refer to «Clutch Plate and Hub Assembly Disassembly and Assembly»(ref-257102-S24077132492007062900000) .
5. Remove the pulley rotor and bearing assembly retaining ring using the snap ring pliers J-6083.
6. With the compressor mounted to the compressor holding fixture J-34992, install the pulley puller J-33020 into the inner circle of slots in the pulley rotor. Turn the pulley puller J-33020 clockwise in the slots to engage the puller tangs with the segments between the slots in the rotor.
7. Hold the pulley puller J-33020 in place and tighten the puller bolt against the compressor shaft to remove the pulley rotor and bearing assembly.
8. Remove the puller bolt from the pulley puller J-33020. With the puller tangs still engaged in the rotor slots, invert the assembly onto a solid flat surface or blocks.
9. Drive the bearing out of the rotor hub with the bearing remover J-9398-A and the driver handle J-8092.

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

1. Invert the pulley rotor and place it on a support block to fully support the rotor hub during bearing installation.
2. Align the new bearing squarely in the pulley bore. Use the bearing installer J-9481 and the driver handle J- 8092, drive the bearing fully into the pulley bore.
3. Place the bearing staking guide J-33019-1 and the bearing staking pin J-33019-2 in the rotor hub core. Shift the rotor and bearing assembly on the block to give full support to the hub under the staking pin. A heavy-duty rubber band may be used to hold the staking tool pin in the guide. The pin should be properly positioned in the guide after each impact on the pin.
4. Strike the pin with a hammer until a metal stake, similar to the original, is formed down to, but not touching, the bearing. The metal stake should not contact the outer race of the bearing to avoid the possibility of distorting the outer race. Stake in three places 120° apart.
5. With the compressor mounted to the holding fixture J-34992, position the rotor and bearing assembly on the compressor housing.
6. Position the pulley rotor and bearing installer J-33017 and the puller pilot J-33023-A directly over the inner race of the bearing.
7. Position the puller crossbar J-8433-1 center forcing bolt on the puller pilot J-33023-A and assemble the two through-bolts and the washers through the slots on the puller crossbar J-8433-1. Thread the through-bolts into the holding fixture J-34992. The thread of the through-bolts should engage the full thickness of the fixture.
8. Tighten the center forcing screw J-8433-3 in the puller crossbar J-8433-1 to force the pulley rotor and bearing assembly onto the compressor housing.
9. Install the rotor and bearing assembly retainer ring using the snap ring pliers J-6083.
10. Reinstall the clutch drive plate and hub assembly. Refer to «Clutch Plate and Hub Assembly Disassembly and Assembly»(ref-257102-S24077132492007062900000) .
11. Install the compressor. Refer to «Condenser Removal and Installation»(ref-257102-S19134011802007062900000) .
12. Connect the negative battery cable.
13. Evacuate and recharge the A/C system. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .

Clutch Coil Removal and Installation

Tools Required

J-8433-1 Puller Crossbar

J-8433-3 Forcing Screw

J-33023-A Puller Pilot

J-33024 Clutch Coil Installer Adapter

J-33025 Clutch Coil Puller Legs

J-34992 Compressor Holding Fixture

Scheme 66

1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .
3. Remove the compressor. Refer to «Condenser Removal and Installation»(ref-257102-S19134011802007062900000) .
4. Remove the clutch plate and hub assembly. Refer to «Clutch Plate and Hub Assembly Disassembly and Assembly»(ref-257102-S24077132492007062900000) .
5. Remove the clutch rotor and bearing. Refer to «Clutch Rotor and Bearing Disassembly and Installation»(ref-257102-S11241879352007062900000) .
6. Mark the clutch coil terminal location on the compressor housing.
7. Install the puller pilot J-33023-A on the compressor housing. Also install the puller cross bar J-8433-1 with the clutch coil puller legs J-33025.
8. Tighten the forcing screw J-8433-3 against the puller pilot J-33023-A to remove the clutch coil.

Scheme 67

Scheme 68

Scheme 69

1. Place the clutch coil installer adapter J-33024 over the internal opening of the clutch coil housing and align the clutch coil installer adapter J-33024 with the compressor housing.
2. Place the clutch coil installer adapter J-33024 over the internal opening of the clutch coil housing and align the clutch coil installer adapter J-33024 with the compressor housing.
3. Center the puller crossbar J-8433-1 in the countersunk center hole of the clutch coil installer adapter J- 33024. Install the through-bolts of the compressor holding fixture J-34992 and the washers in the crossbar slots. Thread them into the holding fixture to the full thickness of the holding fixture.
4. Turn the forcing screw J-8433-3, or use a suitable vise, to force the clutch coil onto the compressor housing.
5. When the clutch coil is fully seated on the compressor housing, use a 3 mm (1/8 in.) diameter drift punch and stake the housing at three places, 120° apart, to ensure that the clutch coil will remain in position. Stake point size should be only one-half the area of the punch tip and approximately 0.28 - 0.35 mm (0.010 - 0.015 in.) deep.
6. Install the clutch rotor and bearing assembly. Refer to «Clutch Rotor and Bearing Disassembly and Installation»(ref-257102-S11241879352007062900000) .
7. Install the clutch plate and hub assembly. Refer to «Clutch Plate and Hub Assembly Disassembly and Assembly»(ref-257102-S24077132492007062900000) .
8. Install the compressor. Refer to «Condenser Removal and Installation»(ref-257102-S19134011802007062900000) .
9. Connect the negative battery cable.
10. Evacuate and recharge the A/C system. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .

Shaft Seal Replacement

Should a compressor shaft seal ever have to be replaced, the receiver-dryer in this system must also be removed from the vehicle. The oil in the receiver-dryer must then be drained, measured and replaced. Refer to Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System .

Tools Required

J-5403 Snap Ring Pliers

J-9553-1 O-ring Remover

J-23128-A Seal Seat Remover/Installer

J-33011 O-ring Installer

J-34614 Shaft Seal Protector

Scheme 70

Scheme 71

Scheme 72

1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .
3. Loosen and reposition the compressor in the mounting brackets.
4. Remove the clutch drive plate and hub assembly from the compressor. Refer to «Clutch Plate and Hub Assembly Disassembly and Assembly»(ref-257102-S24077132492007062900000) .
5. Use the snap ring pliers J-5403 to remove the shaft seal retaining ring.
6. Thoroughly clean the inside of the compressor housing area surrounding the shaft, the exposed portion of the seal, the shaft itself, and the O-ring groove.
7. Fully engage the knurled tangs of the seal seat remover/installer J-23128-A into the recessed portion of the seal by turning the handle clockwise. Remove and discard the seal from the compressor with a rotating pulling motion. The handle should be hand-tightened securely. Do not use a wrench or pliers to tighten the handle.
8. Remove and discard the O-ring from the compressor neck using the O-ring remover J-9553-1.
9. Thoroughly clean the seal O-ring groove in the compressor housing.
10. Inspect the shaft and the inside of the compressor housing neck for dirt or foreign material. These parts must be perfectly clean before installing any new parts.

Scheme 73

Scheme 74

1. Dip the new seal O-ring in clean Polyalkaline Glycol (PAG) refrigerant oil and assemble the O-ring onto the O-ring installer J-33011.
2. Insert the O-ring installer J-33011 into the compressor neck until the installer "bottoms." Lower the moveable slide of the O-ring installer J-33011 to release the O-ring into the seal O-ring lower groove. (The top groove of the compressor neck is for the shaft seal retainer ring.) Rotate the installer to seat the O-ring and then remove the installer.
3. Attach the shaft lip seal to the seal seat remover/installer J-23128-A. Dip the seal in clean PAG oil.
4. Install the shaft seal protector J-34614 in the seal. Place it over the shaft and push the seal into place with a rotary motion.
5. Use the snap ring pliers J-5403 to install the shaft seal retaining ring with its flat side against the seal.
6. Remove any excess oil around the shaft and the inside of the compressor housing neck.
7. Install the clutch plate and hub assembly. Refer to «Clutch Plate and Hub Assembly Disassembly and Assembly»(ref-257102-S24077132492007062900000) .
8. Reposition the compressor in its mounting.
9. Adjust the tension on the serpentine accessory drive belt.
10. Connect the negative battery cable.
11. Evacuate and recharge the A/C system. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .
12. Perform a leak test of the system. Refer to «Leak Testing Refrigerant System»(ref-257102-S14835443392007062900000) .

Control Valve Assembly Removal and Installation

Tools Required

J-5403 Snap Ring Pliers

Scheme 75

1. Recover the refrigerant. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .
2. Remove the control valve retaining ring using the snap ring pliers J-5403.
3. Remove the control valve assembly.

Scheme 76

1. Coat all the O-rings with clean Polyalkaline Glycol (PAG) oil.
2. Push the control valve in place using thumb pressure.
3. Use the snap ring pliers J-5403 to install the valve retaining ring. The high point of the curved sides must be against the valve housing. Be sure the retaining ring is properly seated in the ring groove.
4. Evacuate and recharge the A/C system. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .

Rear Head, Gasket, Valve Plate, Reed Plate, and O-ring Removal and Installation

Tools Required

J-34993 Cylinder Alignment Rods

Scheme 77

1. Recover the refrigerant. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .
2. Discharge the A/C system. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .
3. Remove the compressor. Refer to «Condenser Removal and Installation»(ref-257102-S19134011802007062900000) .
4. Drain the oil from compressor into a suitable container. Measure and record the amount of oil drained from the compressor. Discard the used oil.
5. Remove the clutch plate and hub assembly. Refer to «Clutch Plate and Hub Assembly Disassembly and Assembly»(ref-257102-S24077132492007062900000) .
6. Remove the clutch rotor and bearing. Refer to «Clutch Rotor and Bearing Disassembly and Installation»(ref-257102-S11241879352007062900000) .
7. Remove the clutch coil. Refer to «Clutch Coil Removal and Installation»(ref-257102-S30718784712007062900000) .
8. Remove the compressor through-bolts. Remove and discard the gaskets.
9. Using a wooden block and a plastic-headed hammer, tap around the edge of the rear head to disengage the head from the compressor cylinder. Separate the rear head, the head gasket, the rear valve plate, the suction reed plate, and the cylinder-to-rear head O-ring. Discard the head gasket and the O-ring.

Scheme 78

1. Place the rear head on a clean, flat surface. Position the head with the control valve at the 6 o'clock position.
2. Install the cylinder alignment rods J-34993 in the mounting holes at the 11 o'clock and the 5 o'clock positions.
3. Install the head gasket over the cylinder alignment rods J-34993 with the elongated hole at the upper left pin (the 11 o'clock position).
4. Install the rear head valve plate over the guide pins with the elongated hole at the upper left pin. Lower the rear head valve plate into place.
5. Install the suction reed plate over the cylinder alignment rods J-34993. Remove the alignment rod at the 5 o'clock position.
6. Lubricate the cylinder to the new rear head O-ring with clean Polyalkaline Glycol (PAG) refrigerant oil.
7. Install the O-ring in the cylinder O-ring groove. The O-ring seal surface of the head may be lubricated to ease assembly.
8. With the O-ring in place on the rear of the cylinder assembly, locate the relief boss for the compressor guide pin at the 6 o'clock position, directly above the hole in the side of the rear head. Carefully lower the cylinder and the front head assembly over the guide pin to the rear head.
9. Press the cylinder and the compressor housing assembly down onto the rear head using both hands.
10. Add the new through-bolt gasket to the through-bolts and install it into the compressor assembly. Four of the through-bolts must thread into the rear head before removing the alignment rod. Tighten: Alternately tighten the through-bolts in progressive torque sequence to 10 N.m (89 lb-in).
11. Add new PAG refrigerant oil as determined in Step 1 of Removal Procedure.
12. Place the shaft nut on the shaft and rotate the compressor shaft several times.
13. Perform a leak test on the compressor. Refer to «Leak Testing Refrigerant System»(ref-257102-S14835443392007062900000) .
14. Install the clutch coil. Refer to «Clutch Coil Removal and Installation»(ref-257102-S30718784712007062900000) .
15. Install the clutch rotor and bearing. Refer to «Clutch Rotor and Bearing Disassembly and Installation»(ref-257102-S11241879352007062900000) .
16. Install the clutch plate and hub assembly. Refer to «Clutch Plate and Hub Assembly Disassembly and Assembly»(ref-257102-S24077132492007062900000) .
17. Install the compressor. Refer to «Condenser Removal and Installation»(ref-257102-S19134011802007062900000) .
18. Evacuate and recharge the A/C system. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .

Cylinder-to-Front Head O-ring Removal and Installation

Tools Required

J-34993 Cylinder Alignment Rods

J-35372 Support Block

1. Recover the refrigerant. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .
2. Remove the compressor. Refer to «Condenser Removal and Installation»(ref-257102-S19134011802007062900000) .
3. Drain the oil from compressor into a suitable container. Measure and record the amount of oil drained from the compressor. Discard all used oil.
4. Remove the clutch plate and hub assembly. Refer to «Clutch Plate and Hub Assembly Disassembly and Assembly»(ref-257102-S24077132492007062900000) .
5. Remove the clutch rotor and bearing. Refer to «Clutch Rotor and Bearing Disassembly and Installation»(ref-257102-S11241879352007062900000) .
6. Remove the clutch coil. Refer to «Clutch Coil Removal and Installation»(ref-257102-S30718784712007062900000) .
7. Remove and discard the shaft seal parts. Refer to «Shaft Seal Replacement»(ref-257102-S16796129542007062900000) .
8. Remove the compressor through-bolts. Remove and discard the gaskets.
9. Using a wooden block and a plastic-headed hammer, tap the compressor housing at the mounting locations to disengage the housing from the compressor cylinder.
10. Remove the thrust washer and the bearing.
11. Remove and discard the compressor housing-to-cylinder O-ring.

Scheme 79

1. Rest the rear head on the support block J-35372. Locate the control valve at the 6 o'clock position.
2. Install cylinder alignment rod J-34993 through the 11 o'clock and the 5 o'clock bolt holes.
3. Lubricate the new cylinder-to-compressor housing O-ring with clean Polyalkaline Glycol (PAG) oil.
4. Install the new O-ring in the cylinder O-ring groove.
5. Install the thrust washer and bearing in the same order as they were removed.
6. Align the guide pin recess in the compressor housing with the guide pin. Press down on the compressor housing with both hands to force it over the O-ring on the cylinder assembly.
7. Add a new through-bolt gasket to the through-bolts and install it into the compressor assembly. Four through-bolts must thread into the rear head before removing the guide pins. Tighten: Alternately tighten the through-bolts in progressive torque sequence to 10 N.m (89 lb-in).
8. Install a new shaft seal. Refer to «Shaft Seal Replacement»(ref-257102-S16796129542007062900000) .
9. Add new PAG oil equal to the amount drained in Step 3 .
10. Install the clutch coil. Refer to «Clutch Coil Removal and Installation»(ref-257102-S30718784712007062900000) .
11. Install the clutch rotor and bearing. Refer to «Clutch Rotor and Bearing Disassembly and Installation»(ref-257102-S11241879352007062900000) .
12. Install the clutch plate and hub assembly. Refer to «Clutch Plate and Hub Assembly Disassembly and Assembly»(ref-257102-S24077132492007062900000) .
13. Perform a leak test on the compressor. Refer to «Leak Testing Refrigerant System»(ref-257102-S14835443392007062900000) .
14. Install the compressor. Refer to «Condenser Removal and Installation»(ref-257102-S19134011802007062900000) .
15. Evacuate and recharge the A/C system. Refer to «Discharging, Adding Oil, Evacuating, and Charging Procedures for A/C System»(ref-257102-S08954628872007062900000) .