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CUSTOM AIR CONDITIONING
1 B-69
18. Remove shell and remove holding fixture from
compressor. Reverse holding fixture to again hold
compressor by opposite side using short length screws.
19. Remove and discard both shell to cylinder O-rings.
20. Remove retainer rings using J 4245 Pliers (#23) and
remove (2) discharge valve plates from cylinder (Figs. 1B-130
and 1B-131).
21. Rotate compressor and holding fixture in vise for
access and remove remaining two valve plates and retainer
rings.
22. Remove compressor high pressure relief valve and
O-ring from cylinder. Discard O-ring.
23. Remove cylinder and shaft asm. from holding fixture
for replacement. Leave holding fixture in vise.
Replace
1. Attach new cylinder and shaft asm. to holding fixture
which is clamped in a vise.
2. Coat new pressure relief valve O-ring with clean
refrigerant oil and install O-ring and valve.
3. Intall discharge valve plates and retainers. Rotate
compressor and holding fixture for access as necessary.
4. Install compresor shell as described in Steps 1 thru
8 of COMPRESSOR SHELL-REPLACE.
5. Install thrust washer on shaft with tang pointing
upward (Fig. 1B- 124). Install belleville washer with high
center of washer up and then install second thrust washer
with tang pointing downward. Lurbicate all three washers
with clean refrigerant oil.
6. Install front head and new O-ring by performing Steps
1 thru 3 of FRONT HEAD AND/OR 0-RING-REPLACE.
7. Install new shaft seal kit parts (Steps 1 thru 6 of
COMPRESSOR SHAFT SEAL KIT-REPLACE).
8. Install clutch rotor and bearing asm., clutch coil and
pulley rim as an assembly onto the front head of the
compressor using J 2627 1 Installer (Fig. 1 B- 1 10).
Before fully seating the assembly on the front head, be
sure clutch coil terminals are in proper location and that the
three protrusions on the rear of the coil align with the locator
holes in the front head.
9. Install rotor and bearing asm. retainer ring using J
6083 Snap-Ring Pliers (#24). See Figure 1B-103.
10. Install the shaft key into the hub key groove (Fig.
1B- 101). Allow key to project approximately 3/16 of an inch
out of the keyway.
The shaft key is curved slightly to provide an
interference fit in the shaft key groove. This allows the key
to project without falling out.
11. Be sure frictional surfaces of clutch plate and clutch
rotor are clean before installing clutch plate and hub asm.
Align the shaft key with the shaft keyway and assemble the
clutch plate and hub asm. on the compressor shaft.
CAUTION:
To avoid internal damage to
compressor, do not drive or pound on clutch hub
or shaft.
12. Place J 9480-2 Spacer Bearing on hub, insert end of
J 9480-1 Clutch Plate and Hub Asm. Installer through spacer
and thread tool onto end of compressor shaft (Fig. 1B-102).
13. Hold hex portion of J 9480-1 body with a wrench
and tighten center screw to press hub onto shaft until there
is .020-.040 inch air gap between frictional surfaces of clutch
plate and clutch rotor.
14. Install new shaft nut with small diameter boss of nut
against crankshaft shoulder using J 9399 Socket. Hold clutch
plate and hub asm. with J 25030 Holding Tool and tighten
nut to 8-12 foot pounds torque using a 0-25 pounds torque
wrench.
15. Remove compressor from J 25008- 1 Holding Fixture
and install on car according to appropriate service procedure.
16. "Evacuate and Charge the Refrigerant System"
according to the DISCHARGING, EVACUATING AND
CHARGING PROCEDURES FOR C.C.O.T. SYSTEMS.
A-6 AND R-4 COMPRESSOR LEAK
TESTING (EXTERNAL AND INTERNAL)
Bench-Check Procedure
1. Install Test Plate J 9625 on rear head of compressor.
2. Attach center hose of manifold gage set on Charging
Station to a refrigerant drum standing in an upright position
and open valve on drum.
3. Connect Charging Station HIGH and LOW pressure
lines to corresponding fittings on Test Plate J 9625, using J
5420 Gage Adapters.
NOTE: Suction port of compressor has large internal
opening. Discharge port has smaller internal opening
into compressor.
4. Open LOW pressure control, HIGH pressure control
and REFRIGERANT control on Charging Station to allow
refrigerant vapor to flow into compressor.
5. Using Electronic Leak Detector, J 23400, check for
leaks at pressure relief valve, compressor shell to cylinder,
compressor front head seal (and also rear head seal and oil
charge port on A-6 compressor), and compressor shaft seal.
After checking, shut off LOW pressure control and HIGH
pressure control on Charging Station.
6. If an external leak is present, perform the necessary
corrective measures and recheck for leaks to make certain the
leak has been corrected.
7:Loosen
the manifold gage hase connections to the
Gage Adapters J 5420 connected to the LOW and HIGH
sides and allow the vapor pressure to release from the
compressor.
8. Disconnect both Gage Adapters J 5420 from the Test
Plate J 9625.
9. Rotate the COMPLETE compressor assembly
(
not
the crankshaft or drive plate hub) slowly several turns
to distribute oil to all cylinder and piston areas.
10. Install a shaft nut on the compressor crankshaft if
the drive plate and clutch assembly are not installed.
1 1. Using a box-end wrench or socket and handle, rotate
the compressor crankshaft or clutch drive plate on the
crankshaft several turns to ensure piston assembly to cylinder
wall lubrication.
12. Connect the Charging Station HIGH pressure line
or a HIGH pressure gage and Gage Adapter J 5420 to the
Test Plate J 9625 HIGH side connector.
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