Disassembly and Reassembly

DISASSEMBLY AND REASSEMBLY

SERVICE POINTS OF DISASSEMBLY





3. REMOVAL OF NUT
(1) Provisionally install two M6 bolts [length 25 mm (.98 in.) or longer] in the bolt holes of the armature plate.

NOTE Provisionally install the M6 bolts in the armature plate so that the ends of the M6 bolts do not contact the front housing.

(2) Use box-end wrenches to hold the provisionally installed bolts (so as to prevent the armature plate from turning), and then remove the nut.
(3) Remove the armature plate from the crankshaft.





14. REMOVAL OF SEAL PLATE
Use a flat-tip 0 screwdriver or snap-ring pliers to remove the seal plate from the front housing.





15. REMOVAL OF BEARING
Use a brass bar to remove the bearing from the front housing.

INSPECTION
- Check the surface of the armature for scoring or bluing.
- Check the surface of the rotor for scoring or bluing.
- Check the sealing surfaces for cracks, scratches and deformation.
- Check the front housing for cracks or scoring on the sealing surfaces.
- Check the compressor shaft for scoring.





HIGH PRESSURE RELIEF VALVE CHECK
The high pressure relief valve is a safety feature which releases part of the refrigerant inside the system into the atmosphere when the high pressure level exceeds 3,550 kPa (505 psi) during air conditioner operation.
Once the pressure inside the system has been reduced to 2,400 kPa (341 psi) or lower, the high pressure relief valve closes, thus allowing continued operation.

(1) If a leak is detected at section A, replace the high pressure relief valve. The valve can be used unless there is a leak from that section.
(2) If a leak is detected at section B, retighten the valve. If the leak still persists after retightening the valve, replace the packing.





REFRIGERANT TEMPERATURE SENSOR CHECK
The refrigerant temperature sensor detects the temperature of the refrigerant delivered from the compressor during the operation of the air conditioner, and deenergizes the magnetic clutch to stop the compressor when the temperature exceeds 175°C (347°F), due to a problem in the system.
(1) Measure the resistance between terminals (1) and (2) of the connector.

Normal resistance: 80.47 K Ohms when ambient temperature is 25°C (77°F)

If the measurement deviates greatly from the above resistance, replace the refrigerant temperature sensor assembly.





CONTROL VALVE CHECK
The control valve detects a low pressure level during the operation of the air conditioner, and adjusts the amount of refrigerant to be bypassed.
(1) Operate the air conditioner under a high temperature load condition (when vehicle interior temperature is high).
(2) Connect a low pressure gauge to the air compressor.
(3) Operate the air conditioner with the engine running at Idle.
(4) Gradually increase the engine speed while observing the low pressure gauge.
If the valve is normal, the low pressure drops slowly as the engine speed Increases until a pressure of 180 kPa (25 psi) is reached, at which point the pressure temporarily ceases to drop. Then, the pressure again starts dropping as the engine speed further increases.
If the valve is abnormal, the low pressure drops in direct proportion to the increase in engine speed without a temporary leveling off at the 180 kPa (25 psi) pressure level.
If the low pressure drops like this, replace the control valve.

SERVICE POINTS OF REASSEMBLY

13. INSTALLATION OF SHAFT SEAL

CAUTION Do not touch the sealing surfaces of shaft seal carbon ring and shaft seal plate.

(1) Lubricate the shaft seal with specified compressor oil.

Specified compressor oil: FREOL S-83 or SUNISO 5GS





(2) Align the notched parts of the shaft seal with the notched parts of the crankshaft, and then install the shaft seal onto the crankshaft, positioning at the base of the crankshaft.





14. INSTALLATION OF SEAL PLATE

CAUTION Do not touch the sealing surfaces of shaft seal carbon ring and shaft seal plate.

(1) Lubricate the seal plate with specified compressor oil.

Specified compressor oil: FREOL S-83 or SUNISO 5G5

(2) Install the shaft seal plate to the front housing so that the surface (the projection side of the centre ring) of the shaft seal plate is at the shaft seal side.





16. INSTALLATION OF FELT
Using the special tool, insert the felt into the front housing.

NOTE Install the felt with its metal section facing as shown.





15. INSTALLATION OF BEARING
Using the special tool and a press, force the bearing into the front housing.

CAUTION
(1) Avoid applying force suddenly to the compressor body.
(2) Set up the compressor in the press so that no force is applied to the sensor or valves.

8. INSTALLATION OF CLUTCH COIL





(1) Align the pin of the clutch coil with the pin hole in the front housing, and then fit it into the hole.





(2) Install the snap ring so that the tapered surface is at the outer side.





6. INSTALLATION OF ROTOR
Install the snap ring so that the tapered surface is at the outer side.





4. INSTALLATION OF ARMATURE PLATE
Align the mating mark of the crankshaft spline and the mating mark of the armature plate, and then fit them together.

3. INSTALLATION OF NUT





(1) Provisionally install two M6 bolts [length 25 mm (.98 in.) or longer] in the bolt holes of the armature plate.

NOTE Provisionally install the M6 bolts in the armature plate so that the ends of the M6 bolts do not contact the front housing.

(2) Use box-end wrenches to hold the provisionally installed bolts (so as to prevent the armature plate from turning), and then tighten the nut.





(3) Check whether or not the air gap of the clutch is within the standard value.

Standard value: 0.3-0.6 mm (.01-.02 in.)

NOTE If there is a deviation of the air gap from the standard value, make the necessary adjustment by adjusting the number of shims.