Removal and Installation
REMOVAL AND INSTALLATION
DISASSEMBLY AND REASSEMBLY (COMPRESSOR)
SERVICE POINTS OF DISASSEMBLY
3. REMOVAL OF NUT
10. REMOVAL OF BEARING
(1) Use a pointed tool such as an awl to remove the bearing cover and retainer.
(2) Insert the arms (3) of the special tool into the bearing groove at regular intervals
(3) Turn the arms 90° to secure the arms to the bearing.
(4) Set the 3 arms installed to the bearing into the notches (3 places) located on the hanger of the special tool.
(5) Lower the base of the special tool to cover the hanger and tighten the top nut unit it touches the base.
(6) Next, with the bolt of the special tool secured, tighten the nut, and remove the bearing from the compressor.
12. REMOVAL OF LIP SEAL
Catch the groove of the special tool on the lip seal tab. and slowly pull the lip seal straight upwards.
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): R-12, 3,741 kPa (532 psi): R-134a during air conditioning operation.
Once the pressure inside the system has been reduced to 2,400 kPa (341 psi) or lower: R-12, 2,942kPa (4l8psi) or lower: R-134a, the high pressure relief valve closes, thus allowing continued operation.
(1) If leak is detector 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 conditioning, 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 kohms when ambient temperature is 25°C (77°F)
If the measurement deviates greatly from the above resistance, replace the refrigerant temperature sensor assembly.
SERVICE POINTS OF REASSEMBLY
12. INSTALLATION OF LIP SEAL
(1) Install the special tool to the compressor crank shaft.
(2) Apply compressor oil to the sliding surface of the lip seal and the 0-ring. and insert the lip seal.
Specified compressor oil:
(3) Use the special tool to insert the lip seal.
10. INSTALLATION OF BEARING
Use a wooden stand and a 21 mm (0.82in.) socket to insert the bearing into, the compressor.
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.
INSTALLATION OF CLUTCH COIL
When installing the clutch Coil to the air-conditioning compressor body, install so that the pin hole of the air-conditioning compressor body and the clutch coil projection are aligned.
7. INSTALLATION OF SNAP RING
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
- AIR GAP ADJUSTMENT
Check whether or not the air gap of the clutch is within the standard value.
Standard value: 0.4-0.6mm (.015- .024in.)
NOTE: If there is a deviation of the air gap from the standard values make the necessary adjustment by adjusting the number of shims.