Fixed Displacement Compressor

REMOVAL

Clutch Retaining Nut:

1. Using a 13 mm socket and spanner wrench Tool C4563, remove the shaft nut and then lock washer.

Removing Clutch Front Plate:

2. Screw clutch front plate puller Tool C-4771 into hub. Tighten center screw and remove front plate, and shims.

CAUTION: Do not use screwdrivers between front plate assembly and pulley to pry off front plate because this may damage the front plate assembly.

Removing Pulley Snap Ring:

3. Remove pulley retaining snap ring with Tool C-4574, and slide pulley assembly off of compressor.
4. Remove snap ring retaining field coil onto compressor housing. After removing screw and wire clip, slide field coil off of housing.
5. Examine frictional faces of the clutch pulley and front plate for wear. The pulley and front plate should be replaced if there is excessive wear or scoring. If the friction surfaces are oily, inspect the shaft nose area of the compressor for oil and remove the felt from the front cover. If the compressor felt is saturated with oil, the shaft seal is leaking and will have to be replaced.
6. Check bearing for roughness or excessive leakage or grease. If grease from bearing has contaminated the faces of the pulley or front plate or if the bearing is rough, the clutch pulley and front plate should be replaced.

CAUTION: The clutch pulley and the front plate were mated at the factory by a burnishing operation. No attempt should be made to separately replace either part because it will result In clutch slippage due to insufficient contact area.

INSTALLATION

Installing Clutch Coil:

1. Align hole in back of field coil with pin in compressor end housing and position field coil into place. Make sure that lead wires are properly routed and fasten with the wire clip retaining screw.
2. Install field coil retaining snap ring (bevel side outward and both eyelets just to the right or left of the pin in the compressor), with snap ring pliers, Tool C4574. With a screwdriver, press all the way around snap ring to make sure it is properly seated in the groove.

CAUTION: If snap ring is not fully seated it will vibrate out resulting in a clutch failure and severe damage to the front face of the compressor.

Installing Pulley Assembly:

3. Install pulley assembly onto compressor. If necessary, tap gently with a block of wood on the friction surface.

CAUTION: Do not mar the pulley frictional surface.

4. Install pulley assembly retaining snap ring, bevel side outward with snap ring pliers Tool C-4574. With a screwdriver, press all the way around the snap ring to make sure it is properly seated in the groove.
5. If the original front plate assembly and pulley assembly are to be reused, the old shims can be used. If not, place a trial stack of shims, 0.100 in. (2.54mm) thick, on the shaft against the shoulder.
6. Install front plate assembly onto shaft making sure the key enters keyway in front plate assembly hub.

Measuring Air Gap:

7. With the front plate assembly tight against the shims, measure the air gap between front plate and pulley face with feeler gauges. The air gap should be between 0.020 and 0.035 inch (.05 and O.9mm). If proper air gap is not obtained, add or subtract shims until desired air gap is obtained.
8. Install lockwasher and shaft nut. Tighten to 155 ± 20 in. lbs. (17.5 ± 2 Nm) using torque wrench and spanner wrench tool C4563.

CAUTION: Shims may compress after tightening shaft nut Check air gap in four or more places to verify if air gap is still correct. Spin pulley for final check.