Disassembly and Reassembly
CompressorDISASSEMBLY
HITACHI A/C
1) Discharging refrigerant
(1) When removing the compressor from the vehicle, using CHARGING HOSE, gradually discharge the refrigerant from the low pressure side.
Do not suddenly discharge the refrigerant. otherwise oil will also be discharged with the refrigerant.
(2) When using the compressor which has been stored, remove the seal cover from the inlet and outlet ports of the high pressure and low pressure sides using INJECTOR NEEDLE (926190000).
a. Insert the INJECTOR NEEDLE into the hole in the seal cover, and gradually discharge the refrigerant.
b. After discharging, remove the seal cover.
2) Discharging oil
Hold the compressor upside down, and discharge the oil from the refrigerant inlet port [approx. 20 to 50 ml (0.7 to 1.7 US fl oz, 0.7 to 1.8 Imp fl oz)].
If the compressor has been removed from the vehicle, measure the amount of oil discharged.
3) Removing clutch ASSY
(1) Remove the 8 mm nut and hub nut using CLUTCH TIGHTENER (925770000) and 13 mm socket.
Fix the CLUTCH TIGHTENER securely when turning the socket wrench.
(2) Remove the clutch armature using CLUTCH ARMATURE REMOVER (926130000).
(3) Remove the spacer ASSY.
Retain the parts for reassembly.
(4) Remove the 40 mm wedge ring using snap ring pliers.
Do not reuse the removed part.
(5) Remove the rotor.
(6) Remove the 5 mm screw fixing the lead wire clamp using standard screwdriver.
(7) Remove the 50 mm wedge ring using snap ring pliers.
Do not reuse the removed part.
(8) Remove the stator.
Check till terminal for damage. Do not damage the terminal when storing.
(9) Remove the key.
Do not reuse the removed part
4) Removing shaft seal
(1) Remove the 32 mm snap ring using snap ring pliers.
Do not damage the cover end (F).
(2) Remove cover plate using refrigerant, charging hose, charging valve and INJECTOR NEEDLE (926190000).
a. Attach the seal cover to tile inlet and outlet ports, and apply pressure to tile low pressure side.
b. Using waste cloth on the shaft portion receive tile cover plate pushed out
c. Do not use air pressure for pressurizing. Water in tile air will cause rust to be formed inside tile compressor.
d. Be sure to cover the shaft portion with cloth since the cover plate will be ejected suddenly.
e. If it does not eject, push it back, and then press it again.
f. Do not reuse the removed part
(3) Remove the seal ring using SHAFT SEAL INSTALLER (926120000).
a. Using the SHAFT SEAL INSTALLER, push the ring while rotating it slowly in either direction, then carefully withdraw it.
b. Do not reuse tile removed parts.
5) Removing cover end (R)
(1) Attach FRONT COVER TIGHTENER (926170000).
Remove dirt and other foreign matter from the tapered surface at the end of the cover end (F).
(2) Remove the 10 mm socket bolt using 8 mm HEXAGON WRENCH or 8 mm HEXAGON SOCKET WRENCH (926180000).
a. Loosen each bolt one turn in diagonal selection, then loosen bolts off.
b. Check the thread and neck portion of each bolt for deformation.
(3) Remove the cover end (R) using plastic hammer.
Slowly withdraw by holding with a hand. If hard to remove, tap the flange portion lightly by diagonal selection with a plastic hammer.
(4) Remove the 0-rings.
115mm, 110 mm, 63 mm
Do not reuse the removed O-ring.
(5) Remove the cylinder head (R) and SV plate.
a. Do not damage the seat surface.
b. Do not deform the SV plate when removing.
6) Removing cover end (F)
(1) Remove the shell using plastic hammer.
a. Place the shell with its clutch side facing up, and pull it off upward while tapping the flange portion with a plastic hammer.
b. Use a stand (90 mm cylinder) to facilitate removal of shell.
(2) Remove the shell packing.
a. Clean the packing surface of the shell using a knife or the like.
b. Replace the shell pecking with a new one.
(3) Remove the cover end (F).
(4) Remove the 0-rings.
115 mm, 110 mm, 63 mm
Replace the O.rings with new one.
(5) Remove the cylinder head (F) and SV plate.
a. Do not damage the seat surface.
b. Do not deform the SV plate when removing.
PANASONIC A/C
Before starting work, remove dirt from outside the detached compressor. Clean the workbench, tool, and your hands.
1) Place compressor on work bench with clutch facing upward.
2) Engage two 5 mm bolts with internal thread holes in armature. Using screwdriver as a lever, remove center bolt with a hex. wrench.
3) Remove armature and shim from shaft.
4) Remove snap ring from boss section of front plate using snap ring pliers.
5) Attach tongue of puller to rear surface of pulley if necessary and remove pulley.
6) Disconnect field core and thermal protector at connection.
7) Remove field core.
HITACHI A/C
When reassembling, wash each part in clean washing fluid (trichene or gasoline) and left dry, then check for damage or any other faults.
Do not reuse the packings, 0-rings keys and snap rings, replace them with new ones when reassembling.
1) Assembling cover end (F)
(1) Fit the knock pins in the knock pin holes of the cylinder ASSY.
(2) Assemble the 12 mm 0-ring, SV plate, and cylinder head (F) in this order.
a. Be careful not to confuse cylinder head (F) with cylinder head (R).
(Assemble it so that the gas pipe is aligned with the 12 mm hole.)
b. Coat the 0-ring with oil when assembling.
c. Carefully assemble the SV plate into correct position.
* (Two knock pin holes will not fit if the plate is incorrectly positioned. Mike sure the valve of the SV plate fits with the valve seat of the cylinder.)
(3) Assemble the 0-ring and seal ring using SHAFT SEAL INSTALLER (926120000).
0-ring:
110 mm, 63 mm
a. Coat the 0-ring and seal ring with oil when assembling.
b. Insert the seal ring by aligning the cut portion of the ring with the cut portion in the shaft
c. Do not damage the 0-ring of the seal ring with the sharp end of the key groove. Be sure not to damage the sliding surface.
(4) Install the cover end (F).
Install the cover end (F) so that the terminal, when installed the coil, will face the same side as the shell inlet port.
(5) Attach the front cover tightener using FRONT COVER TIGHTENER (926170000).
Remove dirt and other foreign matter from the tapered surface at the end of the cover end (F).
(6) Install the shell packing.
a. Coat the packing with oil.
b. If the packing is protruded, re-adjusts position.
(7) Insert the shell.
a. Install the shell so the oil reservoir of the cylinder will be at the lower portion.
b. After installing the shell, turn the assembly upside down by holding the shaft.
2) Assembling cover end (R)
(1) Fit the knock pin into the knock pin hole of the cylinder ASSY.
(2) Install the 12 mm 0-ring, SV plate and cylinder head (R) in this order.
a. Coat the 0-ring with oil when assembling.
b. Carefully install the SV plate into correct position.
(3) Install the 0-rings.
110 mm, 63 mm
Coat the 0-rings with oil when assembling.
(4) Install the 115 mm 0-ring.
Coat the 0.ring with oil when assembling.
(5) Install the cover end (R).
(6) Tighten the 10 mm hexagon socket head bolts together with the wave washers using hexagon wrench, torque wrench and 8 mm HEXAGON SOCKET WRENCH (926180000).
Tighten bolts lightly by diagonal selection, and finally tighten to the torque of 19 to 21 N.m (1.9 to 2.1 kg-m, 14 to 15 ft.lb).
3) Installing shaft seal
(1) Install the cover plate fitted in advance with the 28 mm 0-ring in its outer groove into the cover end (F) using SHAFT SEAL INSTALLER (926120000).
a. Check the 0.ring for damage.
b. Apply oil to the 0-ring.
(2) Install 32 mm snap ring using snap ring pliers.
Make sure the snap ring is fitted correctly into the groove.
4) Installing clutch ASSY
(1) After installing the stator, install 50 mm wedge ring using snap ring pliers.
a. Do not damage the coil hearing portion.
b. Install the wedge ring with its tapered surface facing up.
(2) Tighten 5 mm x 8 screws to secure the clamp using Phillips-head screwdriver and torque driver.
Tightening torque:
2.7 - 3.3 N-m (0.28 -0.34 kg-m, 2.0 - 2.5 ft-lb)
a. Thoroughly wipe off dirt and oil from the clamp mounting surface on the compressor side.
b. Do not damage the lead and earth wires.
c. Avoid interference of the lead and earth wires with the pulley.
(3) Carefully install the rotor while rotating it by a hand.
Remove dirt and oil from the armature contacting surface.
(4) Install the 40 mm wedge ring using snap ring pliers.
Install the wedge ring with its tapered surface facing up.
(5) Install the key to the key groove in the shaft.
Make sure the key is free from burrs or any other damage.
(6) Install the spacer ASSY using thickness gauge.
Spacer sizes:
Thickness 0.1 mm (0.004 in), 0.3 mm (0.012 in), 0.8 mm (0.031 in)
Adjust the spacer ASSY so that the gap between the pulley and armature (armature gap) is within 0.5 to 0.8 mm (0.02 to 0.031 in).
(7) Install the armature while aligning it with the groove.
Remove dirt and oil from the rotor contacting surface.
(8) Install the 8 mm nut and hub nut using CLUTCH TIGHTENER (925770000), torque wrench and 13 mm socket.
Tightening torque:
19 - 21 N.m (1.9 - 2.1 kg-m, 14 - 15 ft-lb)
5) Charging oil and refrigerant
(1) Charge oil using measuring cylinder and plastic oiler.
Measure 150 ml (5.1 US fl oz, 5.3 Imp fl oz) of oil using a measuring cylinder, and charge oil from the inlet port using a plastic oiler. [If some oil is already charged in the cycle of the cycle carrier, adjust the amount of new oil to be charged so that the total amount will be 150 ml (5.1 US fl oz, 5.3 imp fl oz) in the cycle.]
(2) Run the compressor on the cycle carrier for checking DV leakage, and also for checking compressor performance.
Before starting the operation, be sure to evacuate the refrigerant cycle to avoid air trapped inside.
(3) Charge refrigerant using INJECTOR NEEDLE (926190000).
a. Charging pressure 98 to 141 kPa (1.0 to 1.5 kg/cm2, 14 to 21 psi).
b. Refer to "Charging Refrigerant" in manual.
PANASONIC A/C
1) Install field core on compressor with lead wires facing the same direction as before.
Tightening torque (field core retaining screw):
3.4 - 6.4 N-m (35 - 65 kg-cm, 30 - 56 in-lb)
2) Apply a thin coat of compressor oil to the boss section of front plate, and push pulley into compressor with disc surface facing upward. Then, drive pulley into place using PULLER (926620000) and hammer.
3) Install snap ring.
4) Insert a hex. wrench into center hole from the outside of armature, and install 0.2 mm (0.008 in) and 0.5 mm (0.020 in) shims (one each) from the inside, and position armature Onto shaft.
5) Measure hub-to-pulley clearance using a thickness gauge.
Hub-to-pulley clearance:
0.4 - 0.6 mm (0.016 - 0.024 in)
If the specified clearance is not obtained, replace adjusting spacer and readjust.
6) Apply screw lock to threads of center bolt, and tighten center bolt.
Tightening torque:
11 - 13 N.m (1.1 - 1.3 kg-m, 8 - 9 ft-lb)
7) Connect lead wires to their original positions.