Disassembly and Assembly

COMPRESSOR

DISASSEMBLY




1. Remove compressor.
2. Fix armature plate with special tool and remove armature plate screw.

Special Tools
(A): 09991-06020
(B): 09991-06060

NOTE: Do not reuse armature plate nut.




3. Remove armature plate. Use special tool for type A.

Special Tool
(B): 09991-06030




4. Remove lead wire clamp.
5. Remove felt ring and shims from shaft.
6. Using special tool (C), remove circlip.

Special Tool
(C): 09900-06107

7. Remove magnet clutch lead wire clamp screw, and disconnect magnet clutch read wire.




8. Remove magnet clutch with puller.

NOTE: Be careful not to damage pulley when tapping magnet clutch.

9. Remove magnet clutch coil.




10. Remove front head mounting screw (8 pcs).




11. Remove front head pushing cylinder shaft.

NOTE: Be careful not to remove cylinder from case.

12. Remove O-ring.




13. Remove lip seal from front head.

ASSEMBLY




1. Press-fit lip seal into front head using special tool (E).

Special Tool
(E): 09991-06050

CAUTION: Do not reuse mechanical seal once removed from compressor.




2. Coat special tool (F) surface with oil and install it to the shaft.

Special Tool
(F): 09991-06040




3. Install O-ring to case.
4. Apply A/C oil to lip seal and O-ring.
5. Install front head assembly.




6. Tighten front head bolt as specified below.

Tightening Torque
(a): 14 N.m (1.4 kg-m, 10.5 lb-ft)
(b): 23 N.m (2.3 kg-m, 17.0 lb-ft)

NOTE:
- Be sure to use new front head bolt washer.
- Tighten bolt (a) first, and next (b).




7. Install magnet clutch coil.
Protrusion on under side of coil ring must match hole in compressor assembly to prevent movement ant correctly locate lead wire.

8. Using special tool (C), install snap ring as shown.

Special Tool
(C): 09990-06107

9. Clamp covering portion of read wire.




10. Install magnet clutch.
1. Set magnet clutch squarely over clutch installation boss.
2. Place special tool (D) onto clutch bearing.
Ensure that edge rests only on inner race of bearing.
3. Install snap ring.

Special Tool
(D): 09991-06010

CAUTION: Be careful not to scratch bearing seal.




11. Adjust clearance, between armature plate and magnet clutch by putting shim on compressor shaft.

Standard clearance "a": 0.3 - 0.5 mm (0.012 - 0.020 in.)




12. Tighten new armature plate nut as specified below.

Tightening Torque
(a): 14 Nm (1.4 kg-m, 10.5 lb-ft)

Special Tools
(A): 09991-06020
(B): 09991-06060