MAZDA PROTEGE 1992 Workshop Manual

AIR CONDITIONER U
23UOUX-031 DISCHARGE
VALVE BODY
CYLINDER
1
23UOUX-03
4. Installation of discharge valve body
1) Replace the O-ring and gasket with new ones.
Apply compressor oil to the new O-ring and gasket and
properly assemble them.
Note
l Fit the gasket as shown left while checking that its
top side faces upward.
2) Carefully install the discharge valve body on the com-
pressor and finger tighten the six M6 bolts.
Note
Bolt torquing sequence
l Torque the two socket head bolts (A) to the specifi-
cation.
l Torque the four bolts (B) in a diagonal manner to
the specification.
Tightening torgue: 9.8 N,rn (100 cm-kg, 87 in-lb)
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U AIR CONDITIONER
23UOUX-033
DISCHARGE
PLATE
, DISCHARGE VALVE
VALVE
DISCHARGE
PLATE
, DISCHARGE VALVE
VALVE
23UOUX-034
23UOUX-03
Discharge Valve Replacement
1. Removal of discharge valve
Carefully remove the discharge valve body.
Remove the bolts, then remove the discharge valve plate and
discharge valve.
Note
l Do not allow the removed bolts to drop into the suc-
tion port.
2. Installation of discharge valve
Install the discharge valve and the discharge valve plate.
Install the bolts and tighten them to the specified torque.
Tightenlng torque: 2.94 N-m (30 cm-kg, 26 In-lb)
Note
l The machined cylinder surface and the rear plate
must be clean and free from foreign material.
l Do not use the removed O-rlng and gasket again.
l Check that the installed discharge valve is proper-
ly seated and aligned.
l Install the discharge valve body with the new O-ring
and gasket referring to the lnstructlon for the ther-
mal protector replacement.
l Make sure that the suction and discharge ports are
plugged with the caps.
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AIR CONDITIONER U
r 23UOUX-036
L 23UOUX.03
I
L
23UOUX-03 7
Shaft Seal Replacement
1. Remove the armature plate.
Note
l Removal of the clutch pulley and coil is not
necessary.
2. Remove the felt seal and snap ring.
3. Remove the shim(s).
4. Insert the
SST into the compressor aligning the cutout of
the
SST with the groove of the seal plate.
5. Rotate the
SST counterclockwise to make sure that the
cutout is engaged with the seal plate.
6. Pull out the seal plate.
7. Insert the
SST into the compressor aligning the cutout of
the
SST with the metal pawl of the shaft seal.
8. Rotate the
SST counterclockwise to make sure that the cut-
off is engaged with the metal pawl.
9. Pull out the shaft seal.
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U AIR CONDITIONER
23UOUX.04
IO. Lay down the compressor and clean the shaft seal contact-
ing face of the compressor with cleaning solvent.
Caution
l Keep the cleaning solvent and dirt out of the com-
pressor.
l Do not use any cloth for cleaning.
Clean only by rinsing with the solvent.
l Do not spill the refrigerant oil from the compressor.
Refill the same amount of the oil if the oil is spilled
out.
23uoux-039
11. Clean the new shaft seal throughly with cleaning solvent.
12. Lubricate the shaft seal with refrigerant oil (SUNISO 5GS
or equivalent) and install it on the
SST.
Note
l Use only clean refrigerant oil.
l Do not touch the sealing surfaces of the shaft seal
after lubricated.
23UOUX-040
13. Liberally lubricate the compressor shaft with refrigerant oil.
14. Install the shaft seal onto the compressor shaft aligning the
seal case flats with the shaft flats.
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AIR CONDITIONER U
15. Clean the seal plate with cleaning solvent.
Lubricate the seal plate with refrigerant oil (SUNISO 5GS
or equivalent).
Note
l Use only clean refrigerant oil.
l Do not touch the sealing surface of the seal plate
after lubricated.
23lJoux-042
SHAFT SEAL PLATE
14
16. First, slide the seal plate into the compressor by hand as
far as possible.
17. Press the seal plate with grip side of the
SST.
18. Install the snap ring with its chamfered edge inside.
19. Press the snap ring with the grip side of the
SST, then in-
stall the felt seal.
20. Make sure the snap ring is seated correctly in its groove.
21. Install the shim(s).
22. Install the armature plate.
Measure the clearance between the pulley and armature
plate all the way around.
If the clearance is not as specified, add or remove the shim
as required.
Clearance: 0.4-0.5mm (0.016-0.020 in)
Shim
Part number Thickness mm (in)
B455 61 L15 0.2 (0.008)
8456 61 L15 0.5 (0.020)
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AIR CONDITIONER
Adjustment
Drive belt
Vehicle with power steering
1. Loosen bolt A and nuts B and C.
2. Turn adjusting bolt B and adjust the deflection of the drive
belt to within specification.
23UOUX-045
Belt Deflection: When applying moderate pressure
98 N (IO kg, 22 lb)
New 8-9mm (0.31-0.35 in)
Used 9-l Omm (0.35-0.39 in)
3. Tighten bolt A and nuts B and C.
Tightening torque
Bolt A: 36-54 N-m (3.7-U m-kg, 27-40 ft-lb)
Nut B : 36-51 N-m (3.8-5.3 m-kg, 28-38 ft-lb)
Nut C : 32-46 N-m (3.2-4.7 m-kg, 24-34 ft-lb)
DEFLECTION
03uoux-087
Vehicle without power steering
1. Loosen nut A.
2. Turn adjusting bolt B and adjust the deflection of the drive
belt to within specification.
Belt
New
Used Deflection: When applying moderate pressure
98 N (10 kg, 22 lb)
8-9mm (0.31-0.35 in)
9-l Omm (0.35-0.39 in)
3 *Tighten nut A. .-,
Tightening torque:
32-34 N*m (3.2-3.5 m-kg, 24-25 Mb)
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AIR CONDITIONER
MAGNETIC CLUTCH
Disassembly / Assembly
1. Disassemble the magnetic clutch as shown in the figure.
2. Assemble the magnetic clutch in the reverse order of removal.
I
1. Pressure plate
2. Rotor pulley 3. Stator
4. Shim
Inspection
Stator
1. Verify continuity between the stator terminals.
Note
l Set the ohmmeter to x 1,000 range.
2. If there is no continuity, replace the stator.
Adjustment
Magnetic clutch clearance
Adjust the clearance between the pressure plate and the ro-
tor pulley by selecting and installing the proper shim(s).
Clearance: 0.4-0.5mm (0.016-0.020 in)
Part number Thickness mm (in)
8455 61 L15
0.2 (0.008)
8456 61 L15
0.5 (0.020)
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U AIR CONDITIONER
RECEIVER/DRIER
Removal / Installation
1. Discharge the refrigeration system. (Refer to page U-32.)
2. Remove the radiator grille. (Refer to Section S.)
3. Remove the receiver/drier as shown in the figure.
Note
l Immediately plug the open fittings to keep moisture out of the system.
4. Install the receiver/drier in the reverse order of removal.
Note
l Apply clean compressor oil to the O-rings before connecting the fittings.
l Do not apply compressor oil to the fitting nuts.
l When installing a new receiver/drier, add compressor oil through the high-pressure pipe port
of the compressor.
Compressor oil: 10 cc (0.61 cu in)
Tightening torque
Receiver/drier inlet: 9.8-20 N*m (1.0-2.0 m-kg, 7.2-14 ft-lb)
Receiver/drier outlet: 15-25 N-m (1.6-2.6 m-kg, 11-18 ft-lb)
1. Receiver/drier .-
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AIR CONDITIONER U
CONDENSER
Removal / Installation
1. Discharge the refrigeration system. (Refer to page U-32.)
2. Remove the radiator grille. (Refer to Section S.)
3. Remove the receiver/drier. (Refer to page U-52.)
4. Remove the condenser as shown in the figure.
Note
l Insert a protector such as cardboard between the condenser and the radiator.
l Immediately plug the open fittings to keep moisture out of the system.
5. install the condenser in the reverse order of removal.
Note
l Apply clean compressor oil to the O-rings before connecting the fittings.
l Do not apply compressor oil to the fitting nuts.
l Remove the protector before installing the radiator brackets.
l When installing a new condenser, add compressor oil through the high-pressure pipe port
of the compressor.
Compressor oil: 30 cc (1.83 cu in)
Tightening torque
Condenser inlet: 15-25 N*rn (1.5-2.5 m-kg, 11-18 ft-lb)
Condenser outlet: 9.8-20 N#m (1 .O-2.0 m-kg, 7.2-14 ft-lb)
1. Radiator bracket
2. Radiator 3. Condenser
23UOUX-01
Inspection
Check for the following and repair or replace the condenser
as necessary.;
1. Cracks, damage, or refrigerant leakage.
2. Bent fins.
3. Distorted or damaged condenser inlet or outlet.
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AIR CONDITIONER
REFRIGERANT LINES
On-vehicle Inspection
Check for leakage at connections. (Refer to page U-32.)
Repair or replace as necessary.
Replacement
1. Discharge the refrigeration system. (Refer to page U-32.)
2. Replace the faulty pipe or hose.
Note
l Immediately plug the open fittings to keep moisture out of the system.
l Apply clean compressor oil to the O-rings before connecting the fittings.
l Do not apply compressor oil to the fitting nuts.
Tightening torque (fittings):
Location Tightening torque
0 9.8-20 N.m
(1.0-2.0 m-kg, 7.2-14 ft-lb)
0 15-25 N-m (1.5-2.5 m-kg, 11-18 ft-lb)
0 9.8-16 N.m (1.0-1.6 m-kg, 7.2-12 ft-lb)
fa 20-29 N.m
(2.0-3.0 m-ka 15-21 ft-lb)
3. Evacuate, charge, and test the refrigeration system.
1. High-pressure hose
2. Low-pressure hose
3. Cooler pipe No.1 4. Cooler pipe No.2 6. Cooler pipe No.4
5. Cooler
pipe No.3 7. Cooler pipe No.5
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