CHEVROLET PLYMOUTH ACCLAIM 1993 Service Manual

REFRIGERANT SYSTEM DIAGNOSIS
Ä HEATING AND AIR CONDITIONING 24 - 37

FIXED DISPLACEMENT COMPRESSORÐMODEL SD709P INDEX
page page
Compressor ............................. 38
Compressor Clutch/Coil Assembly ............ 38
Compressor Shaft Seal .................... 41 Cylinder Head/Valve Plate
.................. 44
Description ............................. 38
Refrigerant System Diagnosis ............... 45
DESCRIPTION
The Sanden compressor is a 7 piston design. Sys-
tem lubrication is provided by 135 ml 615 ml (4.6 oz.
6 0.5 oz.) of 500 viscosity refrigerant oil.
The clutch used on the compressor consists of 3 ba-
sic components:
² The pulley
² Front plate
² Field coil
The pulley and field coil are attached to the front
head of the compressor with tapered snap rings. The
hub is keyed to the compressor shaft and is retained
on the shaft with a self-locking nut. Special service
tools are required to remove and install the clutch
plate on the compressor shaft.
COMPRESSOR
The A/C compressor may be removed and posi-
tioned without discharging the refrigerant system.
Discharging is not necessary if removing the A/C
compressor clutch/coil assembly, engine, cylinder
head, or generator.
WARNING: REFRIGERANT PRESSURES REMAIN
HIGH EVEN THOUGH THE ENGINE MAY BE
TURNED OFF. BEFORE REMOVING A FULLY
CHARGED COMPRESSOR, REVIEW THE SAFETY
PRECAUTIONS AND WARNINGS SECTION IN THIS
GROUP. DO NOT TWIST OR KINK THE REFRIGER-
ANT LINES WHEN REMOVING A FULLY CHARGED
COMPRESSOR. SAFETY GLASSES MUST BE
WORN.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Loosen and remove drive belts (refer to group
7, Cooling System) and disconnect compressor clutch
wire lead. (3) Remove refrigerant lines from compressor (if
necessary). (4) Remove compressor attaching nuts and bolts.
(5) Remove compressor. If refrigerant lines were
not removed, lift compressor/clutch assembly and tie
it to a suitable component. To install, reverse the removal procedure.
COMPRESSOR CLUTCH/COIL ASSEMBLY
The magnetic clutch consists of a stationary elec-
tro-magnetic coil and a rotating pulley and plate as-
sembly. The electromagnetic coil is retained on the com-
pressor with a snap ring and is dimpled to maintain
its position. The pulley and plate assembly are mounted on the
compressor shaft. When the compressor is not in operation, the pul-
ley free wheels on the clutch hub bearing. When the
coil is energized the plate is magnetically engaged
with the pulley and turns the compressor shaft.
REMOVAL
(1) Insert the 2 pins of the front plate spanner into
any 2 threaded holes of the clutch front plate (Fig.
1). Hold clutch plate stationary. Remove hex nut
with 19 mm (3/4 inch) socket.
(2) Remove clutch front plate using puller. Align
puller center bolt to compressor shaft (Fig. 2). Thumb
tighten the puller bolts into the threaded holes. (3) Turn center bolt clockwise with 19 mm (3/4
inch) socket until front plate is loosened. (4) Remove shaft key by lightly tapping it loose
with a slot screwdriver and hammer (Fig. 3). (5) Remove the external front housing snap ring
by using spread type snap ring pliers (Fig. 4).
Fig. 1 Hex Nut Removal
24 - 38 HEATING AND AIR CONDITIONING Ä

(6) Insert the lip of the jaws of the rotor puller into
the snap ring groove exposed in the previous step
(Fig. 5). (7) Place rotor puller shaft protector over the ex-
posed shaft. (8) Install the puller plate and bolt (Fig. 6). 2 bolts
go through the plate and into the jaws. Finger
tighten bolts. (9) Turn puller center bolt clockwise using 3/4 inch
socket until rotor pulley is free. (10) Loosen coil lead wire from clip on top of com-
pressor front housing (Fig. 7). (11) Using spread type snap ring pliers, remove
snap ring and field coil (Fig. 8).
INSTALLATION
(1) Install the field coil with the snap ring. (2) Place coil lead wire under clip on top of com-
pressor front housing and tighten the retaining
screw. (3) Support the compressor on the 4 mounting ears
at the compressor rear. If a vise is being used, clamp
only on the mounting ears. Never clamp on the com-
pressor body. (4) Align rotor assembly squarely on the front
housing hub.
Fig. 2 Clutch Front Plate Removal
Fig. 3 Shaft Key Removal
Fig. 4 External Snap Ring Removal
Fig. 5 Install Shaft Protector
Ä HEATING AND AIR CONDITIONING 24 - 39

(5) Using Rotor Installer Set, place the ring part of
the set into the bearing cavity (Fig. 9). Make certain
the outer edge rests firmly on the rotor bearing inner
race. (6) Place the tool set driver into the ring (Fig. 10).
(7) With a hammer, tap the end of the driver while
guiding the rotor to prevent binding. Tap until the
rotor bottoms against the compressor front housing
hub. Listen for a distinct change of sound during the
tapping process. (8) Install external front housing snap ring with
spread type snap ring pliers. (9) Install front plate assembly.
² Check that original clutch shims are in place on
compressor shaft.
² Replace compressor shaft key.
² Align front plate key-way to compressor shaft key.
(10) Using shaft protector, tap front plate to shaft
until it has bottomed to the clutch shims (Fig. 11).
Listen for a distinct change of sound during the tap-
ping process.
Fig. 6 Install Puller Plate
Fig. 7 Loosen Coil Lead Wire
Fig. 8 Snap Ring and Field Coil Removal
Fig. 9 Rotor Installer Set
24 - 40 HEATING AND AIR CONDITIONING Ä

(11) Replace shaft hex nut. Tighten the hex nut to 37
N Im (27 ft. lbs.) torque.
(12) Check air gap with feeler gauge (Fig. 12). The
specification is 0.406-0.787 mm (0.016-0.031 inch). If
air gap is not consistent around the circumference,
lightly pry up at the minimum variations. Lightly tap
down at points of maximum variation. The air gap is determined by the spacer shims.
When installing the original or a new clutch
assembly, try the original shims first. When in-
stalling a new clutch onto a compressor that
previously did not have a clutch, use 0.040, 0.020,
and 0.005 shims from the clutch accessory sack. (13) If the air gap does not meet the specification
given, add or subtract shims as required.
COMPRESSOR SHAFT SEAL
Using a refrigerant recovery machine, remove the
refrigerant from the A/C system before replacing
shaft seal.
REMOVAL
(1) Insert the 2 pins of the front plate spanner into
any 2 threaded holes of the clutch front plate (Fig.
1). Hold clutch plate stationary. Remove hex nut
with 19 mm (3/4 inch) socket.
(2) Remove clutch front plate using puller (Fig. 2).
Align puller center bolt to compressor shaft. Thumb
tighten the 3 puller bolts into the threaded holes. (3) Turn center bolt clockwise with 19 mm (3/4
inch) socket until front plate is loosened.
Fig. 12 Check Air Gap
Fig. 1 Hex Nut Removal
Fig. 10 Tool Set Driver
Fig. 11 Front Plate Installation
Ä HEATING AND AIR CONDITIONING 24 - 41

Shaft seal replacement should be done on the
bench. Never use any old parts of the shaft seal
assembly. Rebuild the complete assembly. (4) Using either of the snap ring tools, insert the tool
points into the 2 holes of the felt ring metal retainer.
Lift the felt ring out (Fig. 3).
(5) Remove the clutch shim. Use O-ring hook and a
small screwdriver to prevent shim from binding on
shaft (Fig. 4). (6) Remove shaft seal seat retaining snap ring with
pinch type snap ring pliers (Fig. 5). (7) Remove the shaft seal seat, using seal seat tool
(Fig. 6). (8) Insert the Seal Remover and Installer Tool
against the seal assembly. Press down against the
seal spring and twist the tool until it engages the
slots of the seal cage (Fig. 7). Lift out seal assembly.
INSTALLATION
(1) Clean seal cavity thoroughly with a lint-free or
synthetic cloth and clean refrigerant oil. Then blow
out with dry pressurized vapor. (2) Make sure all foreign substances are thor-
oughly removed. (3) Insert Seal Sleeve Protector over compressor
shaft (Fig. 8).
Fig. 4 Clutch Shim Removal
Fig. 5 Snap Ring Removal
Fig. 2 Remove Clutch Front Plate
Fig. 3 Felt Ring Removal
24 - 42 HEATING AND AIR CONDITIONING Ä

(4) Do not touch the new seal lapping surfaces. Dip
the mating surfaces in clean refrigerant oil before
proceeding. (5) Engage slots of Seal Remover and Installer to
new seal cage and insert seal assembly firmly into
place in the compressor seal cavity (Fig. 9). Twist
tool in opposite direction to disengage tool from seal
cage. Remove tool. (6) Coat seal retainer with clean refrigerant oil.
Use seal seat tool to install (Fig. 10). Press lightly
against seal. (7) Install snap ring. Beveled edge lies outward
from compressor. Flat side lies toward compressor. It
may be necessary to lightly tap the snap ring to se-
curely position it in its groove. (8) Replace clutch spacer shims.
(9) Tap new felt ring into place (Fig. 11).
(10) Align front plate key-way to compressor shaft
key. (11) Using shaft protector, tap front plate to shaft
until it has bottomed to the clutch shims. Listen for
a distinct change of sound during the tapping pro-
cess. (12) Replace shaft hex nut. Tighten the hex nut to
37 N Im (27 ft. lbs.) torque.
(13) Check air gap with feeler gauge (Fig. 12). The
specification is 0.406-0.787 mm (0.016-0.031 inch). If
Fig. 6 Shaft Seal Seat Removal
Fig. 7 Seal Assembly Removal
Fig. 8 Insert Seal Sleeve Protector
Fig. 9 Compressor Shaft Seal Installation
Ä HEATING AND AIR CONDITIONING 24 - 43

air gap is not consistent around the circumference,
lightly pry up at the minimum variations. Lightly tap
down at points of maximum variation.The air gap is determined by the spacer shims.
When installing the original or a new clutch
assembly, try the original shims first. When in-
stalling a new clutch onto a compressor that
previously did not have a clutch, use 0.040, 0.020,
and 0.005 shims from the clutch accessory sack. (14) If the air gap does not meet the specification
given, add or subtract shims as required.
CYLINDER HEAD/VALVE PLATE
REMOVAL
(1) Remove cylinder head bolts.
(2) Using a small hammer and a gasket scraper
separate the cylinder head from the valve plate (Fig.
1).
Fig. 12 Check Air Gap
Fig. 1 Cylinder Head and Valve Plate
Fig. 10 Install Seal Retainer
Fig. 11 Install New Felt Ring
24 - 44 HEATING AND AIR CONDITIONING Ä

(3) Visually inspect all parts for damage.
(4) Separate the valve plate from the cylinder
block (Fig. 2).
INSPECTION
Visually inspect the rear valves and discharge re-
tainer for damage. Discard any component if any por-
tion is damaged.
CLEANING
If valve plate and/or cylinder head are to be reused,
carefully remove gasket materials using the gasket
scraper. Do not damage cylinder block or valve plate
surfaces.
INSTALLATION
When installing the cylinder head valve plate,
use the new gaskets in the parts kit. (1) Coat new valve plate gasket with clean refriger-
ant oil. (2) Install valve plate gasket by aligning valve plate
gasket to locating pin holes and oil orifice in cylinder
block. (For easy reference, the gaskets have a notch at
the bottom outside edge). (3) Install valve plate by aligning valve plate locat-
ing pins to the pin holes in the block and position valve
plate. (4) Install cylinder head and tighten bolts in order to
32 N Im (24 ft. lbs.) torque (Fig. 3).
REFRIGERANT SYSTEM DIAGNOSIS
Refer to the Refrigerant System Diagnosis chart in
this section.
Fig. 2 Valve Plate Removal
Fig. 3 Cylinder Head Bolt Torque Sequence
Ä HEATING AND AIR CONDITIONING 24 - 45

REFRIGERANT SYSTEM DIAGNOSIS
24 - 46 HEATING AND AIR CONDITIONING Ä