DAEWOO NUBIRA 2004 Service Repair Manual

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 39
DAEWOO V–121 BL4
3. Align the clutch hub key with the shaft keyway.
Place the clutch drive plate and the hub assembly
onto the compressor shaft.
4. Remove the hub and drive plate remover/installer
J–33013–B center bolt and reverse the body direc-
tion on the center bolt. The body of the hub and
drive plate remover/installer J–33013–B should be
backed off sufficiently to allow the center bolt to be
threaded onto the end of the compressor shaft.
Notice : If the center bolt is threaded fully onto the end of
the compressor shaft, or if the body of the hub and drive
plate remover/installer J–33013–B is held and the center
bolt is rotated, the key will wedge and could break the
clutch drive plate and the hub assembly.
5. Install the hub and drive plate remover/installer
J–33013–B and the bearing onto the clutch drive
plate. Thread the center bolt onto the compressor
shaft.
6. Hold the center bolt with a wrench. Tighten the hex
portion of the hub and drive plate remover/installer
J–33013–B body to press the hub onto the shaft.
Tighten the body several turns.
7. Remove the hub and drive plate remover/installer
J–33013–B and check to see that the clutch hub
key is still in place in the keyway before installing
the clutch drive plate and the hub assembly to its
final position. The air gap between frictional sur-
faces of the clutch drive plate and the clutch pulley
rotor should be 0.38 to 0.64 mm (0.015 to 0.025
inch.).
8. Remove the hub and drive plate remover/installer
J–33013–B. Check for proper positioning of the
clutch hub key. It should be even or slightly above
the clutch hub.
9. Install the shaft nut. Hold the clutch drive plate and
the hub assembly with the clutch hub holding tool
J–33027. Use the shaft nut socket J–33022 and
tighten the nut against the compressor shaft shoul-
der.
Tighten
Tighten the clutch plate and hub assembly retaining
nut to 17 NSm (13 lb–ft).
10. Spin the pulley rotor by hand to verify that the
pulley is not rubbing the clutch drive plate.

7B – 40IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
11. Remove the compressor from the bench vise and
remove the J–34992 compressor holding fixture
from the compressor.
12. Install the compressor. Refer to ”Compressor” in
this section.
CLUTCH ROTOR AND BEARING
Tools Required
J–6083 Snap Ring Pliers
J–9398–A Bearing Remover
J–9481 Bearing Installer
J–33020 Pulley Puller
J–33023–A Puller Pilot
J–33019 Bearing Staking Tool Set
Includes: J–33019–1 Bearing Staking Guide
Includes: J–33019–2 Bearing Staking Pin
Includes: J–33019–1 Bearing Staking Guide
J–33017 Pulley Rotor and Bearing Installer
J–8433–1 Puller Crossbar
J–34992 Compressor Holding Fixture
J–8092 Driver Handle
J–8433–3 Forcing Screw
Disassembly Procedure
1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to ”Discharging,
Adding Oil, Evacuating, and Charging for A/C Sys-
tem” in this section.
3. Remove the compressor. Refer to ”Compressor” in
this section.
4. Remove the clutch drive plate and hub assembly.
Refer to ”Clutch Plate and Hub Assembly” in this
section.
5. Remove the pulley rotor and bearing assembly re-
taining ring using the snap ring pliers J–6083.
6. With the compressor mounted to the compressor
holding fixture J–34992, install the pulley puller
J–33020 into the inner circle of slots in the pulley
rotor. Turn the pulley puller J–33020 clockwise in
the slots to engage the puller tangs with the seg-
ments between the slots in the rotor.
7. Hold the pulley puller J–33020 in place and tighten
the puller bolt against the compressor shaft to re-
move the pulley rotor and bearing assembly.

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 41
DAEWOO V–121 BL4
Notice : The rotor hub must be properly supported to pre-
vent damage to the pulley rotor during bearing removal.
8. Remove the puller bolt from the pulley puller
J–33020. With the puller tangs still engaged in the
rotor slots, invert the assembly onto a solid flat sur-
face or blocks.
Notice : Notice: It is not necessary to remove the staking
in front of the bearing to remove the bearing. It will be nec-
essary to file away the old stake metal for proper clearance
for the new bearing to be installed into the rotor bore or the
bearing may be damaged.
9. Drive the bearing out of the rotor hub with the bear-
ing remover J–9398–A and the driver handle
J–8092.
Installation Procedure
Notice : Do not support the rotor by resting the pulley rim
on a flat surface during the bearing installation or the rotor
face could be damaged.
1. Invert the pulley rotor and place it on a support
block to fully support the rotor hub during bearing
installation.
2. Align the new bearing squarely in the pulley bore.
Use the bearing installer J–9481 and the driver
handle J–8092, drive the bearing fully into the
pulley bore.
3. Place the bearing staking guide J–33019–1 and the
bearing staking pin J–33019–2 in the rotor hub
core. Shift the rotor and bearing assembly on the
block to give full support to the hub under the stak-
ing pin. A heavy–duty rubber band may be used to
hold the staking tool pin in the guide. The pin
should be properly positioned in the guide after
each impact on the pin.
CAUTION : When striking the pin with a hammer, take
care to avoid personal injury.
4. Strike the pin with a hammer until a metal stake,
similar to the original, is formed down to, but not
touching, the bearing. The metal stake should not
contact the outer race of the bearing to avoid the
possibility of distorting the outer race. Stake in
three places 120 degrees apart.

7B – 42IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
5. With the compressor mounted to the holding fixture
J–34992, position the rotor and bearing assembly
on the compressor housing.
6. Position the pulley rotor and bearing installer
J–33017 and the puller pilot J–33023–A directly
over the inner race of the bearing.
7. Position the puller crossbar J–8433–1 center forc-
ing bolt on the puller pilot J–33023–A and assemble
the two through–bolts and the washers through the
slots on the puller crossbar J–8433–1. Thread the
through–bolts into the holding fixture J–34992. The
thread of the through–bolts should engage the full
thickness of the fixture.
8. Tighten the center forcing screw J–8433–3 in the
puller crossbar J–8433–1 to force the pulley rotor
and bearing assembly onto the compressor hous-
ing.
9. Install the rotor and bearing assembly retainer ring
using the snap ring pliers J–6083.
10. Reinstall the clutch drive plate and hub assembly.
Refer to ”Clutch Plate and Hub Assembly” in this
section.
11. Install the compressor. Refer to ”Compressor” in
this section.
12. Connect the negative battery cable.
13. Evacuate and recharge the A/C system. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.
CLUTCH COIL
Tools Required
J–8433–1 Puller Crossbar
J–8433–3 Forcing Screw
J–33023–A Puller Pilot
J–33024 Clutch Coil Installer Adapter
J–33025 Clutch Coil Puller Legs
J–34992 Compressor Holding Fixture
Removal Procedure
1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to ”Discharging,
Adding Oil, Evacuating, and Charging Procedures
for A/C System” in this section.
3. Remove the compressor. Refer to ”Compressor” in
this section.
4. Remove the clutch plate and hub assembly. Refer
to ”Clutch Plate and Hub Assembly” in this section.
5. Remove the clutch rotor and bearing. Refer to
”Clutch Rotor and Bearing” in this section.
6. Mark the clutch coil terminal location on the com-
pressor housing.
7. Install the puller pilot J–33023–A on the compres-
sor housing. Also install the puller cross bar
J–8433–1 with the clutch coil puller legs J–33025.
8. Tighten the forcing screw J–8433–3 against the
puller pilot J–33023–A to remove the clutch coil.

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 43
DAEWOO V–121 BL4
Installation Procedure
1. Place the clutch coil installer adapter J–33024 over
the internal opening of the clutch coil housing and
align the clutch coil installer adapter J–33024 with
the compressor housing.
2. Place the clutch coil installer adapter J–33024 over
the internal opening of the clutch coil housing and
align the clutch coil installer adapter J–33024 with
the compressor housing.
3. Center the puller crossbar J–8433–1 in the counter-
sunk center hole of the clutch coil installer adapter
J–33024. Install the through–bolts of the compres-
sor holding fixture J–34992 and the washers in the
crossbar slots. Thread them into the holding fixture
to the full thickness of the holding fixture.
Important : Important: Be sure the clutch coil and the in-
staller stay ”in–line” during installation.
4. Turn the forcing screw J–8433–3, or use a suitable
vise, to force the clutch coil onto the compressor
housing.
5. When the clutch coil is fully seated on the compres-
sor housing, use a 3 mm (1/8 inch) diameter drift
punch and stake the housing at three places, 120
degrees apart, to ensure that the clutch coil will re-
main in position. Stake point size should be only
one–half the area of the punch tip and approximate-
ly 0.28 to 0.35 mm (0.010 to 0.015 inch) deep.
6. Install the clutch rotor and bearing assembly. Refer
to ”Clutch Rotor and Bearing” in this section.
7. Install the clutch plate and hub assembly. Refer to
”Clutch Plate and Hub Assembly” in this section.
8. Install the compressor. Refer to ”Compressor” in
this section.
9. Connect the negative battery cable.
10. Evacuate and recharge the A/C system. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.

7B – 44IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
DAEWOO V–121 BL4
SHAFT SEAL REPLACEMENT
Tools Required
J–5403 Snap Ring Pliers
J–9553–1 O–Ring Remover
J–23128–A Seal Seat Remover/Installer
J–33011 O–Ring Installer
J–34614 Shaft Seal Protector
Important : A shaft seal should not be replaced because
a small amount of oil is found on the adjacent surface. The
seal is designed to leak some oil for lubrication purposes.
A shaft seal should be changed only when a large amount
of sprayed oil is found and then only after actual refrigerant
leakage is found by using an approved leak detection pro-
cedure. Refer to ”Leak Testing the Refrigerant System” in
this section.
Should a compressor shaft seal ever have to be replaced,
the receiver–dryer in this system must also be removed
from the vehicle. The oil in the receiver–dryer must then
be drained, measured and replaced. Refer to ”Discharg-
ing, Adding Oil, Evacuating, and Charging Procedures for
A/C System” in this section.
Removal Procedure
1. Disconnect the negative battery cable.
2. Recover the refrigerant. Refer to ”Discharging, Add-
ing Oil, Evacuating, and Charging Procedures for
A/C System” in this section.
3. Loosen and reposition the compressor in the
mounting brackets.
4. Remove the clutch drive plate and hub assembly
from the compressor. Refer to ”Clutch Plate and
Hub Assembly” in this section.
5. Use the snap ring pliers J–5403 to remove the shaft
seal retaining ring.
Notice : Any dirt or foreign material that enters the com-
pressor may cause damage.
6. Thoroughly clean the inside of the compressor
housing area surrounding the shaft, the exposed
portion of the seal, the shaft itself, and the O–ring
groove.
7. Fully engage the knurled tangs of the seal seat re-
mover/installer J–23128–A into the recessed por-
tion of the seal by turning the handle clockwise.
Remove and discard the seal from the compressor
with a rotating–pulling motion. The handle should
be hand–tightened securely. Do not use a wrench
or pliers to tighten the handle.

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 45
DAEWOO V–121 BL4
8. Remove and discard the O–ring from the compres-
sor neck using the O–ring remover J–9553–1.
9. Thoroughly clean the seal O–ring groove in the
compressor housing.
10. Inspect the shaft and the inside of the compressor
housing neck for dirt or foreign material. These
parts must be perfectly clean before installing any
new parts.
Installation Procedure
Notice : Seals must not be reused. Always use a new
specification service seal kit. Be sure that the seal to be
installed is not scratched or damaged in any way. The seal
must be free of lint and dirt that may damage the seal sur-
face or prevent proper sealing.
1. Dip the new seal O–ring in clean polyalkaline glycol
(PAG) refrigerant oil and assemble the O–ring onto
the O–ring installer J–33011.
2. Insert the O–ring installer J–33011 into the com-
pressor neck until the installer ”bottoms.” Lower the
moveable slide of the O–ring installer J–33011 to
release the O–ring into the seal O–ring lower
groove. (The top groove of the compressor neck is
for the shaft seal retainer ring.) Rotate the installer
to seat the O–ring and then remove the installer.
3. Attach the shaft lip seal to the seal seat remover/in-
staller J–23128–A. Dip the seal in clean PAG oil.
4. Install the shaft seal protector J–34614 in the seal.
Place it over the shaft and push the seal into place
with a rotary motion.

7B – 46IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
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5. Use the snap ring pliers J–5403 to install the shaft
seal retaining ring with its flat side against the seal.
6. Remove any excess oil around the shaft and the
inside of the compressor housing neck.
7. Install the clutch plate and hub assembly. Refer to
”Clutch Plate and Hub Assembly” in this section.
8. Reposition the compressor in its mounting.
9. Adjust the tension on the serpentine accessory
drive belt.
10. Connect the negative battery cable.
11. Evacuate and recharge the A/C system. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.
12. Perform a leak test of the system. Refer to ”Leak
Testing the Refrigerant System” in this section.
CONTROL VALVE ASSEMBLY
Tools Required
J–5403 Snap Ring Pliers
Removal Procedure
1. Recover the refrigerant. Refer to ”Discharging,
Adding Oil, Evacuating, and Charging Procedures
for A/C System” in this section.
2. Remove the control valve retaining ring using the
snap ring pliers J–5403.
3. Remove the control valve assembly.
Installation Procedure
1. Coat all the O–rings with clean polyalkaline glycol
(PAG) oil.
2. Push the control valve in place using thumb pres-
sure.
3. Use the snap ring pliers J–5403 to install the valve
retaining ring. The high point of the curved sides
must be against the valve housing. Be sure the re-
taining ring is properly seated in the ring groove.
4. Evacuate and recharge the A/C system. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.

MANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM 7B – 47
DAEWOO V–121 BL4
REAR HEAD, GASKET, VALVE
PLATE, REED PLATE, AND O–RING
Tools Required
J–34993 Cylinder Alignment Rods
Removal Procedure
1. Recover the refrigerant. Refer to ”Discharging, Add-
ing Oil, Evacuating, and Charging Procedures for
A/C System” in this section.
2. Discharge the A/C system. Refer to ”Discharging,
Adding Oil, Evacuating, and Charging Procedures
for A/C System” in this section.
3. Remove the compressor. Refer to ”Compressor” in
this section.
4. Drain the oil from compressor into a suitable con-
tainer. Measure and record the amount of oil
drained from the compressor. Discard the used oil.
5. Remove the clutch plate and hub assembly. Refer
to ”Clutch Plate and Hub Assembly” in this section.
6. Remove the clutch rotor and bearing. Refer to
”Clutch Rotor and Bearing” in this section.
7. Remove the clutch coil. Refer to ”Clutch Coil” in
this section.
8. Remove the compressor through–bolts. Remove
and discard the gaskets.
9. Using a wooden block and a plastic–headed ham-
mer, tap around the edge of the rear head to disen-
gage the head from the compressor cylinder. Sepa-
rate the rear head, the head gasket, the rear valve
plate, the suction reed plate, and the cylinder–to–
rear head O–ring. Discard the head gasket and the
O–ring.
Installation Procedure
1. Place the rear head on a clean, flat surface. Posi-
tion the head with the control valve at the 6 o’clock
position.
2. Install the cylinder alignment rods J–34993 in the
mounting holes at the 11 o’clock and the 5 o’clock
positions.
3. Install the head gasket over the cylinder alignment
rods J–34993 with the elongated hole at the upper
left pin (the 11 o’clock position).
4. Install the rear head valve plate over the guide pins
with the elongated hole at the upper left pin. Lower
the rear head valve plate into place.
5. Install the suction reed plate over the cylinder align-
ment rods J–34993. Remove the alignment rod at
the 5 o’clock position.
6. Lubricate the cylinder to the new rear head O–ring
with clean polyalkaline glycol (PAG) refrigerant oil.
7. Install the O–ring in the cylinder O–ring groove. The
O–ring seal surface of the head may be lubricated
to ease assembly.

7B – 48IMANUAL CONTROL HEATING, VENTILATION AND AIR CONDITIONING SYSTEM
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8. With the O–ring in place on the rear of the cylinder
assembly, locate the relief boss for the compressor
guide pin at the 6 o’clock position, directly above
the hole in the side of the rear head. Carefully lower
the cylinder and the front head assembly over the
guide pin to the rear head.
9. Press the cylinder and the compressor housing as-
sembly down onto the rear head using both hands.
10. Add the new through–bolt gasket to the through–
bolts and install it into the compressor assembly.
Four of the through–bolts must thread into the rear
head before removing the alignment rod.
Tighten
Alternately tighten the through–bolts in progressive
torque sequence to 10 NSm (89 lb–in).
11. Add new PAG refrigerant oil as determined in Step
1 of Removal Procedure.
12. Place the shaft nut on the shaft and rotate the com-
pressor shaft several times.
13. Perform a leak test on the compressor. Refer to
”Leak Testing (External)” in this section.
14. Install the clutch coil. Refer to ”Clutch Coil” in this
section.
15. Install the clutch rotor and bearing. Refer to ”Clutch
Rotor and Bearing” in this section.
16. Install the clutch plate and hub assembly. Refer to
”Clutch Plate and Hub Assembly” in this section.
17. Install the compressor. Refer to ”Compressor” in
this section.
18. Evacuate and recharge the A/C system. Refer to
”Discharging, Adding Oil, Evacuating, and Charging
Procedures for A/C System” in this section.
CYLINDER–TO–FRONT HEAD
O–RING
Tools Required
J–34993 Cylinder Alignment Rods
J–35372 Support Block
Removal Procedure
1. Recover the refrigerant. Refer to ”Discharging, Add-
ing Oil, Evacuating, and Charging Procedures for
A/C System” in this section.
2. Remove the compressor. Refer to ”Compressor” in
this section.
3. Drain the oil from compressor into a suitable con-
tainer. Measure and record the amount of oil
drained from the compressor. Discard all used oil.
4. Remove the clutch plate and hub assembly. Refer
to ”Clutch Plate and Hub Assembly” in this section.
5. Remove the clutch rotor and bearing. Refer to
”Clutch Rotor and Bearing” in this section.
6. Remove the clutch coil. Refer to ”Clutch Coil” in
this section.