OPEL FRONTERA 1998 Workshop Manual

6. Loosen three screws and remove the field coil.
7. Remove snap ring by using snap ring pliers.8. Remove shaft seal assembly (2) by using shaft seal
remover J-33942 (1).
Engage the remover hook with the shaft seal
assembly groove and slowly draw the shaft seal
assembly out.
NOTE
The shaft seal is precision-machined and its
critical parts are finished to extremely close
tolerances. The assembly must be handled
with great care, it slips face demanding
particularly careful handling.
The shaft seal can not be reused. Install a new
shaft seal at reassembly.
Take care not to scratch or otherwise damage
the shaft seal face.
Keep the shaft seal free from lint and dirt.
9. Remove through bolt.
871RY00006
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10. Remove front cylinder head.
11. Remove o-ring.
Alternately tap the projections on the
circumference of the front cylinder head with a
screwdriver and a plastic hammer to remove the
front cylinder head.
12. Remove gasket.
13. Remove front valve plate.
14. Remove front suction valve.
NOTE
Check the front valve plate for scratching and
bending.
Check the front valve plate and the front
cylinder head for nicks and burrs on the
sealing surface.
Buff or replace the valve plate and cylinder
head if nicks and burrs are present.
Check that the front valve plate passage is free
from obstructions.
Check the front valve plate and the cylinder
head for cracks.
Replace the valve plate and cylinder head if
cracks are present.15. Remove rear cylinder head.
16. Remove o-ring.Alternately tap the projections on the
circumference of the rear cylinder head with a
screwdriver and a plastic hammer to remove the
rear cylinder head.
17. Remove gasket.
18. Remove rear valve plate.
19. Remove rear suction valve.
20. Remove cylinder and shaft assembly.
NOTE
Check the rear valve plate for scratching and
bending.
Check the rear valve plate and the rear
cylinder head for nicks and burrs on the
sealing surface.
Buff or replace the valve plate and cylinder
head if nicks and burrs are present.
Check that the rear valve plate passage is free
from obstructions.
Check the rear valve plate and the cylinder
head for cracks.
Replace the valve plate and cylinder head if
cracks are present.
871RY00019871RY00020

Installation
1. Install cylinder and shaft assembly.
Clamp the cylinder shaft assembly in a vise.
The rear side of the cylinder shaft assembly must
be facing up.
2. Install rear suction valve.
Apply a coat of new compressor oil to the new
suction valve (2).
Install the suction valve by aligning it with the
spring pin and the cylinder valve relief grooves.
Legend
(1) Escape Groove
(2) Suction Valve
(3) Piston
3. Install rear valve plate.
Apply a coat of new compressor oil to the new
valve plate.
Install the valve plate to the suction valve by
aligning it with the spring pin.
NOTE
Do not mix up the front and rear valve plate.
4. Install gasket.
Apply a coat of new compressor oil to the new
gasket.
Install the gasket (3) to the valve plate (4).
5. Install o-ring (2).6. Install rear cylinder head (1).
Apply a coat of new compressor oil to the new o-
ring (2).
Install the o-ring (2) to the rear cylinder head (1).
Install the rear cylinder head.
Top the rear cylinder head (1) into place with a
plastic hammer.
7. Install front suction valve.
Set the cylinder shaft assembly with the front side
facing up.
Apply a coat of new compressor oil to the new
suction valve (2).
Install the suction valve (2) by aligning it with the
spring pin and the cylinder valve relief grooves.
Legend
(1) Escape Groove
(2) Suction Valve
(3) Piston
1
2
3
871RY00021
54321
871RY00022
1
2
3
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8. Install front valve plate.
Apply a coat of new compressor oil to the new
valve plate.
Install the valve plate to the suction valve by
aligning it with the spring pin.
NOTE
Do not mix up the front and rear valve plates.
9. Install gasket
Apply new compressor oil to the new gasket.
Install the gasket to the valve plate by a aligning it
with the spring pin.
10. Install o-ring.
11. Install front cylinder head.
Apply a coat of new compressor oil to the new O-
ring.
Install the O-ring to the front cylinder head.
Install the front cylinder head.
Tap the front cylinder head into place with a
plastic hammer.
NOTE
When installing the cylinder head, be careful
that the end of the drive shaft does not
damage the shaft seal assembly surface in the
cylinder head.12. Install through bolt.
Gaskets cannot reused. Always replace new
ones. Tighten the bolts to the specified torque a
little at a time in the sequence shown in the
illustration.
Torque: 22Nꞏm (16 lbꞏft)
NOTE
Rotate the compressor drive shaft two or three
times to make sure that it moves smoothly.
1
4
5
2
3
6
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13. Install shaft seal assembly.
Clean the sealing portion of the compressor and
shaft seal (2).
Install the shaft seal guide J-34614 (1) onto the
end of the drive shaft.
Apply new compressor oil to the shaft seal guide.
Install the shaft seal (2) onto the compressor drive
shaft head by using shaft seal installer J-33942 (3).
14. Install snap ring.
15. Install field coil.
16. Install lead wire connector.
Install the field coil to the compressor.
Lead wire must be facing up.
Tighten the field coil fixing screws to the specified
torque.
Torque: 5Nꞏm (44 lbꞏin)17. Install pulley assembly.
Using pulley installer J-33940 (2) and drive handle
J-8092 (1) to install the pulley assembly.
18. Install snap ring.
Install the snap ring with the inside indented
portion facing out.
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32 1
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A
871RY00025
1
2
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19. Install shim(s).
20. Install drive plate.
Install the drive plate to the compressor drive
shaft together with the original shim(s)(1) press
the drive plate by hand.
21. Install drive plate bolt by using drive plate holder
J-7624 (1) to prevent the drive plate from rotating.
Tighten the bolt to the specified torque.
Torque: 15Nꞏm (11 lbꞏin)
NOTE
After tightening the bolt, check to be sure the
pulley rotates smoothly.
Check to be sure that the clutch clearance is
between 0.3–0.6 mm (0.01–0.02 in.)
If necessary, install adjusting shim(s).
Adjusting shims are available in the following
thickness.
Thickness
0.1 mm (0.0039 in.)
0.3 mm (0.0118 in.)
0.5 mm (0.0197 in.)
1
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1
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HD6 TYPE COMPRESSOR
Metric Thread Size Information
Compressor to mounting bracket bolts (Front)
M10
1.5 – 6H
Compressor to mounting bracket bolts (Rear)
M8
1.25 – 6H
Suction-discharge port screw
M10
1.5 – 6HCompressor shaft
M9
1.25 – 6H
Internal hub-clutch drive assembly
M22
1.5 – 6H
COMPRESSOR CLUTCH PLATE AND HUB
ASSEMBLY
Removal
1. Clamp the holding fixture J-33026 in a vise and
attach compressor to holding fixture with thumb
screws J-33026-1.
2. With center screw forcing tip in place to thrust
against the end of the shaft, thread the Clutch Plate
and Hub Assembly Installer-Remover J-33013-B into
the hub. Hold the body of the remover with a wrench
and turn the center screw into the remover body to
remove the clutch plate and hub assembly (1).
CAUTION: Do not drive or pound on the clutch hub
or shaft. Internal damage to compressor may
result. The forcing tip on J-33013-B remover-
installer center screw must be flat or the end of the
shaft/axial plate assembly will be damaged.
3. Remove the shaft key and retain for reassembly.
Installation
1. Install the shaft key into the hub key groove. Allow
the key to project approximately 3.2 mm (1/8 in) out
of the keyway. The shaft key is curved slightly to
provide an interference fit in the hub key groove.2. Be sure the frictional surface of the clutch plate and
the clutch rotor (2) are clean before installing the
clutch plate and hub assembly (1).
3. Align the shaft key (4) with the shaft keyway (3) and
place the clutch plate and the hub assembly onto
the compressor shaft.
4. Remove the forcing tip on J-33013-B clutch plate
and hub assembly installer-remover center screw
and reverse the body direction on the center screw,
as shown in Figure.
5. Install the clutch plate and hub installer-remover J-
33013-B with bearing as shown in Figure.
The body of the J-33013-B installer-remover should
be backed off sufficiently to allow the center screw to
be threaded onto the end of the compressor shaft.
6. Hold the center screw with a wrench. Tighten the
hex portion of the installer-remover J-33013-B body
to press the hub onto the shaft. Tighten the body
several turns, remove the installer and check to see
that the shaft key is still in place in the keyway
before installing the clutch plate and hub
assembly to its finial position.The air gap (2)
between frictional surfaces of the clutch plate and
clutch rotor should be 0.50–0.76 mm (.020–.030 in).
1
J-33013-B
J-33026-1
J-33026
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4
31
2
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CAUTION: If the center screw is threaded fully onto
the end of the compressor shaft. or if the body of
the installer is held and the center screw is rotated,
the key will wedge and will break the clutch hub.7. Remove installer J-33013-B, check for proper
positioning of the shaft key (even or slightly above
the clutch hub).
8. Spin the pulley rotor by hand to see that the rotor is
not rubbing the clutch drive plate.
COMPRESSOR CLUTCH ROTOR AND/OR
BEARING
Removal
1. Remove the clutch plate and hub assembly as
described previously.
2. Remove rotor (1) and bearing assembly retaining
ring (2), using snap ring pliers.
3. Install pulley rotor and bearing puller guide J-33023-A
to the front head and install J-41552 pulley rotor and
bearing puller down into the inner circle of slots (1) in
the rotor. Turn the J-41552 puller clockwise in the
slots in the rotor.4. Hold the J-41552 puller in place and tighten the
puller screw against the puller guide to remove the
pulley rotor and bearing assembly.
Installation
1. With the compressor mounted to the J-34992
holding fixture, position the rotor and bearing
assembly on the front head.
2. Position the J-33017 pulley, rotor and bearing
installer and J-33023-A puller pilot directly over the
inner race of the bearing.
1
2 J-33013-B
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1
2
901RW003
J-41552
1
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3. Position puller crossbar J-8433-1 on the puller pilot
J-33023-A and assemble the two J-33026 through
bolts and washers through the puller bar slots and
thread them into the J-33026 holding fixture. The
thread of the through bolts should engage the full
thickness of the holding fixture.
4. Tighten the center screw in the J-8433-1 puller
crossbar to force the pulley rotor (1) and bearing
assembly onto the compressor front head. Should
the J-33017 pulley rotor and bearing installer slip off
direct in-line contact with the inner race of the
bearing, loosen the J-8433-1 center forcing screw
and realign the installer and pilot so that the J-
33017 installer will properly clear the front head.5. Install rotor and bearing assembly retainer ring,
using snap ring pliers.
6. Reinstall clutch plate and hub assembly as
described previously.
COMPRESSOR CLUTCH COIL
Removal
1. Perform Steps 1 through 4 of "Clutch Rotor and/or
Bearings" removal procedure. Mark clutch coil
terminal location (1) on compressor front head.
2. Install J-33023-A puller pilot on front head of
compressor. Also install J-8433-1 puller crossbar
with J-33025 puller legs as shown in figure.
3. Tighten J-8433-3 forcing screw against the puller
pilot to remove the clutch coil (2).
J-8433-3
J-33023
J-33026 J-8433-1
J-33017
1
901RW005
J-33023-AJ-8433-3
J-8433-1
J-33025
1 2
901RW006

Installation
1. Place the clutch coil assembly (1) on the front head
with the terminals positioned at the "marked" location.
2. Place the J-33024 clutch coil installer over the
internal opening of the clutch coil housing and align
installer with the compressor front head.
3. Center the J-8433-1 puller crossbar in the counter-
sunk center hole of the J-33024 clutch coil installer.
Install the J-33026 through bolts and washers
through the crossbar slots and thread them into the
holding fixture J-33026 to full fixture thickness.
4. Turn the center forcing screw of J-8433-1 puller
crossbar to force the clutch coil onto the front head.
Be sure clutch coil and J-33024 installer stay "in-
line" during installation.
5. When coil is fully seated on the front head, use a
1/8 in diameter drift punch (2) and stake the front
head at three places 120 degrees apart, to ensure
clutch coil (3) remains in position.
Stake size should be only one-half the area of the
punch tip and be only approximately 0.28–0.35
mm (.010–.015 in) deep.
Legend
(1) Stake Front Head 0.28–0.35 mm Deep
(0.10–015 in)
(2) Clutch Coil Housing
(3) Front Head Surface
6. Install rotor and bearing assembly and the clutch
plate and hub assembly as described previously.
J-8433-3
J-8433-1
J-33024
1
901RW007
2
3
871RW004
1
23
871RW005