oil OPEL FRONTERA 1998 Workshop Manual

Inspection and Repair
Drive Plate
If the frictional surface shows signs of damage due to
excessive heat, the drive plate and pulley should be
replaced.
Pulley Assembly
Check the appearance of the pulley assembly. If the
frictional surface of the pulley shows signs of excessive
grooving due to slippage, both the pulley and drive
plate should be replaced. The frictional surfaces of the
pulley assembly should be cleaned with a suitable
solvent before reinstallation.
Coil
Check coil for loose connector or cracked insulation.
Installation
1. Install field coil.
Align the located portion (1) of the field coil and
compressor.
Tighten the mounting screw to the specified torque.
Torque: 5Nꞏm (44 lb in)
2. Connect the lead wire connector with the rubber
hold and tighten the screw.3. Install pulley assembly by using pulley installer
J-33940-A (2) and drive handle J-8092 (1).
4. Install snap ring.
5. Install shim(s).
6. Install the drive plate to the compressor drive shaft
together with the original shim(s)(1). Press the drive
plate by hand.
1
2
871RX032
1
871RX010
1
871RX015

Legend
(1) Drive Plate Bolt
(2) Drive Plate
(3) Shim
(4) Snap Ring
(5) Pulley Assembly
(6) Screw
(7) Field Coil
(8) Through Bolt
(9) Shaft Seal Assembly
(10) Gasket
(11) Front Cylinder Head(12) O-Ring
(13) Gasket
(14) Front Valve Plate
(15) Front Suction Valve
(16) Pin
(17) Cylinder and Shaft Assembly
(18) Rear Valve Plate
(19) Gasket
(20) Rear Cylinder Head
(21) Bolt
(22) Oil Drain Plug
(23) O-Ring
DKS-15CH TYPE COMPRESSOR
16
23 2122 6
7
45
321 (’98)
(’99~)
67
45
321
8
910111213141516
17
1518191220
871RY00015

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
871RY00017
871RY00018

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
871RY00021

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
871RY00016
871RY00023

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.
871RY00006
32 1
871RY00024
A
871RY00025
1
2
871RY00008

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

COMPRESSOR SHAFT SEAL
Service Precaution
When replacing the shaft seal assembly, pressure relief
valve or control switches, it will be necessary to recover
the refrigerant. Other than clutch repair procedures, the
same holds true for any disassembly of the compressor.
A clean workbench covered with a sheet of clean
paper, and a place (clean trays, etc) for all parts being
removed and replaced is important, as is the use of
proper clean service tools.
CAUTION: Any attempt to use makeshift or
inadequate service tools or equipment may result
in damage and/or improper compressor operation.
All parts required for servicing the internal compressor
are protected by a preservative process and packaged
in a manner which will eliminate the necessity of
cleaning, washing or flushing of the parts. The parts
can be used in the internal assembly just as they are
removed from the service package. Seals and
protective packaging should be left intact until just
prior to installation.
If the compressor rear head, front head or cylinder and
shaft assembly is to be serviced or replaced, the oil in
the compressor must be drained, measured, recorded
and replaced.
Legend
(1) Suction Port
(2) Discharge Port
(3) Mounting Boss
(4) Mounting Boss
(5) Pressure Relief Valve
(6) Mounting Boss
Seal Leak Detection
A shaft seal should not be changed because of small
amounts of oil found on an adjacent surface but only
after actual refrigerant leakage is found using an
approved leak detector.
CAUTION: Handling and care of seal protector is
important. If seal protector is nicked or the bottom
flared, the new seal may be damaged during
installation.
Removal
1. Recover the refrigerant using Refrigerant Recovery
System.
2. Loosen and reposition compressor in mounting
brackets, if necessary.
3. Remove clutch plate and hub assembly from
compressor as described previously.
4. Remove the shaft seal retainer ring, using snap ring
pliers.
5. Thoroughly clean inside of compressor neck area
surrounding the shaft, the exposed portion of the
seal, the retainer ring groove and the shaft itself.
Any dirt or foreign material getting into compressor
may cause damage.
6. Fully engage the knurled tangs of Seal Remover-
Installer J-23128-A into the recessed portion of the
Seal (1) by turning the handle clockwise. Remove
the Seal from the compressor with a rotary-pulling
motion.
Discard the seal. The handle must be hand-
tightened securely. Do not use a wrench or pliers.
1
2
3
456
871RW006
J-23128-A1
901RW008

7. Remove and discard the seal seat O-ring (2) from the
compressor neck using O-ring remover J-9553-01.
8. Recheck the shaft and inside of the compressor
neck for dirt or foreign material and be sure these
areas are perfectly clean before installing new parts.
Cleaning
Thoroughly clean O-ring seal groove in front head.
CAUTION: Seals should not be re-used. Always use
a new specification service seal on rebuild. Be sure
that the seal to be installed is not scratched or
damaged in anyway. Make sure that the seal seat
and seal are free of lint and dirt that could damage
the seal surface or prevent sealing.
Installation
1. Dip the new seal seat O-ring (1) in clean 525
viscosity refrigerant oil and assemble onto O-ring
installer J-33011.2. Insert the O-ring installer J-33011 into the
compressor neck until the installer "bottoms". Lower
the moveable slide of the O-ring installer to release
the O-ring into the seal O-ring lower groove (The
compressor neck top groove is for the shaft seal
retainer ring.) Rotate the installer to seat the O-ring
and remove the installer.
3. Dip the new seal in clean 525 viscosity refrigerant oil
and assemble seal to Seal Installer J-23128-A, by
turning handle clockwise. The stamped steel case
side of the lip seal must be engaged with knurled
tangs of installer so that flared-out side of lip seal is
facing and installed towards the compressor. Install
seal protector J-34614, in the seal lip and place over
the compressor shaft, and push the seal in place with
a rotary motion or place the seal protector J-34614
over end of compressor shaft, and slide the new seal
onto the shaft with a rotary motion until it stops. Take
care not to dislodge the O-ring. Be sure the seal (2)
makes good contact with the O-ring. Disengage the
installer from the seal and remove the installer
J-23128-A and the seal protector J-34614.
CAUTION: Handling and care of seal protector is
important. If seal protector is nicked or the bottom
flared, the new seal may be damaged during
installation.
4. Install the new seal retainer ring with its flat side
against the Seal, using Snap-Ring Pliers. Use the
sleeve from O-ring installer J-33011 to press in on
the seal retainer ring so that it snaps into its groove.
5. To leak test, install compressor leak test fixture
J-39893 on rear head of compressor and connect
gage charging lines and Refrigerant Recovery
System. Pressurize suction and high-side of
compressor with R-134a Refrigerant. Temporarily
install (M9
1.25 thread on shaft) nut and, with the
compressor in horizontal position, rotate the
compressor shaft in normal direction of rotation
several times by hand. Leak test the seal area and
correct and leak found. Recover the refrigerant.
Remove shaft nut.
2 J-9553-01
901RW009
1
J-33011
901RW010
J-34614
2
J-23128-A
901RW011