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(8) With the front clutch plate assembly tight against the shims, measure the air gap between armature plate and rotor-pulley face with feeler gauges (Fig. 4). The air gap should be between 0.35 and 0.65 mm (0.013 and 0.025 inch). If proper air gap is not obtained, add or subtract shims until desired air gap is obtained.

Fig. 4 Measuring Air Gap

(9)Install compressor shaft nut. Tighten nut to

17.5NIm (155 in. lbs.) torque.

Shims may compress after tightening shaft bolt. Check air gap in four or more places to verify if air gap is still correct. Spin pulley for final check.

(10) Install the compressor onto the mount.

FIELD COIL-CORE BREAK-IN

After a new field coil-core has been installed, cycle the A/C clutch 20 times (5 sec. on and 5 sec. off). During this procedure, run engine at 1500-2000 rpm and set the A/C on the HIGH mode. This procedure (burnishing) will seat the opposing friction surfaces and provide a higher clutch torque capability.

THERMAL LIMITER SWITCH

After removing the thermal limiter switch, always replace with a new unit.

The refrigerant system can remained fully charged for thermal limiter switch replacement.

REMOVAL

(1)Disconnect wiring connectors from switch.

(2)Remove the bolt retaining the switch holding clamp and the switch to the side of the compressor (Fig. 5).

(3)Pry the switch from compressor case with a screwdriver.

CLEANING

Remove silicone filler from the socket and thoroughly clean the socket with thinners.

Fig. 5 Thermal Limiter Switch

INSTALLATION

(1)Place the new thermal limiter switch so that the flat copper surface faces upward.

(2)Apply the specified silicone filler (KE 347 RTV) to the flat copper surface until the surface is evenly covered. When silicone is applied, apply only from tube and not by hand.

(3)Install the thermal limiter switch into the socket and secure it with the thermal protector (lim-

iting switch) fixing plate and bolt. Tighten the bolt to 1.8 NIm (17 in. lbs.) torque.

(4)Connect wiring connectors to switch.

COMPRESSOR SHAFT BEARING/SEAL

REMOVAL

(1)Remove the compressor from the mounting.

(2)Remove the compressor nut and armature

plate.

(3)Remove the shaft bearing by using Shaft Bearing Removal/Installation Tool 6533 as follows:

(a)With the collet on top of the bearing, insert the 2 jaws into the bearing groove (Fig. 6). Position the jaw retainer over the 2 jaws.

(b)Thread in the screw (Fig. 6). Turn the screw until the bearing is moved up and loosened.

(4)Remove felt washer (Fig. 7).

(5)Remove snap ring using snap ring pliers (Fig.

8).

CAUTION: Be careful not to scratch the inside bore of front boss.

24 - 40 HEATING AND AIR CONDITIONING		Ä

Fig. 6 Bearing Removal using Tool 6533

Fig. 9 Compressor Shaft Seal

INSTALLATION

CAUTION: Do not touch seal contact surfaces.

(1) Insert Seal Sleeve Protector Tool 6552 over compressor shaft (Fig. 10).

Fig. 7 Felt Washer

Fig. 10 Compressor Shaft Seal Sleeve Proctor

(2) Apply a little oil on seal sleeve protector.

(3) Apply oil on O-ring portion of the lip seal.

Fig. 8 Compressor Shaft Seal Snap Ring

(6) Insert Lip Seal Removal/Installation Tool 6551 and twist the tool until it is engaged into the slots of the seal case (Fig. 9). Carefully lift out seal assembly.

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(4)Engage the slots of the Lip Seal Removal/Installation Tool 6551 to the lip seal cage. Install the lip seal into place by pushing gently over the seal protector (Fig. 9).

(5)Twist tool and remove from the seal. Remove seal sleeve protector.

(6)Install snap ring into the snap ring groove (Fig. 8). Push snap ring down to ensure correct positioning by using opposite end of Lip Seal Removal/Installation Tool 6551.

(7)Replace felt washer.

(8)Position the shaft bearing into front boss.

(9)Install bearing with Shaft Bearing Removal/Installation Tool 6533. Use the 2 jaws, the jaw retainer and the collet and gently hammer with a plastic hammer to seat the bearing (Fig. 11). The use of this tool will properly position the bearing.

(10)Install armature plate to the compressor shaft. Note the machined mating splines (Fig. 12).

(11)Install compressor shaft nut. Tighten nut to

17.5NIm (155 in. lbs.) torque.

(12)Install the compressor onto the mount.

HEATING AND AIR CONDITIONING 24 - 41

Fig. 11 Shaft Bearing Installation

Fig. 12 Aligning Clutch Plate Splines