Файл: 92FWD_24.pdf

Fig. 1 Compressor Shaft Nut Removal/Installation

(4)Remove rotor-pulley retaining snap ring with Snap Ring Pliers C-4574. Slide rotor-pulley assembly from compressor. Use a plastic hammer, if necessary.

(5)Loosen the lead wire retaining clamps and remove lead wire from the compressor front end plate. Disconnect the lead wire from the thermal limiter switch.

(6)Remove the snap ring which secures the field coil-core assembly to the front boss (Fig. 2). Note the alignment of field coil-core assembly when removing.

WARNING: TAKE CARE THAT THE SNAP RING DOES NOT FLY OUT FROM THE GROOVE.

Check rotor-pulley bearing for roughness or excessive grease leakage. Check for bearing grease contamination on armature plate faces.

The rotor-pulley and armature plate should be replaced as a matched set.

INSTALLATION

(1)Position the back of the field coil-core over the compressor front boss. This will allow the locating nipple on the back of the coil to line up with the locating indentation on the front boss. This ensures correct angular position of the clutch coil and lead wire.

(2)Fasten lead wire to the compressor front plate with the retaining clip. Connect the lead wire to the thermal limiter switch.

(3)Install field coil-core retaining snap ring (bevel side outward) with Snap Ring Pliers C-4574. Press snap ring to make sure it is properly seated in the groove.

CAUTION: If snap rings on field coil-core and rotorpulley are not fully seated, they will vibrate out. A clutch failure and possible severe damage to the compressor could result.

(4) Slide pulley assembly onto compressor.

CAUTION: Do not mar the pulley frictional surface.

(5)Install rotor-pulley assembly retaining snap ring (bevel side outward) with Snap Ring Pliers C-4574. Press the snap ring to make sure it is properly seated in the groove.

(6)If the original armature plate assembly and ro- tor-pulley assembly are to be reused, the old shim(s) can be used. If not, place a trial stack of shims, 2.54 mm (0.10 in.) thick, on the compressor shaft against the shoulder of the armature plate.

(7)Install armature plate to the compressor shaft. Note the machined mating splines (Fig. 3).

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.

Ä

(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

CONDENSATE WATER DRAINAGE

Condensation that accumulates on the bottom of the evaporator housing is drained from a rubber tube through the dash panel and on to the ground. This tube must be kept open to prevent condensate water from collecting in the bottom of the heater A/C unit housing (Fig. 1).

BLOWER MOTOR VIBRATION AND/OR NOISE DIAGNOSIS

The resistor block (Fig. 2), supplies the blower motor with varied voltage (low and middle speeds) or battery voltage (high speed).

Fig. 1 Condensate Water Drain TubeÐTypical

The tapered end of the drain tube is designed to keep contaminants from entering the heater A/C unit housing. If the tube is pinched or blocked, condensate cannot drain, causing water to back up and spill into the passenger compartment. It is normal to see condensate drainage below the vehicle. If the tube is damaged, it should be replaced.

Fig. 2 Blower Motor Resistor BlockÐTypical

CAUTION: Stay clear of the blower motor and resistor block (Hot). Do not operate the blower motor with the resistor block removed from the heater-A/C housing.

Refer to the Blower Motor Vibration/Noise chart in this section for diagnosis.

BLOWER MOTOR ELECTRICAL DIAGNOSIS

Refer to the Blower Motor Electrical System Diagnosis chart in this section. Also refer to Group 8W, Wiring Diagrams for more information.

TEMPERATURE CONTROL CABLE

REMOVAL AND INSTALLATION

A Temperature Control Cable is used on non-ATC heat or heater-A/C systems only. ATC (Automatic Temperature Control) systems use an electrically operated temperature control. Refer to the ATC section of this Group.

(1)Remove the A/C-Heater control panel assembly. Refer to A/C-Heater Control Replacement in Group 8E Instrument Panel. Disconnect the cable attaching flag from the A/C-heater control and remove the cable from control panel.

(2)Locate and disconnect the cable attaching flag on the bottom of the A/C-heater housing behind the floor air duct (Fig. 1).

Fig. 1 Temperature Control CableÐTypical

(3)Slip cable self-adjusting clip downward from the blend-air door crank.

(4)Insert a 3/16 diameter tool (drill bit or phillips screwdriver shank) into the crank pin access hole and rotate the clip from the cable.

To install, reverse the preceding operation.

To adjust temperature cable, position the TEMP lever on the control to the cool side of its travel. Allowing the self-adjusting clip to slide on the cable, rotate the blend-air door crank counterclockwise by hand until it stops.

TEMPERATURE CONTROL CABLE

REMOVAL AND INSTALLATION

(1)Remove heater-A/C control panel. Refer to Switch and Panel Component Service in Group 8E, Instrument Panel. Disconnect the attaching flag on the control cable from the heater-A/C control panel.

(2)Remove console assembly. Refer to Group 8E, Instrument Panel.

(3)Remove instrument panel lower steering column cover. Refer to Group 8E, Instrument Panel.

(4)Remove the right lower instrument panel/glove box door assembly. This assembly is clipped to the upper instrument panel at the right upper side.

(5)A/C equipped vehicles: From under the hood, disconnect the A/C suction line mounting bracket from the dash panel (above the expansion valve).

(6)From under the hood, loosen (do not remove) the four heater-A/C assembly to dash panel mounting nuts.

(7)From inside the vehicle: Remove the vertical (heater-A/C housing) support bracket (below the glove box).

(8)Tilt the entire heater-A/C housing assembly downward to gain access to the temperature cable.

(9)Locate and disconnect the attaching flag on the control cable at the heater-A/C housing (Fig. 2).

(10)Slip the cable self-adjusting clip from the blend-air door crank (Fig. 1).

(11)Remove the cable from the vehicle.

(12)To remove the self-adjusting clip from cable (Fig. 1):