Opel Frontera UBS. Manual - part 62

 

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Opel Frontera UBS. Manual - part 62

 

 

COMPRESSOR OVERHAUL  1D – 15

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: 22N·m (16 lb·ft)

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

1D – 16 COMPRESSOR OVERHAUL

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: 5N·m (44 lb·in)

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

3

2

1

871RY00024

A

871RY00025

1

2

871RY00008

COMPRESSOR OVERHAUL  1D – 17

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: 15N·m (11 lb·in)

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

871RY00009

871RY00007

1

901RY00010

1D – 18 COMPRESSOR OVERHAUL

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 – 6H

Compressor 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

901RW001

4

3

1

2

871RW003

 

 

 

 

 

 

 

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