Opel Frontera UBS. Manual - part 939

1D – 20 COMPRESSOR OVERHAUL

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

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J-33023-A

J-8433-3

J-8433-1

J-33025

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COMPRESSOR OVERHAUL 1D – 21

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

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871RW004

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1D – 22 COMPRESSOR OVERHAUL

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.

871RW006

J-23128-A

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COMPRESSOR OVERHAUL 1D – 23

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.

J-9553-01

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J-33011

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J-34614

J-23128-A

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