Jeep XJ. Manual — part 514
felt from the front cover. If the felt is saturated with
oil, the shaft seal is leaking and the compressor must
be replaced.
Check the clutch pulley bearing for roughness or
excessive leakage of grease. Replace the bearing, if
required.
INSTALLATION
(1) Install the clutch field coil and snap ring.
(2) Install the clutch coil lead wire harness retain-
ing clip on the compressor front housing and tighten
the retaining screw.
(3) Align the rotor assembly squarely on the front
compressor housing hub.
(4) Install the pulley bearing assembly with the
installer (Special Tool C-6871) (Fig. 27). Thread the
installer on the shaft, then turn the nut until the
pulley assembly is seated.
(5) Install the external front snap ring with snap
ring pliers. The bevel side of the snap ring must be
facing outward. Press the snap ring to make sure it
is properly seated in the groove.
CAUTION: If the snap ring is not fully seated in the
groove it will vibrate out, resulting in a clutch fail-
ure and severe damage to the front housing of the
compressor.
(6) Install the compressor shaft key and the origi-
nal clutch shims on the compressor shaft.
Fig. 23 Shaft Protector and Puller
1 – PULLER JAW
2 – SHAFT PROTECTOR
Fig. 24 Install Puller Plate
1 – PULLER JAW
2 – PULLER
Fig. 25 Clutch Coil Lead Wire Harness
1 – COIL
2 – COIL WIRE
3 – RETAINER SCREW
Fig. 26 Clutch Field Coil Snap Ring Remove
1 – COIL
2 – SNAP RING PLIERS
24 - 30
HEATING AND AIR CONDITIONING
XJ
REMOVAL AND INSTALLATION (Continued)
(7) Install the clutch plate with the driver (Special
Tool C-6463) (Fig. 28). Install the shaft hex nut and
tighten to 14.4 N·m (10.5 ft. lbs.).
(8) Check the clutch air gap with a feeler gauge
(Fig. 29). If the air gap does not meet the specifica-
tion, add or subtract shims as required. The air gap
specification is 0.41 to 0.79 millimeter (0.016 to 0.031
inch). If the air gap is not consistent around the cir-
cumference of the clutch, lightly pry up at the mini-
mum variations. Lightly tap down at the points of
maximum variation.
NOTE: The air gap is determined by the spacer
shims. When installing an original, or a new clutch
assembly, try the original shims first. When install-
ing a new clutch onto a compressor that previously
did not have a clutch, use 1.0, 0.50, and 0.13 milli-
meter (0.040, 0.020, and 0.005 inch) shims from the
clutch hardware package that is provided with the
new clutch.
(9) Reverse the remaining removal procedures to
complete the installation.
CLUTCH BREAK-IN
After a new compressor clutch has been installed,
cycle the compressor clutch approximately twenty
times (five seconds on, then five seconds off). During
this procedure, set the heater-A/C control to the
Recirculation Mode, the blower motor switch in the
highest speed position, and the engine speed at 1500
to 2000 rpm. This procedure (burnishing) will seat
the opposing friction surfaces and provide a higher
compressor clutch torque capability.
COMPRESSOR CLUTCH RELAY
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the cover from the Power Distribution
Center (PDC) (Fig. 30).
(3) Refer to the label on the PDC for compressor
clutch relay identification and location.
(4) Unplug the compressor clutch relay from the
PDC.
(5) Install the compressor clutch relay by aligning
the relay terminals with the cavities in the PDC and
pushing the relay firmly into place.
(6) Install the PDC cover.
(7) Connect the battery negative cable.
(8) Test the relay operation.
Fig. 27 Clutch Pulley Install
1 – PULLEY BEARING ASSEMBLY
2 – INSTALLER
Fig. 28 Clutch Plate Driver
1 – CLUTCH PLATE
2 – DRIVER
Fig. 29 Check Clutch Air Gap
1 – FEELER GAUGE
XJ
HEATING AND AIR CONDITIONING
24 - 31
REMOVAL AND INSTALLATION (Continued)
CONDENSER
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS GROUP BEFORE
PERFORMING THE FOLLOWING OPERATION.
CAUTION: Before removing the condenser, note the
location of each of the radiator and condenser air
seals. These seals are used to direct air through the
condenser and radiator. The air seals must be rein-
stalled in their proper locations in order for the air
conditioning and engine cooling systems to per-
form as designed.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Recover the refrigerant from the refrigerant
system. See Refrigerant Recovery in this group for
the procedures.
(3) Disconnect the discharge line refrigerant line
fitting at the condenser inlet. See Refrigerant Line
Coupler in this group for the procedures. Install
plugs in, or tape over all of the opened refrigerant
line fittings.
(4) Disconnect the liquid line (Left-Hand Drive) or
liquid line jumper (Right-Hand Drive) refrigerant
line fitting at the condenser outlet. See Refrigerant
Line Coupler in this group for the procedures. Install
plugs in, or tape over all of the opened refrigerant
line fittings.
(5) Remove the radiator and the condenser from
the vehicle as a unit. Refer to Group 7 - Cooling Sys-
tem for the procedures.
(6) Remove the two nuts that secure the condenser
studs to the upper brackets of the radiator (Fig. 31).
(7) Slide the condenser down from the radiator far
enough for the condenser studs to clear the upper
radiator bracket holes, and for the lower condenser
bracket holes to clear the dowel pins on the bottom of
the radiator.
(8) Remove the condenser from the radiator.
INSTALLATION
(1) Install the holes of the condenser lower brack-
ets over the dowel pins on the bottom of the radiator.
(2) Slide the condenser upwards until both of the
condenser studs are installed through the holes in
the radiator upper brackets. Tighten the mounting
nuts to 5.3 N·m (47 in. lbs.).
(3) Renstall the radiator and condenser unit in the
vehicle. Refer to Group 7 - Cooling System for the
procedures.
(4) Remove the tape or plugs from the refrigerant
line fittings on the condenser outlet and the liquid
line (Left-Hand Drive) or the liquid line jumper
(Right-Hand Drive). Install the liquid line or the liq-
Fig. 30 Power Distribution Center
1 – RIGHT FENDER
2 – BATTERY
3 – POWER DISTRIBUTION CENTER
Fig. 31 Condenser Remove/Install
1 – NUT
2 – RADIATOR
3 – GROMMET
4 – LOWER CROSSMEMBER
5 – CONDENSER
6 – STUDS
24 - 32
HEATING AND AIR CONDITIONING
XJ
REMOVAL AND INSTALLATION (Continued)
uid line jumper to the condenser outlet. See Refriger-
ant Line Coupler in this group for the procedures.
(5) Remove the tape or plugs from the refrigerant
line fittings on the condenser inlet and the discharge
line. Connect the discharge line to the condenser
inlet. See Refrigerant Line Coupler in this group for
the procedures.
(6) Connect the battery negative cable.
(7) Evacuate the refrigerant system. See Refriger-
ant System Evacuate in this group for the proce-
dures.
(8) Charge the refrigerant system. See Refrigerant
System Charge in this group for the procedures.
NOTE: If the condenser is replaced, add 30 millili-
ters (1 fluid ounce) of refrigerant oil to the refriger-
ant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
DUAL FUNCTION HIGH PRESSURE SWITCH/
HIGH PRESSURE CUT-OFF SWITCH
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Unplug the wire harness connector from the
dual function high pressure switch or the high pres-
sure cut-off switch, which is mounted to a fitting on
the non-flexible section of the discharge line nearest
the compressor.
(3) Unscrew the high pressure switch from the dis-
charge line fitting.
(4) Remove the high pressure switch from the
vehicle.
(5) Remove the O-ring seal from the discharge line
fitting and discard.
INSTALLATION
(1) Lubricate a new O-ring seal with clean refrig-
erant oil and install it on the discharge line fitting.
Use only the specified O-rings as they are made of a
special material for the R-134a system. Use only
refrigerant oil of the type recommended for the com-
pressor in the vehicle.
(2) Install and tighten the high pressure switch on
the discharge line fitting.
(3) Plug the wire harness connector into the high
pressure cut-off switch.
(4) Connect the battery negative cable.
DUCTS AND OUTLETS
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS,
REFER
TO
GROUP
8M
-
PASSIVE
RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING
WHEEL,
STEERING
COLUMN,
OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
PANEL OUTLET DUCTS
The panel outlet ducts are integral to the instru-
ment panel assembly. Refer to Instrument Panel
Assembly in Group 8E - Instrument Panel Systems
for the procedures.
PANEL OUTLET BARRELS
(1) Use a trim stick or another suitable wide flat-
bladed tool to gently pry the panel outlet barrel out
of the panel outlet housing (Fig. 32). The barrel is
retained by a light snap fit.
(2) To install, position the barrel in the panel out-
let housing and press firmly until the barrel snaps
into place.
DEMISTER OUTLETS
The side window demister outlets are integral to
the instrument panel end caps. Refer to Instrument
Panel End Cap in Group 8E - Instrument Panel Sys-
tems for the procedures.
DEFROST DUCT/DEMISTER ADAPTER
(1) Remove the instrument panel assembly from
the vehicle. Refer to Instrument Panel Assembly in
Group 8E - Instrument Panel Systems for the proce-
dures.
(2) Disconnect the demister hoses from the defrost
duct/demister adapter (Fig. 33).
Fig. 32 Panel Outlet Barrels
1 – DEMISTER OUTLETS
2 – PANEL OUTLET BARRELS
XJ
HEATING AND AIR CONDITIONING
24 - 33
REMOVAL AND INSTALLATION (Continued)
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