New A/C Compressor Assembly/Disassembly Procedures (TS 7-04 11192)

NEW A/C COMPRESSOR ASSEMBLY/DISASSEMBLY PROCEDURES

TECHNICAL SERVICE BULLETIN

MODIFICATION OF AIR CONDITIONING COMPRESSOR

Model(s): 1990-93 Suzuki Swift GA/GS/GT, Sidekick JA/KX/JLX

Group: Miscellaneous

Bulletin No.: TS 7-04 11192

Date: December, 1992

CONDITION

Change in front housing and shaft seal.

CAUSE

Factory modification.

CORRECTION

Identify compressor and follow applicable procedure.

Due to the modification of both the cylinder front head and shaft seal assembly, a part of the disassembly procedures and special tools for compressor overhaul have been changed. When servicing the late type compressor, refer to the information contained in this bulletin. See Fig 1 Name plate identification.

MODIFICATION PARTS

1. Compressor and magnet clutch (see Fig 2 ).
2. Compressor (see Fig 3 .
   1. Shaft seal assembly
      • 1-1 Mechanical seal
      • 1-2 Lip seal
   2. Cylinder front head

MODIFICATION DETAIL

1. Shaft seal assembly (Fig 3 early and late style seals).
   Fig 3: Modified Shaft Seal Assembly

   
2. Cylinder front head (Fig 4 early and late style heads).

DISASSEMBLY OF COMPRESSOR (See Fig 5

Name Plate # 047200-9921 (Swift)

# 147200-1221 (Swift)

# 047200-6021 (Sidekick)

1. Remove oil felt. Using a screw driver, pry out oil felt. See Fig 6 .
2. Remove key. Using a hammer and punch, drive key from shaft. See Fig 7 .
3. Remove circlip. Using snap ring pliers, remove circlip. See Fig 8 .
4. Apply compressor oil to inner bore. See Fig 9 .
   Fig 6: Removing Oil Felt

   
   Fig 7: Removal of Key from Shaft

   
   Fig 8: Circlip Removal

   
   Fig 9: Compressor Oil Application

   
5. Remove lip seal using special tool (A). The following explains this removal procedure:
   1. Fit special tool (A) into the clutch installation boss. See Fig 10 . Special tool (A) 09990-48220
   2. Turn special tool (A) until its protrusion engages with the groove provided on lip seal. See Fig 11 .
   3. Check that special tool (A) goes down slightly when the protrusion and groove are engaged.
   4. Turn special tool (A) by 30°-60°.
   5. Pull up on special tool (A) to remove lip seal. See Fig 12 .
      CAUTION: DO NOT re-use lip seal once it has been removed from the compressor.
      Fig 10: Using Special Tool for Lip Seal Removal

      
      Fig 11: Proper Alignment of Special Tool

      
      Fig 12: Lip Seal Removal

      
6. Using shaft seal remover (Special tool), remove shaft seal. See Fig 13 .
7. Remove joint service connector. See Fig 14 ve "O" rings from service valve and discard them.
   NOTE: Do not re-use five washers.
8. Drain oil into container. See Fig 15 .
9. Remove front housing. See Fig 16 ve front housing by prying it at its protrusion. See Fig 17 .
   NOTE: Be careful not to scratch sealing surface of front housing.
   Fig 13: Shaft Seal Removal

   
   Fig 14: Joint Service Connector Removal

   
   Fig 15: Location of Oil Drain Holes

   
   Fig 16: Front Housing Removal

   
   Fig 17: Protrusion Pry Location

   
10. Remove front valve plate. Remove two pins from cylinder block. See Fig 18 .
11. Remove rear housing by prying it at its protrusion. See Fig 19 .
    NOTE: Be careful not to scratch sealing surface of rear housing.
12. Remove rear valve plate. Remove two pins from rear housing. See Fig 20 .
13. Remove front and rear "O" rings from cylinder block and discard them. See Fig 21 .

CHECKING COMPONENTS

Clean all parts with cleaning solvent and apply compressor oil to them. See Fig 22 .

ASSEMBLY OF COMPRESSOR

1. Install rear valve plate on rear cylinder.
   1. Install two pins in rear cylinder.
   2. Lubricate new O-ring with compressor oil and install it in rear cylinder.
   3. Install suction reed valve, rear valve plate, and discharge reed valve to rear cylinder top. For installation locations, refer to Fig 23 .
      NOTE:

      • Front and rear reed valves suction and discharge) are the same.
      • Rear valve plate is marked "R".
   4. Lubricate gasket with compressor oil and install it to valve plate. See Fig 24 .
      Fig 23: Rear Valve Installation Points

      
      Fig 24: Proper Gasket Placement on Rear Valve Plate

      
      NOTE: Front and rear gaskets are not the same, so do not interchange them. See Fig 25 .
      Fig 25: Front & Rear Gasket Comparison

      
      NOTE: Assemble gaskets so that their protruded surfaces face upward.
2. Install rear housing to rear cylinder.
   • Protrusion of housing should come at the top. See Fig 26 .
     Fig 26: Proper Placement of Rear Housing

     
3. Install front valve plate on front cylinder.
   1. Install two pins in front cylinder.
   2. Lubricate new O-ring with compressor oil. Install it in front cylinder.
   3. Install suction reed valve, front valve plate, and discharge reed valve onto front cylinder top. For installation locations, refer to Fig 27 .
      Fig 27: Front Valve Plate Installation Points

      
      NOTE:

      • Front and rear reed valves (suction and discharge) are the same.
      • Front valve plate is marked "F".
   4. Lubricate gasket with compressor oil and install it to valve plate. See Fig 28 .
      NOTE:

      • Front and rear gaskets aren't the same, so do not interchange them. (To differentiate them, refer to description on rear valve plate as shown in Fig 25 .
      • Assemble gaskets so that their protruded surfaces face upward.
      Fig 28: Proper Gasket Placement on Front Valve Plate

      
4. Install front housing front cylinder and tighten five through bolts. See Fig 29 .
   1. Using a torque wrench and hexagon wrench, gradually tighten five through bolts. Tightening torque: 25-27 Nm (2.5-2.7 kg.m/18.1-19.5 lb. ft.)
      NOTE: Protrusion of housing should come at the top.
      Fig 29: Proper Placement of Front Housing

      
5. Install shaft seal.
   1. Lubricate shaft seal with compressor oil and fit it to shaft seal remover using Special tool. See Fig 30 .
      Fig 30: Using Shaft Seal Remover

      
   2. Apply oil to bore. Insert shaft seal remover, and turn it to the left while lightly pressing. Then pull up shaft seal remover. See Fig 31
      Fig 31: Shaft Seal Installation

      
6. Coat the special tool (B) surface with oil and install it to the shaft. See Fig 32 . Special tool (B): 09990-58230
   Fig 32: Installing Special Tool on Shaft

   
7. Apply oil to lip seal O-ring and install it over the special tool (B). When fitting the lip seal over the special tool, care should be taken so as not to confuse its designated direction. See Fig 33 for the designated direction.
   Fig 33: Lip Seal Installation

   
8. Position special tool (C) on lip seal. See Fig 34 Special tool (C): 09990-58220
   Fig 34: Special Tool Placement on Lip Seal

   
9. Press special tool (C) slowly by hand until lip seal contacts the stopper of the front housing. See Fig 35
   NOTE: With lip seal pressed in completely, its upper face must be positioned lower than the circlip fitting groove. Be sure to visually check its position.
   CAUTION: Do not use a press machine, hammer, etc. to push on special tool (C).
   Fig 35: Placement of Lip Seal on Stopper

   
10. Install circlip. See Fig 36
    Fig 36: Circlip Installation

    
11. Install key in shaft groove.
    1. Using a plastic hammer and key installing tool (Special tool) tap key lightly. See Fig 37
       Fig 37: Installation of Key in Shaft Groove

       
12. Install oil felt.
    1. Put new oil felt to inside of bore. See Fig 38
       Fig 38: Oil Felt Installation

       
13. Pour compressor oil into compressor. See Fig 39
    OIL CAPACITY
    
    

    Description	Quantity
    Additional oil after compressor overhauling	40 cc (2.4 cu. in.)
    Oil capacity of air conditioner system	80 +/- 20 cc (4.9 +/- 0.1 cu. in.)

    Fig 39: Oil Filling Hole

    
    NOTE: Compressor assembly supplied from factory is filled with 80 cc. of oil. Therefore, when replacing only compressor assembly with new one, drain 40 cc. oil from it. The rest (40 cc.) of oil remain in other parts than compressor.
14. Install service valves. See Fig 40
    1. Lubricate new O-rings with compressor oil and install them in service connector.
    2. Install service connector to compressor. Tightening torque: 25-27 Nm (2.5-2.7 kg.m/18.1-19.5 lb.ft)
       Fig 40: Service Valve Installation

       
       NOTE: Suction port has larger internal opening than discharge port.
15. Check shaft rotating torque. Starting torque: Less than 30 kg-cm (2.2 lb-ft)

Ref. #	Part Name	Early Part Number	Late Part Number	Supply of Spare Parts
A	Compressor and magneticclutch	95200-60B10 -64B10	95200-60B11 -64B11	Both earlyand late
B	Compressor	95230-60B10 -64B10	95230-60B11 -64B11	Both earlyand late
1	Shaft seal assembly	95260-82000	95260-82001	Both earlyand late
2	Cylinder front head	95231-82000	95231-82001	Both earlyand late