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Hummer H1 (2002+). Manual - part 187

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Heating/Ventilation/Air Conditioning (HVAC) 11-27

05745159

Passenger Side Windshield Defrost Nozzle

Removal

Remove right side crash pad (Section 10).

Remove front console (Section 10).

Remove diverter assembly.

Remove main A/C - heat unit blower housing.

Remove four screws, lockwashers and passenger side
lower windshield retainer from A-beam. Remove plusnuts
(Figure 11-24).

Remove passenger side windshield defrost nozzle and side
window demister vent hose from A-beam.

Remove side window demister vent hose from defroster
nozzle.

Installation

Slide side window demister vent hose on defrost nozzle
(Figure 11-24).

Carefully fit defroster nozzle and demister vent hose into
A-beam while making sure that it aligns and creates a
leak-free overlap joint with the center duct (Figure 11-24).

Install four screws, lockwashers and lower windshield
retainer on A-beam.

Install main A/C - heat unit blower housing.

Install diverter assembly.

Install front console (Section 10).

Install right side crash pad.

Check operation of windshield defrosters.

Driver Side Windshield Defrost Nozzle

Removal

Remove right side crash pad (Section 10).

Remove front console (Section 10).

Remove four screws, lockwashers and driver’s lower wind
shield retainer from A-beam. Remove plusnuts (Figure 11-24)

Remove center windshield defrost duct.

Remove side window demister vent hose and defrost
nozzle. Pull toward center of vehicle.

Remove defrost nozzle from side window demister hose
(Figure 11-24).

Installation

Slide side window demister hose on defrost nozzle
(Figure 11-24).

Install side defrost nozzle and window demister vent hose
on A-beam. Slide them toward driver’s side.

Install center windshield defrost duct.

Install four screws, lockwashers and lower windshield
retainer on A-beam.

Ensure correct overlap joint to adjacent ducts.

Install front console (Section 10).

Check operation of windshield defrosters.

Install right side crash pad (Section 10).

11-28

Heating/Ventilation/Air Conditioning (HVAC)

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COMPRESSOR REPLACEMENT

WARNING: Air conditioning system components are
subject to high-pressure refrigerant R-134a gas. Always
discharge pressure and contain R-134a using approved
service equipment. Use extreme care when handling R-
134a. Direct contact with skin may cause frostbite. Do
not smoke in areas where R-134a is stored or used. Fail-
ure to follow these warnings may result in serious in-
jury.

Removal

Discharge air conditioning system.

Disconnect electrical connector from compressor
(Figure 11-25).

Figure 11-25: Air Conditioner Compressor and

Mounting Hardware

Remove serpentine belt from pulley.

Remove suction/discharge hose assembly and sealing
washers from top of compressor. Discard sealing washers.

Remove four bolts and compressor from compressor
support bracket.

Drain the oil from the compressor and measure the
amount.

Installation

NOTE: Sealing washers, by design, do not require lubrication.
Lubricating sealing washers during replacement will increase
the possibility of contamination, which may result in refriger-
ant leaks.

Drain 8 oz. of oil from the new compressor. Replace the
amount that was drained from the previously removed
compressor +1 oz.

Secure compressor to compressor support bracket with
four bolts (Figure 11-25).

Insert two sealing washers and secure suction/discharge
hose assembly to top of compressor with washer and bolt.
Tighten bolt to 28 lb-ft (38 N•m).

Connect electrical connector to spade terminals on
compressor.

Evacuate and charge air conditioning system.

Perform air conditioning system service, evacuate, charge,
and test for leaks.

Compressor Clutch Plate and
Hub Replacement

Removal

NOTE: Removal and installation of external compressor parts,
and disassembly and assembly of internal parts, must be per-
formed on a clean workbench. The work area, tools, and parts
must be kept clean at all times.

Remove compressor.

Clamp the holding fixture in a vise and attach compressor
to holding fixture from set J–34021-A with thumb-screws
(Figure 11-26).

Figure 11-26: Compressor

SEALING WASHERS

ELECTRICAL

CONNECTOR

COMPRESSOR

SUPPORT BRACKET

SUCTION/DISCHARGE

HOSE ASSEMBLY

COMPRESSOR

CLUTCH HUB

CLUTCH PLATE

THUMB-SCREW

HOLDING FIXTURE

COMPRESSOR

NUT SOCKET

AND HUB ASSEMBLY

HOLDING TOOL

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Heating/Ventilation/Air Conditioning (HVAC) 11-29

05745159

Keep the clutch plate and hub assembly from turning by
using the clutch hub holding tool. Remove the shaft nut
using nut socket.

With center screw forcing tip in place to thrust against the
end of the shaft, thread the hub and clutch drive plate
assembly remover/installer 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 (Figure 11-27).

Figure 11-27: Clutch Plate and Hub Assembly

CAUTION: Do not drive or pound on the clutch hub or shaft.
Internal damage to compressor may result. The forcing tip on
remover/installer center screw must be flat, or the end of the
shaft/axial plate assembly will be damaged.

Remove the shaft key and retain for reassembly
(Figure 11-28).

Figure 11-28: Shaft Key

Installation

Install the shaft key into the hub key groove. Allow the key
to project approximately 1/8 in. (3.2 mm) out of the key-
way. The shaft key is curved slightly to provide an interfer-
ence fit in the hub key groove (Figure 11-28).

Be sure the frictional surface of the clutch plate and the
clutch pulley rotor are clean before installing the clutch
plate and hub assembly.

Align the shaft key with the shaft keyway, and place the
clutch plate and hub assembly onto the compressor shaft.

Remove the forcing tip on clutch plate and hub assembly
installer/remover center screw and reverse the body
direction on the center screw (Figure 11-29).

Figure 11-29: Drive Plate Installation

Install the clutch plate and hub assembly remover/
installer.

NOTE: The body of the remover/installer should be backed
off sufficiently to allow the center screw to be threaded onto
the end of the compressor shaft.

Hold the center screw with a wrench. Tighten the hex
portion of the remover/installer 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 final position. The air gap between
frictional surfaces of the clutch plate and clutch rotor
should be 0.020-0.030 in. (0.50-0.76 mm).

CAUTION: If the center screw is threaded fully onto the end of
the compressor shaft, or if the body of the installer is held and
the center screw is rotated, the key will wedge and will break
the clutch hub.

Remove the remover/installer and check for proper
positioning of the shaft key (even or slightly above the
clutch hub). Install the shaft nut. Hold the clutch plate and
hub assembly with clutch hub holding tool, and using nut
socket, tighten the nut against the compressor shaft
shoulder to 8-16 lb-ft (11-22 N•m) (Figure 11-26).

Spin the pulley rotor by hand to see that the rotor is not
rubbing the clutch drive plate (Figure 11-28).

Add PAG oil to the compressor in an equivelant amount to
the oil in the compressor when it was originally removed.

10. Install compressor.

HUB AND CLUTCH DRIVE PLATE

CLUTCH PLATE

HOLDING FIXTURE

AND HUB ASSEMBLY

ASSEMBLY REMOVER/INSTALLER

SHAFT KEY

CLUTCH PLATE

SHAFT KEYWAY

AND HUB ASSEMBLY

CLUTCH

PULLEY
ROTOR

DRIVE PLATE

CLUTCH PLATE

AIR GAP

(0.50 - 0.76 MM)

0.02 - 0.03 IN.

INSTALLER

AND HUB ASSEMBLY

DRIVE PLATE

INSTALLER BEARING

CENTER

SCREW

11-30

Heating/Ventilation/Air Conditioning (HVAC)

______________________

COMPRESSOR CLUTCH ROTOR AND/OR
BEARING REPLACEMENT

Removal

Remove the clutch plate and hub assembly.

Using snapring pliers, remove retaining ring (Figure 11-30).

Figure 11-30: Retaining Ring

Install pulley rotor and bearing puller guide on the
compressor, and install pulley rotor and bearing puller
down into the inner circle of slots in the rotor. Turn the
puller clockwise in the slots in the rotor (Figures 11-31
and 11-32).

Figure 11-31: Pulley Rotor and Bearing

Puller Guide

Figure 11-32: Pulley Rotor and Bearing Puller

Hold the puller in place and tighten the puller screw
against the puller guide to remove the pulley rotor and
bearing assembly.

To prevent damage to the pulley during bearing removal,
the rotor hub must be properly supported. Remove the
forcing screw from puller, and with the puller tangs still
engaged in the rotor slots, invert the assembly onto a solid
flat surface or blocks (Figure 11-33).

Figure 11-33: Bearing Remover

Drive the bearing out of the rotor hub with bearing
remover and driver handle.

CAUTION: It is not necessary to remove the staking in front of
the bearing to remove the bearing, however, it will be neces-
sary to file away the old stake metal for proper clearance for
the new bearing to be installed into the rotor bore, or the bear-
ing may be damaged.

Installation

Place the pulley rotor on support block to fully support the
rotor hub during bearing installation (Figure 11-33).

Figure 11-34: Bearing Installer

CAUTION: Do not support the rotor by resting the pulley rim
on a flat surface during the bearing installation. The rotor face
will bend.

PULLEY ROTOR

RETAINING

RING

PULLEY ROTOR AND

PULLER

BEARING PULLER GUIDE

PULLEY ROTOR

AND BEARING PULLER

DRIVER HANDLE

BEARING

PULLEY ROTOR

REMOVER

DRIVER

HANDLE

PULLEY

ROTOR

INSTALLER

BEARING

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