Hummer H1 (2002+). Manual - part 188

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Heating/Ventilation/Air Conditioning (HVAC) 11-31

05745159

Align the new bearing squarely with the hub bore, and
using puller and bearing installer with driver handle, drive
the bearing pulley into the hub. The installer will apply
force to the outer race of the bearing if used as shown
(Figure 11-34).

Place bearing staking guide and bearing staking pin in the
hub bore. Shift the rotor and bearing assembly on the
support block to give full support of the hub under the
staking pin location. A heavy-duty rubber band may be
used to hold the stake pin in the guide, and the stake pin
should be properly positioned in the guide after each
impact on the pin (Figure 11-35).

CAUTION: Noisy bearing operation and reduced bearing life
may result if outer bearing race is deformed while staking. The
stake metal should not contact the outer race of the bearing.
Stake three places, 120 degrees apart (Figure 11-36).

Figure 11-35: Bearing Staking Guide and Pin

Using care to prevent personal injury, strike the staking
pin with a hammer until a metal stake, similar to the
original, is formed down to, but not touching, the bearing.

Figure 11-36: Stake Locations

With the compressor mounted to the holding fixture,
position the rotor and bearing assembly on the front head
(Figure 11-37).

Figure 11-37: Pulley Rotor and Bearing

Position the pulley rotor and bearing installer, and puller
pilot directly over the inner race of the bearing.

Position puller crossbar on the puller pilot, and assemble
two through-bolts and washers through the puller bar slots,
and thread them into the holding fixture. The thread of the
through-bolts should engage the full thickness of the
holding fixture.

Tighten the center screw in the puller crossbar to force the
pulley rotor and bearing assembly onto the compressor.
Should the pulley rotor and bearing installer slip off direct
in-line contact with the inner race of the bearing, loosen
the center forcing screw and realign the installer and pilot
so that the installer will properly clear the compressor.

Using snapring pliers, install retaining ring (Figure 11-38).

10. Reinstall clutch plate and hub assembly.

Figure 11-38: Retaining Ring

BEARING STAKING

RUBBER BAND

BEARING STAKING PIN

GUIDE

STAKE THREE

120 DEGREES

LOCATIONS

APART

SCREW

CROSSBAR

ROTOR

PULLEY ROTOR AND
BEARING INSTALLER

BOLT

PULLER PILOT

HOLDING

FIXTURE

PULLEY ROTOR

RETAINING

RING

11-32

Heating/Ventilation/Air Conditioning (HVAC)

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COMPRESSOR CLUTCH CORE REPLACEMENT

Removal

Perform steps 1 through 4 of Clutch Rotor and/or Bearings
replacement procedure. Mark clutch core terminal location
on compressor.

Install puller pilot and puller crossbar with puller legs on
compressor (Figure 11-39).

Tighten forcing screw against the puller pilot to remove
the clutch core.

Figure 11-39: Clutch Core

Installation

Place the clutch core on compressor with the terminal
positioned at the marked location (Figure 11-39).

Place the clutch core installer over the internal opening of
the clutch core housing and align installer with the
compressor.

Center the puller crossbar in the countersunk center hole
of the clutch core installer. Install the through-bolts and
washers through the crossbar slots, and thread them into
holding fixture. The thread of the through-bolts should
engage the full thickness of the holding fixture.
(Figure 11-40).

Figure 11-40: Clutch Core Installer

Turn the center forcing screw of the puller crossbar to
force the clutch core into the compressor. Be sure clutch
core and installer stay aligned during installation.

When core is fully seated on the compressor, use a 1/8-in.
diameter drift punch and stake the front head at three
places, 120 degrees apart, to ensure clutch core remains in
positioning (Figure 11-41).

Figure 11-41: Drift Punch

NOTE: Stake size should be only one-half the area of the
punch tip and approximately 0.010-0.015 in. (0.25-0.38 mm)
deep.

Install rotor and bearing assembly and clutch plate and
hub assembly.

COMPRESSOR SHAFT SEAL REPLACEMENT

Removal

Remove clutch plate and hub assembly.

Using snapring pliers, remove the shaft seal retaining ring
(Figure 11-42).

Figure 11-42: Shaft Seal Retainer Ring

CAUTION: The handle must be hand-tightened securely. Do
not use a wrench or pliers.

NOTE: Thoroughly clean inside of compressor neck area sur-
rounding 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.

Fully engage the knurled tangs of seal remover/installer
into recessed portion of seal by turning handle clockwise.
Remove seal from the compressor with a rotary-pulling
motion. Discard seal (Figure 11-43).

SCREW

PULLER

PULLER PILOT

PULLER LEG

CLUTCH CORE

CROSSBAR

PULLER

SCREW

CLUTCH

CLUTCH CORE

HOLDING
FIXTURE

CORE

INSTALLER

CROSSBAR

CLUTCH CORE

DRIFT

STAKE IN FRONT

HEAD (3 LOCATIONS,

PUNCH

120 DEGREES APART)

RETAINING RING

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Heating/Ventilation/Air Conditioning (HVAC) 11-33

05745159

Figure 11-43: Seal Remover

Using O-ring remover, remove and discard seal seat O-
ring from the compressor neck (Figure 11-44).

Figure 11-44: O-Ring

Recheck shaft and inside of the compressor neck for dirt
or foreign material and be sure these areas are clean before
installing new parts.

Cleaning

Thoroughly clean seal seat O-ring groove in front head.

Installation

CAUTION: Seals should not be reused. Always use a new
specification service seal. Be sure that the replacement seal is
not scratched or damaged. Make sure that the seal seat and
seal are free of lint and dirt.

Dip new seal seat O-ring in clean PAG oil and install onto
O-ring installer (Figure 11-45).

Figure 11-45: O-Ring Installer

Insert O-ring installer into the compressor neck until
installer bottoms. Lower the moveable slide of the O-ring
installer to release the O-ring into the seal seat 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.

Dip new seal in clean PAG oil and assemble seal onto seal
installer by turning handle clockwise. The stamped steel
case side of the lip seal must be engaged with knurled
tangs of installer so that the flared-out side of lip seal is
facing and installed towards the compressor. Install seal
protector 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 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 makes good contact with the O-ring. Disengage the
installer from the seal and remove the installer and the seal
protector (Figure 11-46).

Figure 11-46: Seal Installer

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.

Using snapring pliers, install new seal retaining ring with
its flat side against the seal (Figure 11-47).

Figure 11-47: Seal Retaining Ring

Remove any excess oil from the shaft and inside the
compressor neck.

Install the clutch plate and hub assembly.

SEAL REMOVER/

SEAL

COMPRESSOR

INSTALLER

O-RING

SHAFT

REMOVER

S11-035

O-RING

INSTALLER

SEAL PROTECTOR

SEAL INSTALLER

SEAL

COMPRESSOR

SHAFT

RETAINING RING

11-34

Heating/Ventilation/Air Conditioning (HVAC)

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LOW PRESSURE CUTOFF SWITCH

The low pressure cutoff switch is mounted on the receiver/
dryer. The switch is wired in series with the compressor activa-
tion circuit. Should pressure drop below the switch’s setting,
the switch will open and interrupt current flow to the compres-
sor clutch. The switch will prevent damage to the system from
lack of oil flow due to inadequate charge or very low ambient
temperatures. The switch will close when the system pressure
rises to safe levels (Figure 11-48).

Figure 11-48: Receiver/Dryer with Low Pressure Cut-

off Switch

RECEIVER/DRYER

The receiver/dryer provides storage for high pressure liquid re-
frigerant. Desiccant inside of the receiver/dryer assists in re-
moving moisture from the refrigerant. The receiver/dryer also
act as a filter, filtering out particles of debris and preventing
bubbles of vapor form entering the expansion valve
(Figure 11-48).

AMBIENT TEMPERATURE SWITCH

The ambient temperature switch is mounted on the right front
of the condenser. The switch, which monitors ambient air tem-
perature, is wired in series with the compressor activation cir-
cuit. The switch interrupts current flow to the compressor
clutch when outside temperature drop below 45°F (10°C)
(Figure 11-49).

Figure 11-49: Ambient Temperature Switch

CONDENSER

The condenser provides heat exchange for the A/C system. The
condenser is located on the front of the radiator and cooler as-
semblies. Air from forward movement, and the engine cooling
fan is forced through the fins of the condenser, removing heat
from the highly pressurized refrigerant. Refrigerant enters the
condenser as a vapor, and exits as a liquid.

RECEIVER/DRYER

LOW PRESSURE

AMBIENT TEMPERATURE
SWITCH HARNESS

CUTOFF SWITCH

S11-053

CONDENSER

AMBIENT TEMPERATURE

SWITCH

S11-054

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