SERVICE MANUAL
  Applies to: Hyundai Coupe/Tiburon 1998-2001
GROUP
Heating, Ventilation & Air Conditioning Air Conditioning System
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COMPONENTS 
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DISASSEMBLY 
  1. Remove the clutch hub retaining bolt with the aid of a spanner wrench.

  1. Pull the clutch hub and shims from the compressor shaft. If the hub cannot be pulled from the compress shaft, screw an 8mm bolt into the shaft hole of the clutch hub to force the hub from the shaft.

  1. Remove the pulley retaining snap ring.

  1. Pull the pulley the bearing assembly from the compressor.

REASSEMBLY
  1. Clean the pulley bearing surface of the compressor head to remove any dirt or corrosion.

  1. Install the pulley and bearing assembly on the compressor. The bearing is a slip fit on the compressor head and, if properly aligned, should slip on the compressor head.

  1. Install the pulley retaining snap ring with the bevel side of the snap ring out.

  1. Place one nominal thickness spacer shim inside the hub spline opening and slide the hub on the end of the compressor shaft.

  1. Thread a new hub retaining bolt into the end of the compressor shaft. Tighten the hub retaining bolt.

    TORQUE SPECIFICATION
    Hub retaining bolt 10.2-15.3 Nm ( 102-153 kg·cm, 7.5-11.3 lb·ft )
    NOTE
    Do not use air tools.
  1. Check the clutch air gap between the clutch hub and the pulley mating surfaces with a feeler gauge. The air gap should be as follows:

    MEASUREMENT SPECIFICATION
    Air gap 0.35-0.75 mm ( 0.014-0.030 in )
    Check at three locations equally spaced around the pulley.

  1. If the clutch air gap is not within the dimensions specified above, repeat steps 4 through 6 with the various thickness shims until the air gap is between the specified limits.

CLUTCH FIELD COIL
DISASSEMBLY
  1. Remove the clutch hub and pulley following the procedure given.

  1. Install shaft protector tool on the nose opening of the compressor.

  1. Install the puller on the compressor as shown in the illustration.

    Place the tip of the puller forcing screw on the center dimple of the shaft protector and the jaws of the puller around the back side of the field coil.

  1. Tighten the forcing screw with a wrench to pull the coil loose from the compressor front head.

    NOTE
    Do not use air tools.
REASSEMBLY
  1. Clean the coil press diameter of the front head to remove any dirt or corrosion.

  1. With the compressor in a vertical position (nose up), place the coil in position on the front head of the compressor. Assure that the clutch coil electrical connector is positioned correctly.

  1. Place the coil pressing tool in position over the compressor nose and the inner radius of the field coil.

  1. Position an eight (8) inch, two jaw puller to the compressor and pressing tool as shown in the illustration. The jaws of the puller should be firmly engaged with the rear side of the compressor front mounts and the forcing screw should be piloted on the center of the pressing tool.

  1. Tighten the forcing screw with a wrench by hand until the coil is pressed completely onto the compressor front head. Check to assure that the field coil bottoms are against the front head at all points around the coil outer diameter

  1. Install the clutch pulley and hub on the compressor as outlined.

SHAFT SEAL

The refrigerant system must be discharged and the compressor must be removed from the vehicle prior to replacing the compressor shaft seal.

DISASSEMBLY
  1. Remove the clutch hub from the compressor.

  1. Remove the shaft seal from the nose of the compressor with a pick type tool.

  1. Blow any debris from inside the compressor nose with low pressure compressed air. Then, clean the inside and outside nose area of the compressor with a lint-free cloth to remove any oil and dirt.

  1. Remove the shaft seal retaining snap ring from inside the compressor nose with Snap Ring Remover as follows.

    • Insert tip of Snap Ring Remover into one of the snap ring eyes (View A).
    • Rotate the Snap Ring Remove to position the tool tip and snap ring eye closest to the compressor shaft (View B).
    • Pull the snap Ring Remover tool up quickly while keeping the tool shaft against the side of the nose opening to remove the snap ring (View C).
  1. Position the Shaft Seal Remove Tool (09977-33700) over the compressor shaft and push the tool into the nose of the compressor and down against the shaft seal. Engage the end of the tool with the internal diameter of the shaft seal. While holding the hex part of the tool, turn the tool handle clockwise to expand the tool tip inside the seal inner radius. Then, pull the shaft seal from the compressor with the tool.

REASSEMBLY
  1. Obtain a new shaft seal kit. Carefully remove the contents from the package and locate the plastic shaft seal protector. Inspect the protector for any burrs or other damage. Do not use the protector if it is damaged. Obtain another shaft seal kit and use the protector from it.

  1. Using a clean lint-free cloth, clean the shaft and the seal pocket inside the compressor nose.

  1. Dip the shaft seal protector and seal in clean refrigerant oil and position the seal on the protector with the lip of the seal pointing toward the large end of the protector.

  1. Place the seal protector with shaft seal over the end of the compressor shaft.

  1. Place the shaft seal installer tool over the end of the shaft seal protector. Then, slowly push the shaft seal down the protector until it is seated in the compressor.

  1. Remove the seal installer and seat protector from the compressor.

  1. Place a new seal retaining snap ring into the compressor nose opening and seat the snap ring into the groove with the remover tool.

  1. Test leakage of the shaft seal installation after rotating the shaft about 10 with the clutch hub.

  1. Install a new felt into the compressor nose.

  1. Install the clutch hub on the compressor as outlined in this section.