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SERVICE BULLETIN
Subject:
Group:
No.: MSB-97E55-001
Date: 1998-04-15
CHANGE IN AIR GAP FOR A/C COMPRESSOR
INFORMATION
OVERSEAS
SERVICE
DEPT
Draftno: 97-AL-021
R. USAMI - MANAGER
QUALITY INFORMATION ANALYSIS
<Model>
(EC,EXP) 3000GT
(Z10
(EX,EXP) L400
(PA0V)
(EC,EXP) COLT
(CJ0A)
(EX,EXP) LANCER
(CK0A)
<M/Y>
96-10
96-10
96-10
96-10
1. Description:
This Service Bulletin informs you of change in air gap of the clutch for the A/C compressor.
2. Applicable Manuals:
Manual
COLT/LANCER Workshop Manual
Pub. No.
PWME9117-D
PWMS9118-D
PWMF9119-D
PWMG9120-D
PWMD9121-D
PWMW9122-D
PWUE9119-D
PWWE9410
PWWS9411
PWWF9412
PWWG9413
PWWD9414
PWWW9415
PWME9511
PWMS9512
PWMF9513
PWMG9514
PWMD9515
PWMW9516
PWDE9611
PWDS9612
PWDF9613
PWDG9614
PWDD9615
PWDW9616
Language
(English)
(Spanish)
(French)
(German)
(Dutch)
(Swedish)
(English)
(English)
(Spanish)
(French)
(German)
(Dutch)
(Swedish)
(English)
(Spanish)
(French)
(German)
(Dutch)
(Swedish)
(English)
(Spanish)
(French)
(German)
(Dutch)
(Swedish)
Page(s)
55-2-1, 45-1
55-2, 50
55-5, 68
55-4, 31
55-4, 66
3. Effective Date:
Applicable vehicle
LANCER WAGON
3000 GT
L400
COLT/LANCER
GALANT
Effective Date
From May 28, 1997
From February 5, 1997
From June 4, 1997
From April 18, 1997
From March 5, 1997
4. Details
COLT/LANCER Workshop Manual, page 3, 4
3000GT Workshop Manual, page 5, 6
95 L400 Workshop Manual, page 7, 8
96 COLT/LANCER Workshop Manual, page 9, 10
97 GALANT Workshop Manual, page 11, 12
55-2-1
SERVICE SPECIFICATIONS
Items
Standard value
Idle speed
4G13, 4G15
4G92, 4G93
4D68
Idle up speed
Resistor (for blower motor)
Specifications
r/min.
r/min
<New>
0.3 - 0.5 (0.01 - 0.02)
750 100
800 100
750 100
850 50
<L.H. drive vehicles>
MH: 0.35
ML: 0.97
LO: 2.21
<Old>
Air gap (Magnetic clutch)
Refrigerant temperature switch
ON (continuity) temperature
OFF (no continuity) temperature
Continuity:
No continuity:
55-45-1
Armature
Serration notch
Crankshaft
20A0213
MB991386
3. INSTALLATION OF NUT
<New>
0.3 - 0.5 mm (0.01 - 0.02 in.)
MB991367
20N0087
Thickness gauge
20N0028
55-2
SPECIFICATIONS
E55CA
GENERAL SPECIFICATIONS
Items
Heater unit
Type
Heater control assembly
Compressor
Model
<Vehicles using R-12 refrigerant>
<Vehicles using R-134a refrigerant>
Refrigerant unit lubricant
cm3 (cu.in.)
<Vehicles using R-12 refrigerant>
<Vehicles using R-134a refrigerant>
V belt size
mm (in.)
Dual pressure switch
<Vehicles using R-12 refrigerant>
High pressure switch
kPa (kg/cm2, psi)
Low pressure switch
kPa (kg/cm2, psi)
<Vehicles using R-134a refrigerant>
High pressure switch
kPa (kg/cm2, psi)
Low pressure switch
kPa (kg/cm2, psi)
Freezer prevention
C (F)
Refrigerant and quantity
<Vehicles using R-12 refrigerant>
<Vehicles using R-134a refrigerant>
Specifications
Three -way-flow full-air-mix system
Push button type
FX-105VS
MSC105
FREOL S-83 or SUNISO 5GS 160 20 (9.8 1.2)
SUN PAG 56 160 20 (9.8 1.2)
1,150 (45.3)
g (oz.)
R-12 (CFC - 12) 770 - 870 (27.16 - 30.69)
R-134a (HFC - 134a) 740 - 790 (26.10 - 27.87)
SERVICE SPECIFICATIONS
Item
Standard value
Idle speed when air conditioner on rpm
Resister resistance value
Thermostat
ON temperature C (F)
OFF temperature C (F)
Revolution pick up sensor standard resistance
Clutch clearance mm (in.)
Engine coolant temperature switch
Switch-OFF temperature C (F)
Air mix damper potentiometer motor assembly
resistance
MAX. HOT k
MAX. COOL k
Mode selection damper potentiometer assembly
resistance
DEF. Position k
FACE. Position k
Engine coolant temperature sensor
Sensor-ON temperature C(F)
E55CB
Specifications
900 100
1.76 - 2.06 (Across terminals and )
1.10 - 1.26 (Across terminals and )
0.38 - 0.44 (Across terminals and )
Approx. 110 (230) or less
Approx. 155 (311) or less
405 35 when ambient temperature is 20C (68F)
0.4 - 0.6 (0.01 - 0.02) <Old>
112 - 118 (233 - 244)
<New>
0.3 - 0.5 (0.01 - 0.02)
0.2
4.8
0.2
4.8
26.5 4 (79.7 7)
5
55-50
Armature
Serration notch
Mating mark:
where there
is no spline
Crankshaft
20A0213
MB991386
3. INSTALLATION OF NUT
(1) Use the special tool to tighten the nut.
<New>
MB991367
(2) Check whether or not the air gap of the clutch is within
the standard value.
Standard value:
0.4 - 0.6 mm (0.01 - 0.02 in.)
<Old>
NOTE
If there is a deviation of the air gap from the standard
value, make the necessary adjustment by adjusting the
number of shims.
Thickness gauge
20N0028
SERVICE SPECIFICATIONS
Items
Idle speed r/min.
120002258
HI - LO
Standard value
700 50
750 50
800 50
750 30
850 - 950
900 - 1,000
Approx. 40
1.96 7%
HI - ML
0.95 7%
HI - MH
0.33 7%
4G63-M/T
4G63-A/T
4G64
4D56
4G63
4D56
Approx. 1 - 3
4.7
1.56 7%
HI - MH
0.86 7%
0.44 7%
Approx. 1.7
<Old>
Air gap (Magnetic clutch) mm
Engine coolant temperature switch
(for A/C cut-off) C
Engine coolant temperature switch
(for condenser fan) <4D56> C
Engine coolant temperature switch
(for condenser fan) <4G63, 4G64>
C
LUBRICANTS
Items
Single A/C
Dual A/C
55-5
ON (continuity)
OFF (no continuity)
ON (continuity)
OFF (no continuity)
ON (continuity)
OFF (no continuity)
0.3 - 0.6
108 or less
112 - 118 or more
100 - 104 or more
97 or less
95 - 105 or more
95 or less
Quantity
180
As required
Approx. 650
240
As required
Approx. 950
Remarks
N Range
P Range
N or P Range
Between
terminals 2 - 3
Between
terminals 2 - 1
Between
terminals 2 - 4
Between
terminals 6 - 8 or
Between
terminals 7 - 8
Between
terminal 4 - 3
Between
terminal 4 - 6
Between
terminal 4 - 5
Between
terminal 2 - 3
120002657
Specified lubricants
ZXL 100 PG
R134a (HFC - 134 a)
SUN PAG 56
55-68
Clutch coil
protection
Compressor body
pin hole
A20W0214
Snap ring
Rotor
Clutch coil
Tapered part
A20W0216
Armature plate
Crankshaft
Protection
Notch
A20W0215
MB991386
FNUT INSTALLATION
MB991367
20N0087
Thickness gauge
20N0028
Check whether or not the air gap of the clutch is within the
standard value.
Standard value: 0.3 - 0.6 mm <Single A/C>
0.4 - 0.6 mm <Dual A/C>
<Old>
NOTE
If there is a deviation of the air gap from the standard
value, make the necessary adjustment by adjusting the
number of shims.
55-4
Caution
Do not Heat R-134a above 40C
In most instances, moderate heat is required to
bring the pressure of the refrigerant in its
container above the pressure of the system
when charging or adding refrigerant.
A bucket or large pan of hot water not over 40C
is all the heat required for this purpose. Do not
heat the refrigerant container with a blowtorch or
any other means that would raise temperature
and pressure above this temperature. Do not
weld or steam clean on or near the system
components or refrigerant lines.
Caution
Keep R-134a containers upright when
charging the system.
SERVICE SPECIFICATIONS
Items
Idle speed r/min
55200030110
Standard value
750 100
700 100
850 100
LO: 2.21, ML: 0.97, MH: 0.35
LO: 2.81, ML: 1.28, MH: 0.33
0.40 - 0.65 <Old>
LUBRICANTS
<New>
Items
Each connection of refrigerant line
Compressor refrigerant unit lubricant m
55200040113
0.3 - 0.5
Specified lubricants
SUN PAG 56
SUN PAG 56
Quantity
As required
120
55200060096
SPECIAL TOOLS
Tool
Number
Name
Use
MB991367
Special spanner
MB991386
Pin
55-31
ANUT REMOVAL
MB991367
20N0087
Clutch coil
protection
Compressor body
pin hole
A20S0112
Clutch coil
Snap ring
Tapered part
Crankshaft
A20A0157
Armature plate
Serration notch
DNUT INSTALLATION
Matching mark
Use the special tool to hold the magnet clutch, and tighten
the nut in the same manner as removal.
Crankshaft
A20A0213
Thickness gauge
Check whether or not the air gap of the clutch is within the
standard value. <Old>
Standard value: 0.40 - 0.65 mm
NOTE
If there is a deviation of the air gap from the standard
value, make the necessary adjustment by adjusting the
number of shims.
20N0028
55-4
Caution
Do not Heat R-134a above 40C
In most instances, moderate heat is required to
bring the pressure of the refrigerant in its
container above the pressure of the system
when charging or adding refrigerant.
A bucket or large pan of hot water not over 40C
is all the heat required for this purpose. Do not
heat the refrigerant container with a blowtorch or
any other means that would raise temperature
and pressure above this temperature. Do not
weld or steam clean on or near the system
components or refrigerant lines.
Caution
Keep R-134a containers upright when
charging the system.
SERVICE SPECIFICATIONS
Items
Idle speed r/min
55200030219
Standard value
750 50
650 50
800 30
750 50
650 50
850 50
850 50
900 50
850 50
LO: 2.30, ML: 1.10, MH: 0.40
0.40 - 0.65 <Old>
4G6
6A1
4D6
4G6
6A1
4D6
4G6
6A1
4D6
LUBRICANTS
Items
Each connection of refrigerant line
Compressor refrigerant unit lubricant m
<New>
0.3 - 0.5
Specified lubricants
SUN PAG 56
SUN PAG 56
55200040199
Quantity
As required
120
11
55-66
HEATER, AIR CONDITIONER AND VENTILATION <MANUAL AIR CONDITIONER> - Compressor and Tension Pulley
MB991386
ANUT REMOVAL
MB991367
20N0087
Clutch coil
protection
Compressor
body pin hole
A20S0112
Snap ring
Rotor
Clutch coil
Tapered part
A20i0065
Armature plate
Serration notch
DNUT INSTALLATION
Matching mark
Use the special tool to hold the magnet clutch, and tighten
the nut in the same manner as removal.
Crankshaft
A20A0213
Thickness gauge
Check whether or not the air gap of the clutch is within the
standard value. <Old>
Standard value: 0.40 - 0.65 mm
NOTE
If there is a deviation of the air gap from the standard
value, make the necessary adjustment by adjusting the
number of shims.
20N0028