Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSGEO1993PRIZM L4-1600CC 1.6L DOHCREPAIR AND DIAGNOSISHEATING AND AIR CONDITIONINGCOMPRESSOR HVACSERVICE AND REPAIRMINOR COMPRESSOR REPAIR PROCEDURES
1993 Geo Prizm L4-1600cc 1.6L DOHC
Minor Compressor Repair Procedures
1993 Geo Prizm L4-1600cc 1.6L DOHCSECTION Minor Compressor Repair Procedures
Remove or Disconnect
1. Pressure plate.
A. Using a socket and tool J 7624, remove shaft bolt.
B Remove pressure plate.
C. Remove shims from pressure plate.
2. Rotor.
A. Using snap ring pliers J 5403. remove snap ring.
B. Tap rotor off the shaft using a plastic hammer.
NOTICE: Be careful not to damage the pulley when tapping off rotor.
3. Stator.
A. Disconnect stator lead wires from compressor housing.
B. Using snap ring pliers, remove snap ring.
C. Remove stator.
Install or Connect
1. Stator.
A. Stator on compressor.
B. New snap ring using special tool J 5403.
C. Stator lead wires to compressor housing.
2. Rotor.
A. Rotor on compressor shaft.
B. New snap ring using special tool J 5403.
3. Pressure plate.
A. Adjust the clearance between the pressure plate and the rotor by putting shims on the compressor shaft. Standard Clearance: 0.5 mm ± 0.15 mm (0.020-inch ± 0.0059-inch). If the clearance is not within this tolerance. alter the number of shims to obtain standard clearance.
B. Pressure plate.
C. Using special tool J 7624 and a torque wrench, install the shaft bolt.
Tighten
^ Shaft bolt to 13 N.m (115 lb.in.).
4. Check magnetic clutch clearance.
A. Install a dial indicator set J 8001 to the pressure plate of the magnetic clutch.
B. Connect magnetic clutch lead wire to the positive (+) battery terminal.
C. Check the clearance between the pressure plate and the rotor, then connect the negative (-) terminal of the battery to the clutch lead wire and recheck clearance.
Standard Clearance: 0.5 mm ± 0.15 mm (0.020-inch ± 0.0059-inch).
1. Pressure plate.
Removing Shaft Bolt:
A. Using a socket and tool J 7624, remove shaft bolt.
B Remove pressure plate.
Removing Shim:
C. Remove shims from pressure plate.
2. Rotor.
Removing Snap Ring:
A. Using snap ring pliers J 5403. remove snap ring.
Removing Rotor:
B. Tap rotor off the shaft using a plastic hammer.
NOTICE: Be careful not to damage the pulley when tapping off rotor.
3. Stator.
Disconnecting Stator Wires:
A. Disconnect stator lead wires from compressor housing.
Removing Snap Ring:
B. Using snap ring pliers, remove snap ring.
Removing Stator:
C. Remove stator.
Install or Connect
1. Stator.
A. Stator on compressor.
B. New snap ring using special tool J 5403.
C. Stator lead wires to compressor housing.
2. Rotor.
A. Rotor on compressor shaft.
B. New snap ring using special tool J 5403.
3. Pressure plate.
A. Adjust the clearance between the pressure plate and the rotor by putting shims on the compressor shaft. Standard Clearance: 0.5 mm ± 0.15 mm (0.020-inch ± 0.0059-inch). If the clearance is not within this tolerance. alter the number of shims to obtain standard clearance.
B. Pressure plate.
Torquing Shaft Bolt:
C. Using special tool J 7624 and a torque wrench, install the shaft bolt.
Tighten
^ Shaft bolt to 13 N.m (115 lb.in.).
4. Check magnetic clutch clearance.
Installing Dial Indicator Set:
A. Install a dial indicator set J 8001 to the pressure plate of the magnetic clutch.
B. Connect magnetic clutch lead wire to the positive (+) battery terminal.
C. Check the clearance between the pressure plate and the rotor, then connect the negative (-) terminal of the battery to the clutch lead wire and recheck clearance.
Standard Clearance: 0.5 mm ± 0.15 mm (0.020-inch ± 0.0059-inch).
RENDER: 1.0x
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.