Compressor—Out-of-Vehicle

Head Gasket and O-Ring Seal

Tools Required:

• Shaft Key Remover T81P-19623-NH
• Snap Ring Pliers T71P-19703-T
• Shaft Seal Seat Remover T87P-19623-BR
• Shaft Seal Replacer T87P-19623-C
• Shaft Seal Protector T71P-19703-H
• Rotunda Electronic Leak Detector 055-00015

Disassembly

The refrigerant system must be discharged and compressor removed from vehicle to perform head gasket and O-ring replacement operation.

1. Drain refrigerant oil from compressor through suction and discharge port openings into a calibrated container. Record amount of oil removed from compressor.

2. Clamp compressor in a vise. Remove clutch hub, pulley and shims as outlined.
   
   
   
   

3. Remove snap rings retaining clutch field coil to front of compressor. Then pull field coil from front of compressor.
   
   
   
   

4. Carefully remove felt and retainer from inside nose of compressor.

5. Clean compressor front hub and front and rear head areas to remove any accumulation of oil and dirt.

6. Remove shaft key with Shaft Key Remover T81P-19623-NH.

7. Remove shaft seal seat retaining snap ring with Snap Ring Pliers T71P-19703-T.

8. Clean inner bore of compressor nose to prevent dirt from entering compressor when shaft seal seat is removed.

9. Remove seal seat with Shaft Seal Seat Replacer T87P-19623-B.

10. Insert Shaft Seal Replacer T87P-19623-C into compressor nose opening and on top of shaft seal. Rotate tool clockwise while pushing tool inward until tool engages tangs of seal. Then pull shaft from compressor with tool.

11. Hold front and rear heads in position on compressor. Remove five cylinder bolts and washers retaining heads to compressor.

12. Remove rear head, head gasket, rear valve plate, reed valves and dowel pins from rear of compressor (refer to Compressor—Disassembled illustration).

13. Remove front head, head gasket, front valve plate, reed valves and dowel pins from compressor.

Cleaning and Inspection

Clean all components in clean solvent and allow to dry. Do not blow dry the valve plates or reed valves with compressed air. Repeat the cleaning process using new cleaning solvent if necessary.

Inspect the cylinder bores for scratches, corrosion or other signs of damage or wear. Replace compressor if any of these conditions exist.

Inspect valve plates for scratches, corrosion or signs of wear or other damage. Replace the compressor if valve plate damage is found.

Inspect the reed valves for cracks, scratches, deformation and corrosion. Replace the compressor if reed valve damage is found.

Assembly

1. Install two dowel pins in front dowel pins holes of the cylinder assembly.

2. Lubricate head O-ring and place it in groove on front of cylinder assembly.

3. Lubricate front suction reed valve with clean refrigerant oil and place it in position on front of cylinder assembly. Ensure the suction reed valve is properly positioned on cylinder assembly as shown in the following illustration.

NOTE: The front and rear reed valves are identical and interchangeable.

4. Lubricate front valve plate (marked with an "F") and place it in position on cylinder assembly. The "F" mark must be showing when the valve plate is properly installed.

5. Lubricate the discharge reed valve and place it in position on the front valve plate. Be certain the two locator holes of the discharge reed valve are positioned over the small pins pressed into the valve plate.

6. Lubricate front head gasket and place it in position on the cylinder assembly. The front and rear head gaskets are not interchangeable so it is essential that the correct gasket is used. The raised portions of the gasket must be positioned away from the cylinder assembly and the gas passage opening must be positioned in line with the cylinder assembly discharge openings.

7. Position front head to cylinder assembly aligning dowel pins with dowel pin holes in front head.

8. Install dowel pins in dowel pin holes at rear of cylinder assembly.

9. Lubricate rear reed valve with clean refrigerant oil and place it in position on the rear of the cylinder assembly. Ensure reed valve is properly positioned on cylinder assembly for cylinder bolts to pass through reed valve to rear head. The gas passage opening must be to the right of center and aligned with the discharge openings.

10. Lubricate rear valve plate (marked with an "R") and place it in position on rear of cylinder assembly. The "R" mark must be showing when valve plate is properly installed.

11. Lubricate the discharge reed valve and place it in position on the rear valve plate. Be certain the locator holes of the discharge reed valve are positioned over the small pins pressed into the valve plate.

12. Lubricate rear head gasket and place it in position on cylinder assembly with raised portion of gasket away from cylinder assembly. Be certain gasket does not block cylinder bolt passages and gas passage opening is positioned in line with the cylinder assembly discharge openings.

13. Lubricate rear head O-ring and place it in the groove on back of cylinder assembly.

14. Position rear head to cylinder assembly, aligning dowel pins with dowel pin holes in rear head.

15. Hold front and rear heads on the cylinder assembly. Install one cylinder bolt until it is snug. This will prevent the heads from separating from the cylinder assembly while the other cylinder bolts are installed.

16. Using a torque wrench, tighten five cylinder bolts in three steps: 16 Nm (12 lb-ft), 20 Nm (15 lb-ft) and 25 Nm (19 lb-ft) in a diagonal sequence as shown in the Cylinder Bolt Tightening Sequence illustration.

17. Lubricate new shaft seal with clean refrigerant oil and carefully attach shaft seal to Shaft Seal Replacer T87P-19623-C.
    
    
    
    

     CAUTION: DO NOT TOUCH the sealing surface of the shaft seal or seal seat with bare hands. To do so will damage the sealing surface.

18. Place Shaft Seal Protector T71P-19703-H over end of compressor shaft.

NOTE: Check the thin edge of the shaft seal protector for burrs or other damage. Replace the tool if burrs are found as the burrs could damage the internal sealing portion of the shaft seal assembly during installation.

19. Using Shaft Seal Replacer T92P-19623-BH insert shaft seal into compressor. Rotate seal on compressor shaft while pushing inward until flats of shaft are aligned with flats of shaft seal and seal is positioned against stops on shaft. Remove tool by pushing inward and rotating one-eighth turn counterclockwise.

20. Attach seal seat to Shaft Seal Seat Replacer T87P-19623-B and lubricate seat with clean refrigerant oil. Then insert seal seat into compressor. Push seal seat in against the seal.

21. Install seal seat retaining snap ring into nose of compressor and push snap ring into the groove with handle end of Shaft Seal Replacer T87P-19623-C.

22. Install shaft key in shaft groove with rounded end inward.

23. Pour new refrigerant oil into compressor. Refer to Step 1 of Disassembly and Adding Refrigerant Oil, during compressor replacement.

24. Rotate compressor shaft about 10 revolutions to distribute oil through compressor and around shaft seal. Then leak test the shaft seal with a flame-type leak detector as outlined under Compressor External Leak Test.

25. Install a new felt strip and the original retainer into nose of compressor (refer to Compressor—Disassembled illustration).

26. Install clutch field coil with beveled side of snap ring out.

27. Install clutch pulley with bevel of snap ring out. Then install shims and clutch hub as outlined. Check clutch air gap and adjust as necessary.