Shaft Seal and/or Front Head Gasket and O-Ring

Tools Required:

• Housing Clamp T81P-19623-LH
• Shaft Key Remover T81P-19623-NH
• Valve Plate Remover T81P-19623-PH
• Shaft Seal Seat Remover T81P-19623-OH
• Shaft Seal Seat Installer T81P-19623-C

Removal

1. Remove clutch assembly following the procedure for Clutch Field Coil Removal.

2. Invert compressor and pour the refrigerant oil from the compressor into a calibrated measuring container from the manifold openings. Record the amount of oil removed.

3. Install Housing Clamp T81P-19623-LH on compressor to retain the cylinder assembly and the rear head in position. Then, clamp the tool in a vise.
   
   
   
   

4. Remove the key from the compressor shaft with Shaft Key Remover T81P-19623-NH.

5. Remove the six cylinder bolts from the compressor using a 6mm Allen wrench. Then, pull the front head from the compressor. The valve plate assembly, inlet reed, shaft seal and cylinder gasket normally will come off with the head assembly.

   NOTE: Use extreme care not to damage any sealing surfaces.

6. Carefully lift inlet reed valve from the head assembly.

7. Remove the front valve plate assembly and gasket from the front head with Valve Plate Remover T81P-19623-PH.

8. Carefully remove the gasket from the valve plate assembly using care not to damage the surface of the valve plate assembly.

9. Remove the two dowel pins from the front head or cylinder assembly.

10. Remove shaft seal assembly and the felt seal from the head.

11. Place the head on a piece of clean corrugated cardboard and remove the seal seat assembly from the head with Shaft Seal Seat Remover T81P-19623-OH.

12. Clean the front head, valve plate assembly and inlet reed with clean cleaning solvent and allow them to dry. DO NOT BLOW DRY the inlet reed or valve plate assembly with compressed air.

Installation

1. Inspect inlet reed, valve plate assembly and front head for damage. Replace any damaged parts.

2. Install the two dowel pins in the dowel pin holes of the cylinder assembly.

3. Lubricate inlet reed with a light coating of clean refrigerant oil. Position the inlet reed to the valve plate assembly, aligning the dowel pin holes.

4. Assemble the valve plate assembly and inlet reed to the cylinder assembly aligning the dowel pin holes with the dowel pins.

5. Assemble a new cylinder gasket to the head side of the valve plate assembly aligning the dowel pin holes with the dowel pins.

6. Carefully remove the shaft seal seat and seal from the protective package.

   DO NOT CUT the transparent protective cover but peel it back from the backing to expose the seal and seat.

   NOTE: DO NOT TOUCH the sealing surfaces of the shaft seal or seal seat.

7. Lubricate shaft seal seat with clean refrigerant oil. Install the seat in the front head with the groove on the seat sealing surface up. Do not touch the sealing surface of the seat. Use Shaft Seal Seat Installer T81P-19623-C in the groove of the seat to install the seat in the head.

8. Lubricate the shaft seal with clean refrigerant oil and assemble the seal to the compressor with the sealing surface toward the end of the shaft. Engage the internal flats of the seal with the two flats on the shaft.

   NOTE: Avoid handling the carbon sealing surface of the seal assembly to prevent damaging the surface. Use extreme care to keep the seal and seal seat clean at all times.

9. Install a new O-ring in the O-ring groove of the front head.

10. Position the front head to the cylinder assembly aligning the dowel pin holes in the head with the dowel pins. Install the six head bolts and tighten to 24.5-26.5 Nm (18-19 lb-ft) in a diagonally opposite sequence. DO NOT USE AIR TOOLS.

11. Add new refrigerant oil to the compressor. Refer to Adding Refrigerant Oil, During Compressor Replacement, as outlined.

12. Install the key in the slot of the compressor shaft. Then, with the clutch hub, turn the compressor shaft 10 complete revolutions to distribute the oil inside the compressor.

13. Leak test the compressor as outlined.

14. Install clutch assembly on the compressor following the procedure for Clutch Field Coil Installation.