Valve Plates and Inlet Reeds

Tools Required:

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

Removal and Installation

1. Remove clutch assembly from the compressor.

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

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

4. Remove the six-cylinder bolts from the compressor using a 6mm Allen wrench. Remove the rear head from the compressor. The valve plate assembly, inlet reed and the cylinder gasket will normally be removed with the rear head. Use care not to lose the two dowel pins.

5. Remove the O-ring and inlet reed from the rear head.

6. Remove the valve plate assembly from the rear head with Valve Plate Remover T81P-19623-PH.

7. Clean the rear head with clean cleaning solvent. Dry the head with compressed air.

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

9. Position inlet reed (lightly lubricated with refrigerant oil) to the valve plate assembly, aligning the dowel pin holes.

10. Position the valve plate assembly and inlet reed to the cylinder assembly, aligning the dowel pin holes with the dowel pins.

11. Install the cylinder gasket over the valve plate assembly, aligning the dowel pin holes with the dowel pins.

12. Install a new O-ring into the O-ring groove of the cylinder assembly. Position the rear head to the cylinder assembly, aligning the dowel pin holes in the head with the dowel pins.

13. Hold the rear head against the cylinder assembly. Install two cylinder bolts into opposite holes to hold the rear head in place. Tighten the two bolts just snug.

14. Remove the Housing Clamp T81P-19623-LH from the front of the compressor. Install the tool to clamp the rear head to the cylinder assembly.

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

16. Remove the two cylinder bolts from the compressor.

17. Pull the front head from compressor assembly. The valve plate assembly, inlet reed and shaft seal assembly will usually come off with the front head. Then remove the two dowel pins.

18. Remove the O-ring and inlet reed from the front head.

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

20. Remove the shaft seal and the cylinder gasket from the front head.

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

22. Remove the felt wick and retainer from the drain hole in the front head.

23. Clean the front head with clean cleaning solvent and dry with compressed air.

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

25. Lubricate inlet reed with a light coating of clean refrigerant oil ESH-M2C31-A2 or equivalent. Position the inlet reed to the cylinder assembly, aligning the dowel pin holes of the inlet reed with the dowel pins.

26. Assemble the valve plate assembly to cylinder assembly, aligning the dowel pin holes with the dowel pins.

27. Assemble the cylinder gasket to valve plate assembly, aligning the dowel pin holes with the dowel pins.

28. Carefully remove shaft seal seat and seal from protective package. DO NOT CUT the transparent protective cover but peel it from the backing to expose the seal and seat.

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

29. Lubricate the new shaft seal seat with clean refrigerant oil and install the seat in the front head (groove side up) with Shaft Seal Seat Installer T81P-19623-C. Do not touch the sealing surface of the seat. Ensure the shaft seal seat is seated against the recess in the front head.

30. Lubricate the shaft seal with clean refrigerant oil and carefully assemble the seal on the compressor shaft 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.

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

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

33. Pour new refrigerant oil into the compressor. Refer to Adding Refrigerant Oil, During Compressor Replacement, in this Section.

34. Install a new felt wick and retainer in the front head drain hole.

35. Install the key in the slot of the compressor shaft with the rounded end toward the compressor body.

36. Rotate the compressor shaft with the clutch hub about 10 revolutions to distribute the oil in the compressor.

37. Leak test the compressor as outlined.

38. Install the clutch assembly on the compressor.