Cylinder to Front Head O-Ring Replacement

Cylinder to Front Head O-Ring Replacement

Tools Required

* J 34993 Cylinder Alignment Rods

* J 35372 Support Block

Removal Procedure





1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.

2. Remove the compressor. Refer to Air Conditioning Compressor Replacement Service and Repair.

3. Drain the oil from compressor into a suitable container. Measure and record the amount of oil drained from the compressor. Discard all used oil.

4. Remove the clutch plate and hub assembly. Refer to Compressor Clutch Plate and Hub Assembly Removal Service and Repair.

5. Remove the clutch rotor and bearing. Refer to Compressor Control Valve Assembly Removal Compressor Control Valve Assembly Removal.

6. Remove the clutch coil. Refer to Air Conditioning Clutch Coil Removal Service and Repair.

7. Remove and discard the shaft seal parts. Refer to Air Conditioning Compressor Shaft Seal Replacement Air Conditioning Compressor Shaft Seal Replacement.

8. Remove the compressor through-bolts. Remove and discard the gaskets.

9. Using a wooden block and a plastic-headed hammer, tap the compressor housing at the mounting locations to disengage the housing from the compressor cylinder.

Important:
Note the assembly sequence of the thrust washer and bearing for ease of assembly.


10. Remove the thrust washer and the bearing.

11. Remove and discard the compressor housing-to-cylinder O-ring.

Installation Procedure





1. Rest the rear head on the J 35372 (2). Locate the control valve at the 6 o'clock position.

2. Install J 34993 (1) through the 11 o'clock and the 5 o'clock bolt holes.

3. Lubricate the new cylinder-to-compressor housing O-ring with clean polyalkaline glycol (PAG) oil.

4. Install the new O-ring in the cylinder O-ring groove.

5. Install the thrust washer and bearing in the same order as they were removed.

6. Align the guide pin recess in the compressor housing with the guide pin. Press down on the compressor housing with both hands to force it over the O-ring on the cylinder assembly.

Notice:
Refer to Fastener Notice Fastener Notice in Cautions and Notices.

7. Add a new through-bolt gasket to the through-bolts and install it into the compressor assembly. Four through-bolts must thread into the rear head before removing the guide pins.

Alternately tighten the through-bolts in progressive torque sequence to 10 Nm (89 lb in).

8. Install a new shaft seal. Refer to Air Conditioning Compressor Shaft Seal Replacement Air Conditioning Compressor Shaft Seal Replacement.

9. Add new PAG oil equal to the amount drained in step 3.

10. Install the clutch coil. Refer to Air Conditioning Clutch Coil Removal Service and Repair.

11. Install the clutch rotor and bearing. Refer to Compressor Control Valve Assembly Removal Compressor Control Valve Assembly Removal.

12. Install the clutch plate and hub assembly. Refer to Compressor Clutch Plate and Hub Assembly Removal Service and Repair.

13. Perform a leak test on the compressor. Refer to Compressor Leak Testing Testing and Inspection.

14. Install the compressor. Refer to Air Conditioning Compressor Replacement Service and Repair.

15. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging Refrigerant Recovery and Recharging.