Cylinder to Front Head O-Ring

Tools Required
J-34993 Cylinder Alignment Rods
J-35372 Support Block




Disassembly Procedure
1. Recover the refrigerant.
2. Remove the compressor.
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.
5. Remove the clutch rotor and bearing.
6. Remove the clutch coil.
7. Remove and discard the shaft seal parts.
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 bearing.
11. Remove and discard the compressor housing-to-cylinder O-ring.




Assembly Procedure
1. Rest the rear head on the support block J-35372. Locate the control valve in the 6 o'clock position.
2. Install cylinder alignment rod J-34993 through the 11 o'clock and the 5 o'clock bolt holes.
3. Lubricate the new cylinder-to-compressor housing O-ring with clean polyalkalene 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 cylinder alignment rod recess in the compressor housing with the cylinder alignment rod. Press down on the compressor housing with both hands to force it over the O-ring on the cylinder assembly.
7. Add new through-bolt gaskets to the through-bolts and install them into the compressor assembly. Four through-bolts must thread into the rear head before removing the guide pins.

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

8. Install a new shaft seal.
9. Add new PAG oil equal to the amount drained in Step 3.
10. Install the clutch coil.
11. Install the clutch rotor and bearing.
12. Install the clutch plate and hub assembly.
13. Perform a leak test on the compressor. Refer to "Leak Testing (External)".
14. Install the compressor.
15. Evacuate and recharge A/C system.