Major Compressor Repair Procedures

COMPRESSOR OVERHAUL

Remove or Disconnect

1. Compressor service valves.

Draining Compressor Oil:

^ Drain compressor oil into measuring flask.

Important
^ Measure the quantity of oil drained from compressor; that amount of oil should be replaced after compressor is re-assembled.

2. Discharge cover.

Removing Discharge Cover:

A. Two rear Allen-head bolts.

Cover Top Bolts:

B. Four top Allen-head bolts.

Important
^ Do not remove the three screws atop the cover.

Checking Temperature Switch:

^ Using an ohmmeter, check the operation of the temperature switch.

Oil Temperature: 120°C (248°F)---No Continuity
Oil Temperature: 180°C (356°F)---No Continuity

If switch operation is not as specified, replace the switch.

Important
^ After inspection, thoroughly clean switch before re-assembly.

Removing Discharge Valve:

3. Two Alien-head bolts securing discharge valve and remove the valve.

Removing Front Housing:

Removing Rear Housing:

4. Five Allen-head through bolts; remove front and rear housing.

Removing Pins And Gasket:

5. Pins and front housing gasket.

Removing Shaft Seal:

6. Shaft seal from shaft.

Pump Subassembly:

NOTICE: Do not disassemble pump subassembly.

Using Special Tool J 9393-A:

^ Insert special tool J 9393-A into seal plate.

Removing Seal Plate:

7. Seal plate from front housing.

Revolution Detector:

^ On vehicles equipped with power steering, remove the revolution detector.

Install or Connect

NOTICE: Thoroughly clean all compressor parts with solvent and air dry before reassembly. Replace all gaskets and O-rings with new ones.

Special Tool J 9393-A:

^ Fit seal plate on J 9393-A.

Installing Seal Plate:

1. Seal plate into front housing.

Installing Shaft Seal:

2. A new shaft seal on compressor shaft. Lubricate seal with compressor oil prior to installation.
3. A new front gasket on housing assembly.
4. Front and rear housings on pump subassembly.

Installing Discharge Valves:

6. Install discharge valves using torque wrench.

Tighten
^ Bolts to 5 N.m (44 lb. in.).

Installing Discharge Cover:

7. Discharge cover; Tighten 4 bolts loosely.
8. Two discharge cover through bolts.

Compressor To Compressor Bracket:

9. Compressor bracket to compressor using 4 bolts.

Tighten
^ Bolts to 25 N.m (19 lb. ft.).

NOTICE: The bracket is attached at this point in the procedure to ensure proper alignment of the compressor housing. Misalignment of the compressor will cause seizure during operation.

Tightening Through Bolts:

^ Using a torque wrench, tighten the five through bolts as shown in the illustration.

Tighten
^ Bolts to 25 N.m (19 lb. ft.).

Tightening 2 Through Bolts:

^ Remove compressor bracket from housing and using a torque wrench, tighten the two through bolts.

Tighten
^ Bolts to 11 N.m (8 lb. ft.).

Installing Discharge Cover Bolts:

^ Using a torque wrench, tighten four bolts on the discharge cover.

Tighten
^ Bolts to 11 N.m (8 lb. ft.).

^ If vehicle is equipped with power steering, install revolution detector.

Tighten
^ Bolts to 11 N.m (8 lb. ft.).

Adding Oil To Compressor:

^ Add the same amount of new oil to the compressor as was removed at the beginning of the disassembly procedure, plus an additional 20cc.

Installing Service Valves:

10. Service valves on compressor using a torque wrench.