Major Compressor Repair Procedures

Remove or Disconnect

Tools Required:

J 33942-B Seal Seat Remover

1. A/C compressor clutch.

Oil Felt Seal And Retainer:

2. Oil felt seal and retainer from shaft. Pry off with screwdriver.

Removing Snap Ring:

3. Snap ring; using appropriate snap ring pliers.
^ Apply compressor oil to inner bore to ease disassembly.

Removing Shaft Seal:

4. Shaft seal, using a J 33942-B. Insert tool, turn 45 degrees and pull shaft seal out.

Removing Joint Service Valve Connector:

5. Four Allen-head bolts, joint service connector and O-rings.

Draining Compressor Oil:

^ Drain compressor oil into a container and save.

Removing Front Compressor Housing Bolts:

6. Five Allen-head bolts and washers securing front compressor housing.

NOTICE: Do not reuse five front housing washers.

Removing Front Compressor Housing:

7. Front compressor housing; pry off with a screwdriver.
8. Front gasket and reed valve from front of compressor.

Front Valve Plate:

9. Two pins from front of compressor and valve plate.
10. Front suction valve from compressor.

Removing Rear Compressor Housing:

11. Rear compressor housing; pry off with a screwdriver.

NOTICE: Be careful not to damage or scratch sealing surfaces of the front and rear housings.

Rear Valve Plate:

12. Rear gasket and reed valve.
13. Two pins from rear of compressor and valve plate.
14. Rear suction plate.

Front And Rear Compressor Seals:

15. Front and rear compressor seals and discard them.

Important
^ Do not disassemble the compressor any further. The compressor cylinder (subpump assembly) is replaced as a whole unit.

Clean
^ Clean all compressor parts with solvent and let dry completely. When dry, apply compressor oil to them.

Inspect

Compressor Checkpoint Chart:

^ All compressor parts that were removed. Refer to the "Component Checkpoint Chart".

Install or Connect

Tools Required:
J 34614 Shaft Seal Protector
J 33942-B Seal Seat Remover

NOTICE: Do not reuse shaft seal gasket O-rings, front or rear compressor seals, or washers. Use new washers and a compressor gasket set.

Important
^ Before beginning reassembly procedures, make sure that all parts are clean and that the work area is clean.

1. New compressor seal to rear of compressor. Lubricate seal with compressor oil.
2. Two pins on rear of compressor.
3. Suction valve, valve plate and reed valve to rear of compressor, lining up the plates with the 2 pins.

Important

Compressor Valves:

^ The front and rear suction and reed valves are identical. The front and rear valve plates are marked "F" and "R".

Rear Compressor Gasket:

Front And Rear Compressor Gaskets:

4. New rear gasket. lubricate with compressor oil prior to installation.

Important
^ The front and rear gaskets are different. Do not interchange them.
^ Assemble gaskets so that their protruded surfaces face upward.

Rear Compressor Housing Installation:

5. Rear housing to compressor.

6. New compressor seal to front of compressor. Lubricate seal with compressor oil.
7. Two pins on front of compressor.
8. Suction valve, valve plate and reed valve to front of compressor, lining up the plates with the 2 pins.

Rear Compressor Gasket:

9. New front compressor gasket; lubricate with compressor oil prior to installation.

Front Compressor Housing Installation:

10. Front compressor housing and five through bolts and new washers.

NOTICE: Do not reuse the five old front housing washers.

Tighten
^ Compressor through bolts to 27 N.m (20 lb.ft.).

11. Compressor shaft seal.

Installing J 34614:

A. Coat the J 34614 with compressor oil and install onto compressor shaft.

Installing Compressor Shaft Seal Onto J 34514:

B. Apply compressor oil to shaft seal O-ring and install onto J 34614 (when fitting the shaft seal onto the J 34614, be sure to have the O-ring facing down).

C. Place the J 33942-B onto the shaft seal.

NOTICE: Do not use a press, hammer or other similar tools to press the J 33942-B or shaft seal into place.

Installing Compressor Shaft Seal:

D. Using hand pressure only, slowly press the J 33942-B to seat the shaft seal (the shaft seal upper face must he beneath the snap ring fitting groove when seated).

12. New snap ring using snap ring pliers.
13. New oil felt and retainer inside the bore.

Adding Oil To The Compressor:

^ Pour new compressor oil into compressor through service valve opening. Add the same amount of oil that was removed at the beginning of the overhaul procedure.

^ If a new compressor is being installed, it is shipped from the factory with 100 ml (3.4 fl.oz.) of PAG compressor oil in it. Drain 40 ml (1.4 fl.oz.) of oil from the new compressor before installation, as that much oil remains in other components within the vehicle's refrigeration system.

Joint Service Connector Installation:

14. Joint service connector. Lubricate new O-rings with compressor oil.

Tighten
^ Four joint service connector bolts to 27 N.m (20 lb.ft.).

Important
^ The suction port has a larger internal opening than the discharge port. The O-rings are not interchangeable.

15. A/C compressor clutch.

Inspect
^ Compressor shaft rotating torque. Torque should be less than 3 N.m (27 lb.in.).