Shaft Seal, Removal and Installation
A/C Compressor Shaft Seal, Removing/Installing
Tools required
Use Mastercool A/C compressor service kit No.91296 or equivalent. Kit contains:
Tool No. Description
90902 Clutch plate puller
90414 Shaft seal seat remover/installer
SD-508 only
90412 0-ring hook
90906 Shaft seal remover/installer
SD-508 only
90910 Compressor shaft protector
91139 Shaft seal seat remover/installer
SD-709 only
91146 Feeler gauges
91138 Shaft seal remover/installer
SD-709 only
90903 Snap ring pliers
90907 Shaft Seal protector
90901 Spanner wrench
Removing
WARNING:
- Follow all recommended safety precautions before performing any A/C system servicing. [1][2]Service Precautions
- Automotive refrigerants containing CFC's are hazardous to the earth's atmosphere. To protect our environment, use an Underwriters Laboratory (UL) approved refrigerant recovery/recycling unit such as Kent-Moore ACR3 or equivalent, whenever discharging an A/C system.
- The A/C system should only be serviced by trained personnel familiar with:
- equipment use
- related safety procedures
- regulations governing the discharging, handling and disposal of automotive refrigerants.
CAUTION:
- Some A/C compressor replacement parts are not available. Always check with your Parts Department for latest parts information before attempting compressor repairs.
- Always follow manufacturer's instructions when using a refrigerant recovery/recycling unit.
- discharge A/C refrigerant system using refrigerant recovery/recycling unit Kent-Moore ACR3 or equivalent.
Note: If the vehicle is received with no refrigerant in the A/C system , always replace the receiver drier.
- remove A/C lines from compressor
- plug A/C lines with a suitable plug to prevent moisture contamination of receiver drier
- remove compressor from vehicle
Note:
- Perform all A/C compressor repairs on a clean dry service bench equipped with a vise.
- When servicing A/C compressors, verify the model number of the compressor, for example SD-709, to insure correct replacement parts are ordered.
- insert spanner wrench (Mastercool tool No. 90901 or equivalent) into clutch plate 18 of compressor
- hold plate 18 stationary with spanner and remove 19 mm hex nut 19 from compressor shaft
- remove front clutch plate 18 with clutch plate puller (Mastercool tool No. 90902 or equivalent similar tool shown)
- if equipped, carefully remove bearing dust cover with screwdriver
CAUTION: Do not distort dust cover when removing.
- remove shaft key 17 by lightly tapping with slotted screwdriver and small hammer
- remove all clutch shims 14, 15, 16 from compressor shaft
CAUTION: Shaft seal replacement must be performed on a clean, dry surface. Do not use old parts on the shaft seal assembly. Never touch the shaft seal with your fingers. Oil from skin contact will cause seal deterioration. Always use the metal carrier to handle the seal assembly.
- remove felt ring 8 with small screwdriver or 0-ring hook
- remove shaft seal retainer snap ring 7 with snap ring pliers (Mastercool tool No.90903 or equivalent)
- remove shaft seal seat 6 with seal seat remover/installer tool (Mastercool tool No. 91139 or equivalent)
CAUTION: Do not scratch the 0-ring groove. Scratches will cause refrigerant leaks in the seal area.
- carefully remove 0-ring from seal seat using 0-ring hook (Mastercool tool No.90412 or equivalent)
91138:
- insert shaft seal remover/installer tool (Mastercool tool No.91138 or equivalent) onto compressor shaft and against seal assembly
- press down seal remover/installer tool on seal assembly and twist tool until it engages slots on seal
- pull out shaft seal assembly 4
- clean seal cavity thoroughly with a suitable cleaning fluid, blow out cavity with dry pressurized air
Note: Insure that dirt and all foreign substances are removed from the seal cavity area.
Installing
90907:
- install shaft seal protector (Mastercool tool No.90907 or equivalent) over compressor shaft
- dip new shaft seal assembly 4 in clean, new refrigerant oil
CAUTION: Do not touch the sealing surfaces of the shaft seal. Skin oil will contaminate the seal and cause it to leak.
- engage seal remover/installer tool (Mastercool tool No.91138, or equivalent) into slots of shaft seal assembly 4
- insert shaft seal 4 into compressor seal cavity
- twist installer tool in opposite direction to disengage tool from shaft seal
- remove tool and shaft seal protector from compressor shaft
- coat new 0-ring 5 with new clean refrigerant oil
CAUTION: Do not scratch 0-ring groove when installing 0-ring.
- install new 0-ring on new seal seat and coat with clean refrigerant oil
- coat seal seat 6 with clean, new refrigerant oil
91139:
- install seal seat 6 with remover/installer tool (Mastercool tool No.91139, or equivalent)
- lightly press against seal seat 6 with tool to insure proper seating of seal seat
- install snap ring 7 with snap ring pliers (Mastercool tool No.90903 or equivalent)
- beveled edge of snap ring lies outward (toward clutch) and flat side towards compressor
- lightly tap snap ring into groove to ensure snap ring is fully seated
- dip new felt ring 8 into fresh, clean refrigerant oil and install onto compressor shaft
- using a small hammer, lightly tap new felt ring 8 into place
- install shims 14, 15, 16
- install shaft key 17 using small hammer and screwdriver
- install bearing dust cover, if equipped
- align front clutch plate keyway to compressor shaft key 17
- install front clutch plate 18 onto compressor shaft
- install shaft protector (Mastercool tool No.90910 or equivalent) onto compressor shaft and tap with a small hammer until clutch plate 18 bottoms on shims 14, 15, 16
- install 19 mm hex nut 19 onto compressor shaft
- insert spanner wrench (Mastercool tool No. 90901 or equivalent) into holes of front clutch plate 18 and hold stationary
CAUTION: Use a beam type torque wrench. Damage may result from use of inaccurate "click" wrenches.
- tighten hex nut 19
- 30-34 Nm (22-25 ft lb)
Note: Air gap a is determined by spacer shims 14,15,16. When installing a clutch assembly, try the original shims first. When installing a new clutch on a new compressor use the 1 mm, 0.5 mm, and the 0.127 mm shims provided in the clutch installation kit. If the air gap does not meet specification, add or remove shims accordingly.
- check air gap a of clutch with feeler gauge (Mastercool tool No.91146 or equivalent)
- a = 0.400 mm to 0.800 mm gap (0.016 in. to 0.031 in.)
Note: If air gap a is not consistent around the circumference, lightly pry up on the front face plate at the low spots and lightly tap down on the high spots with a small hammer.
- lubricate all 0-rings with clean refrigerant oil
- wash exterior case of compressor with hot soapy water to remove any CFC residues
- dry compressor with dry pressurized air
- install compressor in vehicle
- remove plugs from A/C lines.
- install A/C lines (arrows) on compressor and tighten as follows:
- suction line: 35 Nm (26 ft lb)
- discharge line : 25 Nm (18 ft lb)
- install and properly tension compressor drive belt
- evacuate and charge A/C system
- check compressor clutch and A/C system for proper operation
Note: If the front bearing seal still leaks after a new seal has been installed replace the compressor. No further repairs are possible to the seal; the mating surfaces are damaged beyond repair.