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Compressor HVAC: Service and Repair





COMPRESSOR

REMOVAL
1. Magnetic clutch assembly
- Refer to "MAGNETIC CLUTCH ASSEMBLY" removal procedure.
- Drain compressor oil

2. Felt

3. Shaft seal cover





- Using shaft seal remover (J-33942-B) to remove the shaft seal cover.
- Engage the remover hook with the shaft seal cover groove and slowly draw the shaft seal cover out.

4. Snap ring





- Using snap ring pliers to remove the snap ring.

5. Shaft seal assembly





- Using shaft seal remover (J-33942-B) to remove the shaft seal assembly.
- Engage the remover hook with the shaft seal assembly groove and slowly draw the shaft seal assembly out.

6. Through bolt with gasket

7. Front cylinder head

8. O-ring





- Alternately tap the projections on the circumference of the front cylinder head with a screw-driver and a plastic hammer remove the front cylinder head.

9. Gasket

10. Front valve plate

11. Front suction valve

12. Rear cylinder head

13. O-ring





- Alternately tap the projections on the circumference of the rear cylinder head with a screw-driver and a plastic hammer to remove the rear cylinder head.

14. Gasket

15. Rear valve plate

16. Rear suction valve

17. Cylinder and shaft



INSPECTION AND REPAIR

Shaft Seal Assembly
- The shaft seal assembly is precision-machined and its critical parts are finished to extremely close tolerances. The assembly
- must be handled with great care, its slip face demanding particularly careful handling.
- The shaft seal can not be reused. Install a new shaft seal at reassembly.
- Take care not to scratch or otherwise dam- age the shaft seal face.
- Keep the shaft seal free from lint and dirt.

Front Valve Plate and Front Cylinder Head
Rear Valve Plate and Rear Cylinder Head
- Check the front and rear valve plates for scratching and bending.
- Check the front and rear valve plates and the front and rear cylinder heads for nicks and burrs on the sealing surfaces.
- Buff or replace the valve plates and cylinder heads if nicks and burrs are present.
- Check that the front and rear valve plate passages are free from obstructions.
- Check the front and rear valve plates and the cylinder heads for cracks.
- Replace the valve plates and cylinder heads if cracks are present.

INSTALLATION

17. Cylinder and shaft
- Clamp the cylinder shaft assembly in a vise. The rear side of the cylinder shaft assembly must be facing up.

16. Rear suction valve
- Apply a coat of new compressor oil to the new suction valve.





- Install the suction valve by aligning it with the spring pin and the cylinder valve relief grooves.

15. Rear valve plate
- Apply a coat of new compressor oil to the new valve plate.
- Install the valve plate to the suction valve by aligning it with the spring pin.

NOTE: Do not mix up the front and rear valve plates.

14. Gasket
- Apply a coat of new compressor oil to the gasket.
- Install the gasket to the valve plate.

13. O-ring





12. Rear cylinder head
- Apply a coat of new compressor oil to the new O-ring.
- Install the 0-ring to the rear cylinder head.
- Install the rear cylinder head.
- Tap the rear cylinder head into place with a plastic hammer.

11. Front suction valve
- Set the cylinder shaft assembly with the front side facing up.
- Apply a coat of new compressor oil to the suction valve.





- Install the suction valve by aligning it with the spring pin and the cylinder valve relief grooves.

10. Front valve plate
- Apply a coat of new compressor oil to the new valve plate.
- Install the valve plate to the suction valve by aligning it with the spring pin.

NOTE: Do not mix up the front and rear valve plates.

9. Gasket
- Apply new compressor oil to the new gasket
- Install the gasket to the valve plate by aligning it with the spring pin.

8. O-ring

7. Front cylinder head
- Apply a coat of clean compressor oil to the new O-ring.
- Install the 0-ring to the front cylinder head.
- Install the front cylinder head.





- Tap the front cylinder head into place with a plastic hammer.

NOTE: When installing the cylinder head, be careful that the end of the drive shaft does not damage the shaft seal surface in the cylinder head.

6. Through bolt with gasket
- Gaskets cannot reused. Always replace new ones.





- Tighten the bolts to the specified torque a little at a time in the sequence shown in the illustration.

Torque N.m (lb.in.) 22 (16)

- Rotate the compressor drive shaft two or three times to make sure that it moves smoothly.





5. Shaft seal assembly
- Clean the sealing portion of the compressor and shaft seal.
- Install the shaft seal guide (J-34614) onto the end of the drive shaft.
- Apply new compressor oil to the shaft seal guide.
- Install the shaft seal onto the compressor drive shaft head by using shaft seal installer (J-33942-B).

4. Snap ring
- Using snap ring pliers to install the snap ring.





3. Shaft seal cover

2. Felt
- Clean the sealing portion of the compressor and shaft seal cover.
- Install the shaft seal guide (J-34614) onto the end of the drive shaft.
- Apply new compressor oil to the shaft seal guide.
- Install the shaft seal cover onto the drive shaft by using shaft seal installer (J-33942-B). The installation position of the shaft seal cover is shown in the illustration.

1. Magnetic clutch assembly
- Refer to "MAGNETIC CLUTCH ASSEMBLY" installation procedure.

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