A/C - Compressor Shaft Seal Repair Procedure
HEATING AND AIR CONDITIONINGAC002-01
November 16, 2001
Title:
A/C COMPRESSOR SHAFT SEAL REPAIR
Models:
'99-'02 ES 300 & RX 300
Introduction
This bulletin provides a repair procedure for the A/C compressor shaft seal. When it is necessary to replace the shaft seal use the following procedure.
Applicable Vehicles
Parts Information
Special Service Tools
Warranty Information
Applicable Warranty *:
This repair is covered under the Lexus Comprehensive Warranty. This warranty is in effect for 48 months or 50,000 miles, whichever occurs first, from the vehicle's in-service date.
* Warranty application is limited to correction of a problem based upon a customer's specific complaint.
Inspection procedure
A/C COMPRESSOR INSPECTION
1. Oil Leak Mechanism.
A. Oil leak due to wear of shaft seal.
B. Oil leak from front housing die cast cavities.
2. External Check of Compressor.
If one of the following can be confirmed, an oil check should be performed.
^ Presence of oil on contact surface of clutch.
^ Felt is saturated with oil.
^ Oil leak from small die cast hole in front housing.
3. Compressor Residual Oil Check.
If one of the following is confirmed (locked/near locked compressor shaft), repair using this procedure is NOT POSSIBLE.
^ Oil color has turned black.
^ Large amount of wear particles (aluminum dust) can be found in oil.
4. Front Housing Replacement. Execute the repair as instructed. During repair, confirm that there is no rust or damage on the compressor shaft.
Replacement Procedure
A/C COMPRESSOR FRONT HOUSING (W/ Shaft Seal) REPLACEMENT
1. Clean Surface of Compressor. The surface of the compressor should be cleaned by air blowing to remove bits of trash and dust.
2. Drain Compressor Oil Into Measuring Flask.
Measure the quantity of drained oil because the same amount should be replaced later.
3. Remove Front Housing and Gasket.
A. Remove the bolt and lock sensor bracket so that you can place the compressor on the vice.
NOTE:
Do not remove the lock sensor.
B. Place the compressor on the vice as shown in the illustration.
NOTE:
Place the front cylinder as shown in the illustration.
C. Loosen the 5 bolts one complete turn (360°).
NOTE:
Do not remove the bolts - just loosen them.
D. Move the compressor to the work stand from the vice, then remove the 5 bolts and 5 washers completely.
NOTE:
^ Do not disassemble the rear housing parts.
^ The removed bolts and washers will not be used again.
E. Remove the front housing and gasket while holding the valve plate so that it does not separate from the compressor body.
NOTE:
Do not disassemble the front valve plate and rear housing parts.
4. Install New Front Housing.
NOTE:
Make sure that each plate and gasket surface is clean before assembly.
A. Install the SST
^ SST P/N: 07112-85010
B. Install a new gasket, while taking care to align the locating pins correctly.
C. Install a new front housing, while taking care to align the locating pins correctly.
5. Install New Seal Washers and Bolts.
A. Apply compressor oil to the bolt thread surface, bolt ridge and back side of the bolt head of the front housing.
Compressor oil: ND-OIL8
B. Install 5 new seal washers and 5 new bolts.
NOTE:
Make sure the bolt contact surface on the front housing is clean before assembly.
C. Place the compressor on the vice and remove the SST.
NOTE:
Place the front cylinder as shown in the illustration. (If you clamp both the front cylinder and rear housing on the vice, you cannot tighten the bolts properly.)
D. Tighten the 5 bolts a little at a time in the order shown in the illustration. Repeat the process until all the bolts are torqued to:
10.8 Nm (110 kgf.cm, 8 ft.lbf)
Then loosen the 5 bolts one complete turn (360°).
E. Retighten the 5 bolts a little at a time in the order shown in the illustration. Repeat the process until all the bolts are torqued to:
3.9 Nm (40 kgf.cm, 2.9 ft.lbf)
F. Turn the 5 bolts 180°.
a. Place two diagonal lines on the socket as shown in the illustration.
b. By putting the socket onto the bolt and matching the mark A of the socket, apply a mark to the housing.
c. Turn the socket wrench until mark B meets the mark on the housing.
G. Wipe off any oil on the housing.
6. Pour Compressor Oil Into Compressor. Add the same quantity of oil as removed, plus 20 cc, into the compressor.
Compressor oil: ND-OIL8