General

DELCO REFRIGERANT COMPRESSOR (Engine 116 and 117)

Data:
Designation Delco
- 6 cylinder swashplate compressor, 206.5 cc, model no.59 10 763
Max. speed
- 6400 1/min
Required input at max. compressor speed
- approx. 6.3 (8.5) kW (HP)

Oil Filling Capacity:
Oil type
- Refrigerant oil (for approved refrigerant oils refer to "Specifications" for service products.
Oil quantity for new refrigerant compressor
- 300 cc
Oil quantity for removed compressor following repair or removal
- 200 cc

Tightening Torques:
Pipeline to refrigerant compressor
- 17 Nm
Oil check screw
- 15-17 Nm
8 mm screws
- 35 Nm
10 mm screws
- 30-35 Nm
12 mm screws
- 40-45 Nm
Hex. nuts on threaded bolts
- 25-30 Nm

Special Tools:
Holding device for refrigerant compressor
- 109 589 00 31 00
Mount for inner mechanism
- 109 589 01 31 00
Pressure test plate
- 109 589 00 25 00

Conventional Tool:
Double open end wrench
- 3/8" x 7/16" for oil check screw

NOTE: Operational trouble on air-conditioning system, particularly with a defective refrigerant compressor, e.g. caused by blocking or broken poppet valves, will result in considerable contamination of system under influence of burnt refrigerant oil or abrasives. Since the fact cannot be eliminated that abrasives of refrigerant compressor may enter lines of air.conditioning system, renew pipe line with hoses on refrigerant compressor in such a case. Always replace expansion valve and receiver dehydrator when renewing valve plate.

Removal:
1. Remove refrigerant compressor and clean at outer surfaces.
2. Unscrew oil check screw (3) and drain all the refrigerant oil in compressor. To speed-up draining of refrigerant oil, rotate drive shaft several times. Do not use drained refrigerant oil again.
3. Remove spring plate, pulley, clutch coil and shaft sealing ring.






Removing rear exhaust valve plate
1 Exhaust valve plate
2 Spring holder
3 Exhaust valve

4. Turn compressor around in holding device with its front end in downward direction. Unscrew hex. nuts on compressor housing and remove rear head section. If head section is binding, apply uniform blows around head section by means of a rubber hammer.
5. Wipe refrigerant oil from sealing surfaces of rear head section and check sealing surfaces. If damage shows up, replace head section.






1 Head section rear
2 Sealing surface

6. Remove suction strainer, check and clean if required.
7. Apply an identification mark on outer surface of inner and outer oil pump gear wheel. Then remove gear wheels.
8. Remove sealing ring between head section and housing.






1 Inner gear wheel
2 Outer gear wheel
3 Sealing ring

9. Carefully remove rear valve plates, while applying two screwdrivers underneath spring holders - not between spring and spring seat - and force out valve plates.
10. Check valve springs and valve seats. Replace entire valve plate, if damaged.






Removing rear exhaust valve plate
1 Exhaust valve plate
2 Spring holder
3 Exhaust valve

11. Lift Out rear intake valve plate by means of two screwdrivers, but do not use leaf spring valves as support
12. Check leaf springs of valve plate for damage and exchange, if required.






Removing rear intake valve plate
1 intake valve plate

13. Remove oil intake pipe (1 and remove sealing ring from oil intake.
14. Loosen compressor from holding device. Place mount for inner assembly group over oil pump shaft. Lift compressor from holding device. Turn compressor pressor around and place on work bench in such a manner that the mount for the inner assembly group rests on work bench.





Removing oil intake pipe
1 Oil intake pipe
2 O-ring
3 Removing tool

15. Lift off front head section and compressor housing. Inner mechanism remains on mount.

Attention!: Do not knock against end of compressor shaft to push out inner mechanism. If inner mechanism is not sliding out of compressor housing, knock with plastic hammer against front head section.

16. Put compressor housing with front head section aside and push.out head section through compressor housing, making sure that the sealing surfaces on in side of front head section are not damaged.
17. Wipe refrigerant oil from sealing surface of front head section and check sealing surface. If damage shows up, replace head section.
18. Remove front exhaust and intake valve plate. Check leaf springs and their seats. Replace these parts, if required.
19. Check inner mechanism for damage. If essential damage (e.g. seized spots on cylinder running surface) shows up caused by a shortage of refrigerant or oil, it is recommended to install a complete exchange compressor or a new compressor.

Installation:
20. Place inner mechanism on mount.
21. Insert new guide pins (2) into front cylinder half, if previously removed.
22. Mount front intake valve plate (1) on front cylinder half. Align oil return slot and overflow pipe by means of guide pins (2).






Installation of front intake valve plate
1 Intake valve plate
2 Guide pins
3 Oil return slot
4 Overflow pipe

23. Install front exhaust valve plate, making sure that bores in valve plate are in alignment with guide pins.






Installation of front exhaust valve plate
1 Exhaust valve plate
2 Guide pin

NOTE: The front exhaust valve plate (1) is recognized by a large diameter hole in center of plate.

24. Coat sealing surfaces of ribs on front head section with refrigerant oil.






1 Intake valve plate
2 Exhaust valve plate rear
3 Exhaust valve plate front

25. Determine position of head section (1) in relation to guide pins (2) of inner assembly group. Mark location of bores on outside of head section. Insert head section in correct position, without touching sealing surfaces with shaft (3). Do not rotate head section for engaging guide pins, since sealing surfaces will then make contact with valve bores.






Installation of front head section
1 Head section front
2 Exhaust valve plate
3 Shaft

26. Provide chamfered groove on lower end of head section (1) well with refrigerant oil and insert a new sealing ring (2) into groove.






1 Head section front
2 Sealing ring

27. Coat inner surface of compressor housing with refrigerant oil and then slip housing over inner mechanism until it is seated on sealing ring (3).






28. Carefully push mechanism (2), until housing (1) slips down over mechanism. When housing slips down, align oil pan (4) with bore (5).
29. Turn compressor around while holding mount in position and insert into holding device. Then remove mount.
30. Insert new guide pins into rear cylinder half (if previously removed).
31. Insert new sealing ring into bore for oil intake pipe.






1 Exhaust valve plate
2 Spring holder
3 Exhaust valve

32. Provide oil intake pipe with refrigerant oil and install, while turning compressor mechanism around until oil intake pipe (1) is in alignment with hole in housing wall.






Removing oil intake pipe
1 Oil intake pipe
2 0-ring
3 Removing tool

33. Insert rear intake valve plate over guide pins with oil return slot in direction Of oil pan.






Installing rear intake valve plate
1 Intake valve plate

34. Install rear exhaust valve plate over guide pins.
35. Slip inner oil pump gear wheel (1) on shaft with the previously applied mark pointing upwards.
35. Slip outer oil pump gear wheel (2) over inner gear wheel (1), with the previously applied mark pointing upwards.






1 Inner gear wheel
2 Outer gear wheel
3 Sealing ring

37. Provide rear exhaust valve plate completely and around outer diameter between housing and valve plate with refrigerant oil.
38. Provide new sealing ring (3) between head section and housing with refrigerant oil and place on exhaust valve plate or in housing.
39. Insert suction strainer into rear head section. Caution! Do not damage.
40. Provide sealing surfaces of ribs on head section with refrigerant oil.
41. Slip rear head section over studs while making sure that the strainer is not falling out of its seat and that the teflon gasket is undamaged.

NOTE: If the rear head section is not engaging in guide pins, turn front head section and push manually.






1 Head section rear
2 Sealing surface

42. Screw hex nuts on threaded bolts and tighten uniformly.
43. Turn compressor around in holding device and install shaft seal, clutch coil, pulley and spring plate.
44. Fill fresh refrigerant oil (200 cc) into compressor.
45. Check Delco refrigerant compressor for leaks.






Components of Delco Refrigerant Compressor