Cylinder to Front Head O-Ring

Tapping Front Or Rear Head Free Of Cylinder:

Remove or Disconnect

1. Discharge the refrigerant system and remove the compressor from the car. Drain the oil from the compressor into a container, measure and discard the oil.

2. Remove the clutch drive and hub assembly, pulley rotor and bearing assembly and the clutch coil per previous procedure.

3. Remove the shaft seal parts per previous procedure and discard the old seal parts.

4. Remove the six (6) compressor through bolts and gaskets. Discard the gaskets.

5. Using a plastic headed hammer, tap the front head at the mounting locations to disengage the head from the compressor cylinder.
Remove the front head, and cylinder to front head O-ring. Discard the O-ring.
Note assembly sequence of thrust washer and bearing for reassembly.

Install or Connect

1. Rest the rear head on support block J-35372. Install one (1) assembly guide pin J-34993 through 11 o'clock hole.

2. Lubricate a new cylinder to front head O-ring with clean 525 viscosity refrigerant oil and install O-ring in cylinder O-ring groove.

3. Install thrust washers and bearing in same order as removed.

4. Align guide pin recess in front head with guide pin and using both hands, press down on the front head to force it over O-ring on cylinder assembly.

5. Add new through bolt gasket to the through bolts and install the bolts into the compressor assembly. Be sure four (4) of the through bolts thread into the rear head before removing the guide pin. Assemble clamp to holding fixture.
Alternately tighten the through bolts in progressive torque until a torque of 8-10 N-m (72-84 in. lbs.) is achieved on all six (6) bolts.

6. Install new shaft seal kit per previous procedure.

7. Add amount of new 525 viscosity refrigerant oil to be added as determined in Step 1 of Remove. Install test plate J-9625-A.

8. Leak test complete compressor assembly according to (Bench-Check) Leak testing procedure.

9. Remove shaft nut and install clutch parts on compressor according to previous procedure.

10. Install compressor assembly on car.

11. Evacuate and charge the refrigerant system.