Special Tools

1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging .
2. Remove the compressor. Refer to Air Conditioning Compressor Replacement .
3. Drain the oil from compressor into a suitable container. Measure and record the amount of oil drained from the compressor. Discard all used oil.
4. Remove the clutch plate and hub assembly. Refer to Compressor Clutch Plate/Hub Assembly Replacement .
5. Remove the clutch rotor and bearing. Refer to Clutch Rotor and/or Bearing Replacement .
6. Remove the clutch coil. Refer to Air Conditioning Clutch Coil Replacement .
7. Remove and discard the shaft seal parts. Refer to Compressor Shaft Seal Replacement .
8. Remove the compressor through-bolts. Remove and discard the gaskets.
9. Using a wooden block and a plastic-headed hammer, tap the compressor housing at the mounting locations to disengage the housing from the compressor cylinder.

Important: Note the assembly sequence of the thrust washer and bearing for ease of assembly.

10. Remove the thrust washer and the bearing.
11. Remove and discard the compressor housing-to-cylinder O-ring.

1. Rest the rear head on the J 35372  (2). Locate the control valve at the 6 o'clock position.
2. Install J 34993  (1) through the 11 o'clock and the 5 o'clock bolt holes.
3. Lubricate the new cylinder-to-compressor housing O-ring with clean polyalkaline glycol (PAG) oil.
4. Install the new O-ring in the cylinder O-ring groove.
5. Install the thrust washer and bearing in the same order as they were removed.
6. Align the guide pin recess in the compressor housing with the guide pin. Press down on the compressor housing with both hands to force it over the O-ring on the cylinder assembly.

Notice: Refer to Fastener Notice in the Preface section.

7. Add a new through-bolt gasket to the through-bolts and install it into the compressor assembly. Four through-bolts must thread into the rear head before removing the guide pins.

Tighten
Alternately tighten the through-bolts in progressive torque sequence to 10 N·m (89 lb in).

8. Install a new shaft seal. Refer to Compressor Shaft Seal Replacement .
9. Add new PAG oil equal to the amount drained in step 3.
10. Install the clutch coil. Refer to Air Conditioning Clutch Coil Replacement .
11. Install the clutch rotor and bearing. Refer to Clutch Rotor and/or Bearing Replacement .
12. Install the clutch plate and hub assembly. Refer to Compressor Clutch Plate/Hub Assembly Replacement .
13. Perform a leak test on the compressor. Refer to Compressor Leak Testing .
14. Install the compressor. Refer to Air Conditioning Compressor Replacement .
15. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging .