A/c Compressor Servicing Mazda RX-7 FC

NIPPONDENSO 10-CYLINDER

SHAFT SEAL

Note. Check compressor refrigerant oil level when replacing seals. See COMPRESSOR REFRIGERANT OIL CHECKING article in this section.

Removal

1. Hold clutch hub stationary and remove center nut. Screw remover into center of hub. Turn center bolt to remove pressure plate.
2. Remove shims from shaft. Remove snap ring from inside of pulley. Tap pulley off of shaft with plastic mallet. Be careful not to distort pulley while removing.
3. Disconnect clutch coil wires from compressor housing. Remove snap ring inside coil and lift coil off compressor. Pry dust seal out from around compressor shaft (if equipped).
4. Place shaft key remover on shaft and turn to remove key. Remove drain plug (if equipped). Remove bolts holding service valves to body of compressor and remove valves. Discard "O" rings. Drain oil out of compressor.
5. Remove 6 through bolts from front head of compressor and discard washers. Tap head loose from compressor, being careful not to scratch sealing surfaces. Remove snap ring (if equipped) from front housing. Press seal plate out. Remove seal from shaft.

Installation

1. Lubricate shaft seal with clean refrigerant oil. Place on compressor shaft. Lubricate seal plate (and "O" ring, if equipped) and install in front housing. Install snap ring (if equipped).
2. Place front housing on compressor body. Using new washers, install through bolts. Tighten bolts evenly and alternately to 18 ft. lbs. (24 N.m). Install shaft key with installer and plastic mallet. Insert dust seal into front of compressor.
3. Install drain plug using new gasket. Add correct amount of refrigerant oil to compressor. If service valves were removed, coat new "O" rings with refrigerant oil and install service valves.
4. Place clutch coil on compressor and install snap ring. Install shims on shaft to adjust clearance between pressure plate and rotor to .016-.028" (.41-.71 mm). Tighten shaft nut to 12 ft. lbs. (16 N.m). See REFRIGERANT OIL & R-12 SPECIFICATIONS table for system capacities.

Note. Check compressor refrigerant oil level when replacing seals. See COMPRESSOR REFRIGERANT OIL CHECKING article in this section.

1. Hold clutch hub stationary and remove shaft nut with thin wall socket. Use clutch plate puller to remove clutch plate. Tap key out of slot in crankshaft.
2. Remove seal retainer with seal remover and 3/4" socket wrench. Use seal seat remover tongs to pull seal seat off compressor shaft. Insert seal remover into front housing and turn to engage tangs on seal. Lift seal out. Remove seal "O" ring from front housing, being careful not to scratch shaft.

1. Coat "O" ring with refrigerant oil and install into groove. Load a new seal onto installer, being careful not to touch carbon sealing surface with fingers. Install shaft protector. Dip seal in refrigerant oil and install on shaft. Rotate seal clockwise until seal fits into flats on shaft. Remove seal installer by turning counterclockwise.
2. Coat seal seat with refrigerant oil and install with tongs. Reinstall seal seat retainer (with flat side down). Install shims and shaft key. Rotate shaft several times to help break in seal.
3. Use a press to install clutch plate. Make sure that air gap is .016-.031" (.41-.79 mm). Hold plate stationary and install shaft nut. See REFRIGERANT OIL & R-12 SPECIFICATIONS table for system capacities.

1. Hold clutch hub stationary and remove shaft nut. Remove clutch plate using puller. Remove external front housing snap ring and internal bearing snap ring. (Scheme 2)
2. Install puller and pull off rotor assembly. Remove 3 screws and clutch coil. Use driver and hammer to drive out bearing from hub.

1. Install new bearing, ensuring that installer contacts outer race of bearing. Install snap ring and check that bearing turns freely. Install clutch coil on compressor.
2. Support compressor on rear mounting ears. Align rotor on front housing hub. Use adapter and press to install rotor (or drive into place with soft mallet). After rotor is seated, install front snap ring.

Sanden 5-Cylinder Compressor. Scheme 2

REFRIGERANT OIL & R-12 CAPACITY