Mazda RX-7 Compressor Servicing
Mazda RX-7 1993-1995 FD3SFORD FS-10
Due to variety of clutch and shaft seal configurations, obtain appropriate AC compressor service tools for compressor being serviced.
CLUTCH COIL
Removal
1. Using clutch holder, remove clutch plate bolt. Using an 8-mm bolt threaded into clutch plate, remove clutch plate and shim(s). See Fig. 1 .
2. Remove snap ring and pulley assembly. Install Shaft Protector (49 UN01 045) over shaft seal opening. Use a 2-jaw puller to remove clutch coil from compressor.
Installation
1. Ensure clutch coil mounting surface is clean. Use coil installer and 2-jaw puller engaged to rear side of compressor front mounts to press coil into place.
2. Install pulley assembly. Install snap ring with bevel side of snap ring facing out. Install shim(s) and clutch plate. Install a new clutch plate bolt and tighten to 97-115 INCH lbs. (11-13 N.m).
3. Use a feeler gauge to check clearance between clutch plate and pulley. Clearance should be .014-.033" (.35-.84 mm). If clearance is incorrect, add or remove shims as necessary.
SHAFT SEAL
Removal
1. Using clutch holder, remove clutch plate bolt. Using an 8-mm bolt threaded into clutch plate, remove clutch plate and shim(s). See Fig. 1 .
2. Remove shaft seal felt. Thoroughly clean seal area of compressor. Remove shaft seal snap ring. Position shaft seal remover over compressor shaft.
3. Push shaft seal remover downward against seal. Ensure end of shaft seal remover is engaged with inside of seal. Rotate shaft seal remover clockwise to expand remover tip inside seal. Pull shaft seal from compressor.
Installation
1. Lubricate shaft seal protector and shaft seal with refrigerant oil. Install shaft seal on shaft seal protector so lip seal is toward compressor (large end of shaft seal protector).
2. Install shaft seal protector on compressor shaft. Using shaft seal installer, push shaft seal down seal protector until seal is seated.
3. Remove shaft seal installer and protector. Install a new shaft seal retaining snap ring and shaft seal felt. Install shim(s) and clutch plate. Install a new clutch plate bolt and tighten to 97-115 INCH lbs. (11-13N.m).
4. Use a feeler gauge to check clearance between clutch plate and pulley. Clearance should be .014-.033" (.35-.84 mm). If clearance is incorrect, add or remove shims as necessary.
Fig. 1: Exploded View Of Compressor Clutch (Ford FS-10)
HITACHI 6-CYLINDER
CLUTCH COIL AND SEAL
Removal
1. Hold clutch hub with Clutch Tightener (925770000). Remove shaft nut from shaft. Using Clutch Hub Remover (926130000), remove clutch hub. Use snap ring pliers to remove inner snap ring.
2. Remove pulley and bearing assembly. Remove screws securing clutch coil lead. Remove inner snap ring from clutch coil. Remove clutch coil from front cover.
3. Remove shaft key. Use snap ring pliers to remove shaft seal snap ring. Wrap a rag around compressor shaft. Using Injector Needle (92619000) and refrigerant can, slowly pressurize compressor at low pressure (suction) service port. See Fig. 2 . Catch shaft seal seat in rag.
4. Insert Shaft Seal Remover/Installer (926120000) through open end of front cover. Slowly pull out remover/installer to remove shaft seal.
Installation
1. Ensure shaft seal contact surface is free of dirt. Lubricate with refrigerant oil. Using shaft seal remover/installer, insert shaft seal.
2. To install clutch coil and hub, reverse removal procedure. Tighten shaft nut to 14-15 ft. lbs. (19-21 N.m). Ensure clearance between pressure plate and pulley is 0.020-0.031" (.50-.80 mm).
Fig. 2: Removing Compressor Shaft Seal Seat (Hitachi 6-Cylinder)
MATSUSHITA ROTARY VANE
CLUTCH COIL REMOVAL AND INSTALLATION
1. Using Pressure Plate Holder (07112-76060) and socket, remove center bolt. Thread Puller (07112-66040) onto pressure plate. Hold pressure plate with pressure plate holder and tighten puller to remove pressure plate.2. Remove shim(s) from shaft. Remove snap ring and, using a plastic hammer, tap pulley off. Remove screw for clutch coil lead. Remove snap ring and clutch coil. See Fig. 3 .
3. To install, reverse removal procedure. Tighten shaft bolt to 10 ft. lbs (14 N.m). Using feeler gauge, ensure clearance between pressure plate and pulley is .014-.026" (.35-.65 mm). If clearance is incorrect, add or remove shim(s) as necessary.
Fig. 3: Exploded View Of Compressor (Matsushita Rotary Vane)
NIPPONDENSO ROTARY VANE
CLUTCH COIL
Removal
1. Hold clutch plate with Clutch Holder (00007-10331) and remove shaft nut. Install Clutch Disc Remover 4992-02-020) and remove clutch plate and shims. See Fig. 4 .
2. Remove pulley snap ring and tap pulley (with bearing) off of compressor. Remove screw for clutch coil lead. Remove snap ring and clutch coil.
Installation
To install, reverse removal procedure. Ensure pulley-to-clutch plate clearance is .016-.024" (.40-.60 mm). If clearance is incorrect, add or remove shim(s) as necessary.
DISCHARGE VALVE AND SHAFT SEAL
Removal
1. Drain and measure compressor oil in compressor. Remove discharge valve body through-bolts. Remove discharge valve body bolts and body. Remove discharge valve plate and discharge valve.
2. Remove compressor through-bolts. Remove front and rear housing (oil separator case). Remove pins and gaskets. Remove shaft seal from shaft. Press shaft seal plate off of front housing (head cover).
Installation
To install components, reverse removal procedure. Tighten compressor through-bolts to 19 ft. lbs. (26 N.m). Tighten discharge valve bolts to 41 INCH lbs. (4.6 N.m). Tighten discharge valve body and body through-bolts to 96 INCH lbs. (10.8 N.m).
Fig. 4: Exploded View Of Compressor (Nippondenso Rotary Vane)
NIPPONDENSO 10-CYLINDER
Due to variety of clutch and shaft seal configurations, obtain appropriate AC compressor service tools for compressor being serviced.
Fig. 5: Exploded View Of Compressor (Nippondenso)
SHAFT SEAL
Remove compressor through-bolts and front housing to remove shaft seal. See Fig. 5 . Alternately tighten through-bolts to 18-21 ft. lbs. (24-28 N.m).Removal
1. Remove clutch plate and pulley. Remove shim(s) from shaft. Remove clutch coil if necessary. Remove felt and felt retainer (if equipped). See Fig. 5 . Place shaft key remover on shaft and turn to remove key.
2. Remove seal plate snap ring. Engage plate remover on seal plate, and pull up to remove seal plate. Engage shaft seal remover/installer to shaft seal, and pull up to remove shaft seal from front housing.
Installation
1. Apply clean refrigerant oil to compressor housing bore. Lubricate shaft seal with refrigerant oil and install in front housing. Lubricate seal plate and install in front housing.
2. Install shaft key, snap ring, felt retainer and felt. With clutch plate installed, ensure air gap between clutch plate and pulley is .014-.026" (.35-.65 mm). If air gap is incorrect, add or remove shim(s) as necessary.
PANASONIC ROTARY VANE
CLUTCH COIL
Removal
Hold clutch disc stationary and remove shaft bolt. Remove clutch disc and shim(s) from shaft. Remove snap ring. Using a puller, remove pulley. Remove screw from clutch coil lead. Remove screws and field coil.
Installation
To install, reverse removal procedure. Ensure air gap is .016-.024" (.41-.61 mm). If air gap is incorrect, add or remove shim(s) as necessary. Tighten shaft bolt to 11 ft. lbs. (15 N.m).
DISCHARGE VALVE REMOVAL AND INSTALLATION
Remove compressor head cover. Remove discharge valve stopper and discharge valve. See Fig. 6 . Install replacement discharge valve and stopper. Tighten discharge valve bolts to 35-56 INCH lbs. (4.0-6.3 N.m). Tighten compressor head cover bolts to 79-104 INCH lbs. (8.9-11.7 N.m).Fig. 6: Exploded View Of Compressor (Panasonic Rotary Vane)
OIL CONTROL VALVE REMOVAL AND INSTALLATION
Remove compressor rear cover. Remove oil control valve. Remove springs, valve, and rear cover seal. To install, reverse removal procedure. Tighten oil control valve bolts to 96-104 INCH lbs. (10.8-11.7 N.m). Tighten rear cover nuts to 22-25 ft. lbs. (30-34 N.m) and bolts to 113-156 INCH lbs. (12.8-17.6 N.m).SHAFT SEAL REMOVAL AND INSTALLATION
Remove clutch disc and shim(s). Remove felt seal and snap ring. Using Seal Plate Remover (49 B061 005), engage and remove shaft seal plate. Remove shaft seal with Seal Remover/Installer (49 B061 006). To install, reverse removal procedure. Coat new seal plate and seal with clean refrigerant oil. DO NOT touch seal surfaces with fingers.SANDEN SCROLL
CLUTCH COIL AND SHAFT SEAL
Due to variety of clutch and shaft seal configurations, obtain appropriate AC compressor service tools for compressor being serviced.Fig. 7: Exploded View Of Compressor (Sanden - MSC105; MSC90C Is Similar)
Fig. 8: Exploded View Of Compressor (Sanden - FX105V)
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Mazda RX-7 1993-1995 FD3S
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