ND AC compressor replacement

[Dave Head <dhead@sundial.sundial.net>]

Replaced the Nippondenso compressor today with a rebuilt unit. Not a fun
job. Biggest problem - Aluminum corrodes around steel bolts... Every bolt
was a pain. Glad I had plenty of liquid wrench!

Notes:
Take it out as a unit, including the upper and lower brackets, if the unit
is original. The bolts will probably be stuck, making it impossible to get
all the pieces off to swap. Loosen all 3 17MM bolts (2 in back, one in front
with the belt in the way, making is an absolute pain to get out) and the
15MM in front, before touching the Star adjustment bolt.  Notice that the
belt really dosn't want to come off, even with the unit all the way to the
oil pan. The two top bolts come out over an inch after unthreading - wonder
about this until you try to put it back in and align it...

The clutch comes off with screwdrivers on each side to lever it back and
forth. Do not be gentle. That doesn't work here. Don't lose the woodruff key.
The washers under the clutch are for proper spacing. Local AC guy sez the
"special tool" does a great job of screwing things up.

Have snap ring pliers available. Thats what holds the pulley and the coil
on. One snap ring each. Notice that the pulley has a bearing which can be
easily replaced.

Swap the hose distribution plate. Only 3 allen heads hold it on. Leave the
other two alone. 

Plug the inlet back up before attempting to put the unit back in the car.
Compressor oil in the face while holding 20 pounds is no fun. After its
installed, it won't leak anymore. Of course, if you pour it all out, it
won't leak anymore either.

After you get it back together, plan on going down later to pick up the
O-rings you forgot to replace when you pulled the hoses off. Pick up 2 new
Schrader valve cores to replace your old ones.

Total time: 4 hours. I could do it in well under 2 if the bolts were good.

Hey - Sunday we get to do the dryer/accumulator... It comes with O rings!


********************************AUDI FAN******************************
EMCM(SW) Dave Head (nuclear grade electrician)
87 5KCSTQ 170K miles and not counting (damned VDO odometers)...
1.9 bar boost (charlie spring, no shim) - @ 1.3 the shuttle launches!
Maitland FL
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