How to rebuild your AC Compressor

[Talasas]

Nice guide, I started writing one of these a few years ago with the intention of completely rebuilding the Denso TV12C found on AE93s. I pulled one apart to see. It's not actually that complicated and you don't need a 100% dust free clean room (where do you think they rebuild the others?).

That's the word straight from more than one aircon specialist.

The first thing you do is stop listening to this. I have spent A LOT of time investigating this with so called "AC professionals" over the phone, in person and through several friends in the industry. I'll say it like this; the AC/fridge business is one of the best guarded industries, right up there with paintless dent repair. Proper information is sparse at best and the reason is this keeps the rebuild companies guaranteed business - it's not hard for them either as much of the parts/tools/equipment is not allowed to be sold to the general public (for the most part for environmental reasons). This means they can charge astronomical prices for simple jobs. The TV12C compressor costs roughly $450 for a rebuilt one and I've been quoted between $380 to $800 for a rebuild of my existing one (if I supply them the compressor only and not still on the car).

So here is what I found in terms of available parts:

- Front bearings - NTN and NSK will often make the correct needle roller bearing you'll need. They sometimes retail as much at $95 (as mine did). A good contact in the industry may get you one for a lot less (I paid $20 for mine).
- Clutch Assembly - Available through many US websites that stock parts. I found at least 4 variations of the TV12C compressor clutch assembly. This is designed not to wear out so often you'll replace this if the electromagnetic side of things are shot.
- Housing Seals - All available online on US websites. "AC Professionals" will tell you that you can't replace these. Funny then that rebuilt compressors are available. I think the one I needed was USD$14 for a R134a type.
- Front Shaft Seal - <--- This is the big one. On many Denso compressors that are similar in design to the TV12C this will be the reason for the refrigerant leak. The bitch part of this is, the seal is designed to only be possible to install using a special tool made by Denso. If you don't use the tool the seal will break while you install it. The tool is very hard to get a hold of and costs something stupid ($200+). I never managed to find pictures of one to see how it works. The shaft seals themselves are again easily available online through US websites.

So, if you tally up the costs of all the seals, bearing and you can get the front shaft seal on there you will have yourself a rebuilt compressor for a fraction of the cost of getting a "professional" to do it.

The job is not hard and if you had all of the parts on hand, a press and the seal tool you could probably do it in about 45 minutes.

[mookschank]

I've seen AC compressor seal kits on US ebay for the 4agze awhile ago, not sure what they included....

[Z2TT]

Matty12, All Auto Compressors and Orion Compressors and Nippon Air Spares, if I remember Orion wanted $230 to replace all the seals on my compressor (10PA15), All Auto wanted $193 and Nippon wanted $220, Nippon told me they also bench test the compressor to check for operation and leaks before sending it out, maybe seals can be sourced from them too??

Also these guys rebuild compressors I've been told and maybe sell parts too like seals, C.A.R (Compressors Automotive Remanufacture) in Victoria – address: 383 Chandler Road, Keysborough VIC Phone: 1300 652 861

And I totally Agree with Talasas, information on Auto A/C is very sparse, and very hard to find, with so much false misleading info around as I too have done quite a bit of research. And re builders will not tell you anything most of the time. Like most people will say "Nah mate don't stuff around with the A/C thats complex shit" or stuff like that.

Haha total rubbish ofcourse the housing seals can be replaced, how else do you stop a leak. Probably just re builders trying to ward off DIY'ers from doing their own rebuilds.

Also Some compressors have broken valves, I had a compressor that would not create suction, took it apart one of the valves had broken off, so it's also important to find out sources for the "Valve plates" I call them, don't know the proper name.

Remember if wobble plate is worn out too, that will need replacing, most of the time they are fine just in cases of catastrophic failure they are totally destroyed. So there is quite a bit of parts when it comes to doing a rebuild, depending on what you classify a rebuild. Most though are just leaky compressors that need a seal job.

Another thing to consider guys, is that replacing seals on old compressors might only prolong it's life a bit more as it's already done a lot of work and mechanical failure could be imminent, this is not saying no don't do it but just something to consider so it might be worth buying a new compressor depending on what is more cost effective.

But you can have a 10PA15/10PA17 for example and they have different mounting holes and locations, different interface plates for hoses so it's hard to find a specific one especially for some of our cars so It's hard to find an engine specific one, well I have trouble finding people who sell them for Toyotas, might email some contacts I have and see what prices can be had for 4a, 1jz, 1g, 7m etc. Nippon Air Spares will be the way to go for replacements and should have a longer life with synthetic compressor oils used today.

Other than leaky Compressors, the other annoying thing I've often been faced with is leaky EPR Valves, it's like a self regulating valve that regulates refrigerant flow back to the compressor on the low side pipe (Bigger line coming from firewall), Looks like a little can. I have absolutely no Idea where to find the seal for these things, I have tried to contact Denso for replacements but have received no assistance from them. People have been successful though taking it apart, milling a part of it on a lathe in order get the seal to get more pressure put on it once it's put back together and that helps.

Well if we can get more sources for rebuild kits (seals), Preferrably get it all in one instead of chasing parts from different places, I might be keen to have a shot at this myself, and anybody who is thinking of giving it a go, go for it. So if anyone has something they like to contribute post as I'd like to hear.

So I am keen to hear for more sources for Seal/Bearing kits and clutches.

Guess this could turn into "The Compressor and Auto A/C Thread"

And to the readers wanting to know a bit more about how compressors work, see this video on your typical swash/wobble plate type:

http://www.youtube.com/watch?v=5Vea2...eature=related

[matty12]

all the seals, bearings and even heads for sanden compressors are readily available.Ive never seen piston or casing assembly available anywhere, i dare say the dont exsist, remember building something from parts is more often than not more expensive.

Also, quite alot of these things require tools to pull apart, they arnt cheap.A service tech does have the right to charge for his/her expertise and training, rent and all the other things that cost a business money right before he even does a job for you, please remember this.

Of course we all like to play with all things mechanical aswell and good on anyone having a crack themselves,im not saying dont give it a go but apples for apples.

Denso also make bare compressors that you fit your style of clutch assembly and you style manifold too ,these are not to expensive either from memory.