9.11 - Compressor Seal Replacement ( ,  )

The clutch plate has three bolt holes which you use to jack off the clutch plate. Screwing in 3 bolts will push the plate off. (All they do is hit other side of clutch so nothing would get scrunched).

Plate comes off easily. Then you have external circlip holding pulley. After removing the clip a few taps with a soft mallet allows pulley and bearing to slide off (a claw puller would be better).

Next is the electromagnet, again held on with circlip. You can get at the seals with it in place.

The shaft from the compressor sits inside a boss that protrudes to carry the pulley bearing (outside) and seals (inside). There is a small tin cap that is pried off to reveal a felt washer (lubrication). Under this is first seal.

Now it gets tricky.

The seal is held in with internal circlip. When this is out you have to get something to hook the seal out. The center (i.e. right around shaft) has a groove/ lip to take a special tool. Make a hook out of an old hose clip and gradually inch it out.

Now below this you have another seal which is fragile. It's made of a piece of hard plastic a spring, o-ring and thin steel carrier. Three prongs from the steel carrier come up from the round base, around the spring and lock onto a plastic bush. The steel base is actually keyed so it won't rotate.

It’s a snug fit so it’s hard to grip. Since you’re replacing it anyway just crack the plastic bush and pulled it out in pieces!

New seals just slide in. Make sure that the bottom seal (spring/ plastic/ metal/ o-ring) sits down in the right position so it's hole engages correctly. If not the second seal will not fit in properly and you could easily break the bottom one trying. Just inch it round till it clicks and won’t rotate further.

Second seal goes in with "extraction lip" facing outwards. The spring of the bottom seal will start compressing when you get near to correct position. At this point pop the circlip back in and push it down the last 2mm with the pliers and get the clip in.

The felt washer is next.

The Sanden seal kit has the two seals and replacement felt. Costs around $25.

Check the bearing while you’re here.