Air Conditioning Compressor Teardown and Failure Analysis:
Last spring, on a warm day, my wife asked to roll up the windows and turn on the air. We quickly figured out that it was not working, blowing only warm and as we pulled up to a stop light the engine stalled. I quickly turned the system off and restarted the engine to keep moving. Once we returned home I confirmed that the compressor was lockup and unplugged it.
I personally never use the air conditioning so it hasn’t been a priority to fix. That being said, I would like to fix it and hopefully doing the work myself.
During my last oil change, I noticed a buildup of grim on the bottom of the compressor.
I decided to pull it out today and take a look. It’s a fairly simple process to remove the unit. I suspected that the system was not under pressure and sure enough barely anything came out of the low or high pressure lines. Being that my system uses the new r1234yf refrigerant I wasn’t to concerned about releasing anything.
Once the unit was out I cleaned off the grim and drained out the PAG Oil:
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I was surprised at how little oil came out maybe 1/2oz or so. Normally about 3oz should come out while rotating the compressor pulley. Since my unit is locked tight I couldn’t do it properly.
Next I attempted to remove the clutch plate and broke the bolt in record time. I suggest heating it since it looks like it has loctite on it:
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A couple circlips later and the clutch was removed. 7 more bolts and some careful prying and persuasion get you mostly disassembled:
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Found the problem - seized piston:
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A lot of debris:
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Well, not what I was hoping for. A slipped half ball is an easy fix, but this unit is destroyed. Threw it back together and reinstalled for now. I guess I will get a new compressor and necessary tools with my stimulus check.
I’m not sure if the oil & freon leaked out and that caused it to seize or did the seizing cause the leakage? Stumped.