Hi all. I searched the forum a bit but did not find anything on this. I replaced my compressor a couple weekends ago on my 85 300D . I also did the expansion valve, drier and all orings. charged it up with Freeze 12 and some good ester oil mixed with synthetic frigi quiet like on diesel giant's page.

Now the oil is leaking from hose the connection at the compressor. The compressor came with a confusing pack of seals -- red, green and yellow colored washers of different thickness with rubber in them. I'm guessing I got that config wrong. Does anyone know how those seals and lines mate with the compressor reliably? The ac line connection is not sitting flat agains the compressor but rather sticking out a bit where the red seal seems too large.

It also came with a silver flange like thing that goes in center of one of the lines. That appears to help hold the seal onto the lines while mating it to the compressor. That's what i used it for. Anyway, i replaced all seals as i thought i found them and in the only config that looked like it would remotely work -- using the red seal and the yellow seal. Looking at it you can see that the compressor lines face in not flush up against the compressor because the red is a bit too big. Perhaps i should have used the green seal and red seal. Then the lines would be a good 1/8 inch off the body of the compressor but may be more equal than using the read and yellow seal.

Thanks for an help

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What Would Rudolph Do?
1975 300D, 1975 240D, 1985 300SD, 1997 300D, 2005 E320 , 2006 Toyota Prius

Green and yellow.

Did you install the pilot insert on the suction side of the manifold? If so, how did you secure it?

Thanks tangofox007. I did install the pilot on the suction side. I did not secure it with anything. The one that came out was not secured and just came right out when i flushed the line. What should i secure it with? And does it matter which way it goes?

With the green and yellow seals, will the ac line assembly sit flat against the compressor or should it be raised off the compressor some? The green seal would go in the high side right? For me the green seal is much thicker than the red seal and i used the red seal because it was closer to flush with the yellow seal in the low side.

thanks

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What Would Rudolph Do?
1975 300D, 1975 240D, 1985 300SD, 1997 300D, 2005 E320 , 2006 Toyota Prius

I would be concerned about the insert coming out and entering the compressor. For that reason, I did not install one, although I do agree that it is needed.

Each of the seals shold be about 1.5mm thicker than the recesses in the compressor, so the manifold should be "flat," but not touch the compressor.

Yeah, I noticed that pilot thing could go right in the compressor. Why do you feel it is necessary? To seal the inner side of that tube? In fact, it fell in compressor as we were trying to figure out the assembly. I just stuck in the suction hose and hoped for the best . Since the previous one did not get sucked in the compressor,i figured it would be ok.

Thanks, i'll give another go on the seals and post back.

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What Would Rudolph Do?
1975 300D, 1975 240D, 1985 300SD, 1997 300D, 2005 E320 , 2006 Toyota Prius

Yes. I have a slow leak at the manifold suction side that I can't stop. I suspect that the lack of a pilot is partly to blame. That said, it's been three years since I installed the compressor and I haven't lost enough R-12 to affect performace, but the leak detector sure goes off when I sniff around the yellow seal. It also sounds the alarm around the brass plug in the end of the expansion valve.

If I had to do it over again, I would be tempted to try some type of adhesive on the pilot insert. Seems to me that it would be bad news for it to get sucked into the compressor.

I'll go crawl under the white wagon and see what colors finally sealed mine. I had all kinds of trouble hitting on the correct-for-me solution.
Will edit my findings........

Green on the driver's side
Red on the passenger side.

Looks like I have a leak after 3 years. I added a can last week and have oil residue back on the compressor that I had just wiped off. I tightened the 15mm "single" bolt just a bit......

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Jimmy L.
'05 Acura TL 6MT
2001 ML430 My Spare

Gone:
'95 E300 188K "Batmobile" Texas Unfriendly Black
'85 300TD 235K "The Wagon" Texas Friendly White
'80 240D 154K "China" Scar engine installed
'81 300TD 240K "Smash"
'80 240D 230K "The Squash"
'81 240D 293K"Scar" Rear ended harder than Elton John

thanks. I'm encouraged this thing will seal now.

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What Would Rudolph Do?
1975 300D, 1975 240D, 1985 300SD, 1997 300D, 2005 E320 , 2006 Toyota Prius

BTW, I also globbed both sides with Nylog just to give it a little added help....

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Jimmy L.
'05 Acura TL 6MT
2001 ML430 My Spare

Gone:
'95 E300 188K "Batmobile" Texas Unfriendly Black
'85 300TD 235K "The Wagon" Texas Friendly White
'80 240D 154K "China" Scar engine installed
'81 300TD 240K "Smash"
'80 240D 230K "The Squash"
'81 240D 293K"Scar" Rear ended harder than Elton John

When I bought my Four Seasons compressor, it came with only green and red seals, but they were clearly not the correct combination. I had to procure the suction side seal from the local NAPA store. Part #TEM 407279.

Yep, you have to really closely measure the connection of the stepped port compressor and manifold lines. I don't believe all applications are the same based on different combos folks have had to use.....

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Jimmy L.
'05 Acura TL 6MT
2001 ML430 My Spare

Gone:
'95 E300 188K "Batmobile" Texas Unfriendly Black
'85 300TD 235K "The Wagon" Texas Friendly White
'80 240D 154K "China" Scar engine installed
'81 300TD 240K "Smash"
'80 240D 230K "The Squash"
'81 240D 293K"Scar" Rear ended harder than Elton John

On my compressor, the diameter of the seal recess was much larger on the suction side as compared to the discharge side, making the red seal much too small. Likewise, the diameter of the yellow (gold) seal was larger than the red or green seals.