19) The Harrison HR100T has two recesses of equal size and equal depth milled into the back – this fooled me into thinking I was prepared. The CompressorWorks has one large shallow recess and one smaller deeper one. Look here for the variety. http://autoacrepairs.com/sealing_washers.htm You may find different AC and parts supply sources that say you need two black ones for your M-B. They may be right for a different model compressor, but not if you’re using the same model CompressorWorks I did.
20) What you’re looking for is the washers to stick up just above the surface of the compressor body. On my old Harrison, the recesses were about 2 mm and the washers are about 3. On the CompressorWorks, the deep one is a little over 4 and the shallow a little over 2. The 15 mm bolt on the manifold will sandwich the rubber sealing faces against the compressor body for a tight fit. If the manifold fits against the body of the compressor, or it’s uneven, then it’ll leak. (Note: this is not an O-ring install).
21) Dry fit all your bolts: the short 15 mm for the manifold and the long ones to bolt up the compressor. First, it’ll be peace of mind that when you’re installing the compressor and the bolts aren’t moving and you’re sure you’re cross-threading a metric thread into an SAE hole that you aren’t actually doing that and they DO fit. Next you’ll see how much dirt and crud are in the threads and how gritty it is and you’ll be inspired to get the old toothbrush out and clean them. You’ll think you’re really clever when the bolts go in easier later.
22) Once you’re sure you’ve got the right parts, you can put oil in the compressor. You MUST do this. I’ve read some compressors come pre-oiled. Mine didn’t, and it’s just as well since I wanted the DEC PAG oil in there. The exact capacity is not entirely clear. The FSM section 83-520 has specific quantities to add depending on what you’re doing and how much oil you’ve removed. The compressor re-install section, 83-522, says a total capacity of 170 cc, or about 6 ounces. Your call. Too little oil is bad, too much is very bad.
23) CompressorWork’s installation instructions http://www.compressorworks.com/InstructionSheets/Install%20Instr%20-%20AC%20Compressors.pdf say to add 2-3 oz to the suction side. This is consistent with pretty much everything else I’ve read. Then they say to turn the compressor at least 10 times. Now you need the loaner clutch wrench from AutoZone.

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