Isuzu N-Series. Service manual - part 71

1D2-8 COMPRESSOR OVERHAUL FOR TAIWAN

12. Shaft Seal Assembly

Using shaft seal remover to remove the shaft seal
assembly.
Engage the remover hook with the shaft seal as-
sembly groove and slowly draw the shaft seal as-
sembly out.
Shaft Seal Remover: 5-8840-0120-0 (J-33942)
The shaft seal (1) is precision-machined and its
critical parts are finished to extremely close toler-
ances. The assembly must be handled with great
care, it slips face demanding particularly careful
handling.
The shaft seal can not be reused. Install a new
shaft seal at reassembly.
Take care not to scratch or otherwise damage the
shaft seal face.
Keep the shaft seal free from lint and dirt.

13. Through Bolt with Gasket
14. Front Cylinder Head
15. O-ring

Alternately tap the projections on the circumfer-
ence of the front cylinder head with a screwdriver
and a plastic hammer to remove the front cylinder
head.

16. Gasket
17. Front Valve Plate
18. Front Suction Valve

Check the front valve plate for scratching and
bending.
Check the front valve plate and the front cylinder
head for nicks and burrs on the sealing surface.
Buff or replace the valve plate and cylinder head if
nicks and burrs are present.
Check that the front valve plate passage is free
from obstructions.
Check the front valve plate and the cylinder head
for cracks.
Replace the valve plate and cylinder head if cracks
are present.

19. Rear Cylinder Head
20. O-ring

Alternately tap the projections on the circumfer-
ence of the rear cylinder head with a screwdriver
and a plastic hammer to remove the rear cylinder
head.

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COMPRESSOR OVERHAUL FOR TAIWAN 1D2-9

21. Gasket
22. Rear Valve Plate
23. Rear Suction Valve
24. Cylinder and shaft assembly

Check the rear valve plate for scratching and bend-
ing.
Check the rear valve plate and the rear cylinder
head for nicks and burrs on the sealing surface.
Buff or replace the valve plate and cylinder head if
nicks and burrs are present.
Check that the rear valve plate passage is free
from obstructions.
Check the rear valve plate and the cylinder head
for cracks.
Replace the valve plate and cylinder head if cracks
are present.

Reassembly

1. Cylinder and Shaft Assembly

Clamp the cylinder shaft assembly in a vise. The
rear side of the cylinder shaft assembly must be
facing up.

2. Rear Suction Valve

Apply a coat of new compressor oil to the new suc-
tion valve.
Install the suction valve by aligning it with the
spring pin and the cylinder valve relief grooves.

3. Rear Valve Plate

Apply a coat of new compressor oil to the new
valve plate.
Install the valve plate to the suction valve by align-
ing it with the spring pin.

Notice:

Do not mix up the front and rear valve plates.

4. Gasket

Apply a coat of new compressor oil to the new gas-
ket.
Install the gasket to the valve plate.

5. O-ring
6. Rear Cylinder Head

Apply a coat of new compressor oil to the new O-
ring.
Install the O-ring to the rear cylinder head.
Install the rear cylinder head.
Tap the rear cylinder head into place with a plastic
hammer.

7. Front Suction Valve

Set the cylinder shaft assembly with the front side
facing up.
Apply a coat of new compressor oil to the new suc-
tion valve.
Install the suction valve by aligning it with the
spring pin and the cylinder valve relief grooves.

Legend

1. Escape groove
2. Suction valve
3. Piston

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Legend

1. Rear cylinder head
2. Gasket
3. O-ring
4. Valve plate
5. Suction valve

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1D2-10 COMPRESSOR OVERHAUL FOR TAIWAN

8. Front Valve Plate

Apply a coat of new compressor oil to the new
valve plate.
Install the valve plate to the suction valve by align-
ing it with the spring pin.

Notice:

Do not mix up the front and rear valve plates.

9. Gasket

Apply new compressor oil to the new gasket.
Install the gasket to the valve plate by aligning it
with the spring pin.

10. O-ring

11. Front Cylinder Head

Apply a coat of new compressor oil to the new O-
ring.
Install the O-ring to the front cylinder head.
Install the front cylinder head.
Tap the front cylinder head into place with a plastic
hammer.

Notice:

When installing the cylinder head, be careful that the
end of the drive shaft does not damage the shaft seal
assembly surface in the cylinder head.

12. Through Bolt with Gasket

Gaskets cannot reused. Always replace new ones.
Tighten the bolts to the specified torque a little at a
time in the sequence shown in the illustration.

Tighten:

Through bolt to 22 N

⋅m (2.2 kg⋅m / 16 lb⋅ft)

Rotate the compressor drive shaft two or three
times to make sure that it moves smoothly.

13. Shaft Seal Assembly

CIean the sealing portion of the compressor and
shaft seal (1).
Install the shaft seal guide onto the end of the drive
shaft.
Shaft Seal Guide: 5-8840-0368-0 (J-34614)
Apply new compressor oil to the shaft seal guide.
Install the shaft seal onto the compressor drive
shaft head by using shaft seal installer.
Shaft Seal Installer: 5-8840-0120-0 (J-33942)

Legend

1. Escape groove
2. Suction valve
3. Piston

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COMPRESSOR OVERHAUL FOR TAIWAN 1D2-11

14. Snap Ring

Using snap ring pliers to install the snap ring.

15. Shaft Seal Cover (If so equipped)
16. Felt (If so equipped)

Clean the sealing portion of the compressor and
shaft seal cover.
Install the shaft seal guide onto the end of the drive
shaft.
Shaft Seal Guide: 5-8840-0368-0 (J-34614)
Apply new compressor oil to the shaft seal guide.
Install the shaft seal cover onto the drive shaft by
using shaft seal installer.
The installation position of the shaft seal cover is
shown in the illustration.
Shaft Seal Installer: 5-8840-0120-0 (J-33942)

17. Field Coil
18. Lead Wire Connector

Install the field coil to the compressor.
Lead wire must be facing up.
Tighten the field coil fixing screws to the specified
torque.

Tighten:

Field coil screw to 5 N

⋅m (0.5 kg⋅m / 44 lb⋅ft)

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Legend

1. Shaft seal cover
2. Felt

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