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REMOVAL
These instructions are general and are intended to be a guide.
In some cases additional preparations and precautions are
necessary. In all cases follow the instructions contained in
the vehicle maintenance manual in lieu of the instructions,
precautions and procedures presented in this manual.
1. Block the wheels of the vehicle and drain the air pres-
sure from all the reservoirs in the system.
2. Drain the engine cooling system and the cylinder head
of the compressor. Identify and disconnect all air,
water and oil lines leading to the compressor.
3. Remove as much road dirt and grease from the exte-
rior of the compressor as possible.
4. Remove the discharge and inlet fittings, if applicable, and
note their position on the compressor to aid in reassembly.
Note: If a cylinder head or unloader maintenance kit
is being installed, stop here and proceed to PREPA-
RATION FOR DISASSEMBLY. If replacing the
compressor continue.
5. Remove any supporting bracketing attached to the
compressor and note their positions on the
compressor to aid in reassembly.
6. Remove the flange mounting bolts and remove the
compressor from the vehicle.
7. Inspect gear and associated drive parts for visible wear
or damage. Since these parts are precision fitted,
they must be replaced if they are worn or damaged. If
replacing the compressor or replacing the drive gear,
remove the drive gear from the compressor crank-
shaft using a gear puller.
8. If the compressor is being replaced stop here and
proceed to "Installing The Compressor" at the end of
the assembly procedure.
PREPARATION FOR DISASSEMBLY
Remove the balance of road dirt and grease from the ex-
terior of the compressor with a cleaning solvent. Before
the compressor is disassembled, the following items should
be marked to show their relationship when the compres-
sor is assembled. Mark the rear end cover or end cover
adapter in relation to the crankcase. Mark the relationship
of the cylinder head to the valve body assembly and crank-
case and cylinder block assembly.
A convenient method to indicate the above relationships is
to use a metal scribe to mark the parts with numbers or
lines. Do not use marking methods such as chalk that can
be wiped off or obliterated during rebuilding.
Prior to disassembly make certain that the appropriate kits
and or replacement parts are available. Refer to Figure 10
during the entire disassembly and assembly procedure.
10
UNLOADER & INLET VALVE
1. Remove the discharge safety valve (26) from the cylin-
der head.
2. Remove the unloader port plug and sealing washer
(19 & 20).
3. Loosen but do not remove the two 13mm x 60mm bolts (2).
4. Remove the six 13mm x 85mm cylinder head bolts
and washers (1 & 25) and tap the head with a soft
mallet to break the gasket seal. Lift off the cylinder
head and valve body assembly off the cylinder block.
IMPORTANT NOTE: Do not attempt to separate the two
halves of the valve body assembly. Service replacements
and gaskets are not available.
5. Remove the metal gasket (18).
6. Remove both sliding inlet valves (13).
7. Remove both pivot arms (14) and pivot arm studs (15).
8. To remove spring tension from the unloader plunger guide
pin (16), insert a 1/4" brass dowel into one of the un-
loader plunger bore and depress the plunger (21) slightly.
While holding the plunger (21) depressed, remove the
plunger guide pin (16). Slowly extract the dowel rod from
the unloader bore until spring tension is relieved.
Note: As an alternative, to this procedure an appropri-
ately sized nut or dowel rod can be placed in the unloader
bore and the plug (19) installed then removed after the
guide pin is removed.
9. Remove the unloader plunger (21), with its o-ring (22)
and backup ring (23) from the bore. Remove the unloader
spring (24).
10. Repeat steps 7 and 8 for the other unloader plunger.
11. Remove both pivot arm guide pins (17) from the
cylinder block.
DISCHARGE & INLET CHECK VALVES
1. Remove the two 13mm x 60mm cylinder head bolts
(2) and gently tap the head and valve body assembly
with a soft mallet to break the gasket seal. Separate
the cylinder head and valve body assembly.
IMPORTANT NOTE: Do not attempt to separate the two
halves of the valve body assembly. Service replacements
and gaskets are not available
2. Remove the gasket (8).
3. Turn the cylinder head over to expose the inlet check
valves and remove the 10mm x 25mm inlet check
valve bolt (3) that secures the inlet check valve com-
ponents. Remove the spacer sleeve (4), holder (5),
check valve (6) and check valve seat (7).
4. Repeat step 3 for the second inlet check valve
assembly.
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