Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1662

1-34  HEATING AND AIR CONDITIONING

 DISASSEMBLY

Disassembly Steps

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1. Drive plate bolt

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2. Drive plate

3. Shim(s)

4. Snap ring

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5. Cover (If so equipped)

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6. Pulley assembly

7. Lead wire connector

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8. Field coil

9. Felt (If so equipped)

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10. Shaft seal cover (If so equipped)

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11. Snap ring

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12. Shaft seal assembly

13. Through bolt with gasket

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14. Front cylinder head

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15. O-ring

16. Gasket

17. Front valve plate

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18. Front suction valve

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19. Rear cylinder head

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20. O-ring

21. Gasket

22. Rear valve plate

23. Rear suction valve

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24. Cylinder and shaft assembly

HEATING AND AIR CONDITIONING  1-35

Important Operations - Dissassembly

1. Drive Plate Bolt

Using drive plate holder to prevent the drive plate from

rotating, then remove the bolt.

Drive Plate Holder: 5-8840-0117-0 (J-33939)

2. Drive Plate

Using drive plate puller and forcing screw to remove the

drive plate.

Drive Plate Puller: 5-8840-0122-0 (J-33944-A)

If the frictional surface shows signs of damage due to

excessive heat, the drive plate and pulley should be

replaced.

5. Cover (If so equipped)

Using snap ring pliers to remove the snap ring.

5-8840-0111-0

5-8840-0121-0

6. Pulley Assembly

Using pulley puller pilot and pulley puller to remove the

pulley assembly.

Pulley Puller Pilot: 5-8840-0121-0 (J-33943)

Pulley Puller:

5-8840-0111-0 (J-8433)

Check the appearance of the pulley assembly.  If the

frictional surface of the pulley shows signs of excessive

grooving due to slippage, both the pulley and drive plate

should be replaced.  The frictional surfaces of the pulley

assembly should be cleaned with a suitable solvent before

reinstallation.

1-36  HEATING AND AIR CONDITIONING

8.Field Coil

Loosen three screws and remove the field coil with lead

wire.

Check coil for loose connector or cracked insulation.

10.Shaft Seal Cover (If so equipped)

Using shaft seal remover to remove the shaft seal cover.

Engage the remover hook with the shaft seal cover groove

and slowly draw the shaft seal cover out.

Shaft Seal Remover: 5-8840-0120-0 (J-33942)

11.Snap Ring

Using snap ring pliers to remove the snap ring.

HEATING AND AIR CONDITIONING  1-37

12.Shaft Seal Assembly

Using shaft seal remover to remove the shaft seal

assembly.

Engage the remover hook with the shaft seal assembly

groove and slowly draw the shaft seal assembly out.

Shaft Seal Remover: 5-8840-0120-0 (J-33942)

The shaft seal is precision-machined and its critical parts

are finished to extremely close tolerances.  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.

14.Front Cylinder Head

15.O-ring

Alternately tap the projections on the circumference of the

front cylinder head with a screwdriver and a plastic hammer

to remove the front cylinder head.

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.