Isuzu D-Max / Isuzu Rodeo (TFR/TFS). Manual - part 1663

1-38  HEATING AND AIR CONDITIONING

19.Rear Cylinder Head

20.O-ring

Alternately tap the projections on the circumference of the

rear cylinder head with a screwdriver and a plastic hammer

to remove the rear cylinder head.

24.Cylinder and shaft assembly

Check the rear valve plate for scratching and bending.

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.

HEATING AND AIR CONDITIONING  1-39

  REASSEMBLY

Reassembly Steps

▲

1. Cylinder and shaft assembly

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2. Rear suction valve

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3. Rear valve plate

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4. Gasket

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5. O-ring

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6. Rear cylinder head

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7. Front suction valve

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8. Front valve plate

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9. Gasket

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10. O-ring

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11. Front cylinder head

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12. Through bolt with gasket

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13. Shaft seal assembly

14. Snap ring

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15. Shaft seal cover (If so equipped)

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16. Felt (If so equipped)

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17. Field coil

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18. Lead wire connector

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19. Pulley assembly

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20. Cover (If so equipped)

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21. Snap ring

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22. Shim(s)

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23. Drive plate

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24. Drive plate bolt

1-40  HEATING AND AIR CONDITIONING

Important Operation - Resassembly

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

Install the suction valve by aligning it with the spring pin and

the cylinder valve relief grooves.

3. Rear Valve Plate

Install the valve plate to the suction valve by aligning it with

the spring pin.

Note:

Do not mix up the front and rear valve plates.

4. Gasket

1) Apply a coat of new compressor oil to the new gasket.

2) Install the gasket to the valve plate.

5. O-ring

6. Rear Cylinder Head

1) Apply a coat of new compressor oil to the new O-ring.

2) Install the O-ring to the rear cylinder head.

3) 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.

Install the suction valve by aligning it with the spring pin and

the cylinder valve relief grooves.

HEATING AND AIR CONDITIONING  1-41

8. Front Valve Plate

Install the valve plate to the suction valve by aligning it with

the spring pin.

Note:

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.

Note:

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.

Through Bolt Torque

N

⋅

m (kg

⋅

m/lb

⋅

ft)

22 (2.2/16)

Rotate the compressor drive shaft two or three times to

make sure that it moves smoothly.