Disassemble/assemble compressor

AR13.30-Y-5511A

Disassemble/assemble compressor

05.02.2020

Engine

400.950 in model 400.204/207/212/216/231

Engine

400.951 in model 400.216/241/243/262/281

Engine

400.954/956 in model 831.247

Air compressor dismantling procedure

179

Air compressor drive gear

180

Special tool locking device 904 589 03 63 00

181

Drive gear lock nut

182

Two jaw puller

399

Air compressor O-ring

52

Air compressor

208

Cylinder head unit

400

Dummy cap

401

Outlet port adapter

402

Cylinder head inlet seal

116

Connecting rod bearing caps

118

Piston

127

Crankshaft

403

Power-steering pump cover

107

Cylinder head seal

404

Crankshaft bush

405

Pump cover O-ring

406

Cylinder head cover

117

Connecting rod

407

Reed valve

408

Internal snap ring

409

Piston pin

410

Piston rings

Air compressor assembling procedure

127

Crankshaft

403

Power-steering pump cover

404

Crankshaft bush

405

Pump cover O-ring

117

Connecting rod

408

Internal snap ring

409

Piston pin

410

Piston rings

411

Piston ring compressor

107

Cylinder head seal

116

Connecting rod bearing cap

406

Cylinder head cover

407

Reed valve

208

Cylinder head unit

399

Air compressor O-ring

401

Outlet port adapter

402

Cylinder head inlet seal

179

Air compressor drive gear

180

Special tool locking device 904 589 03 63 00

400

Dummy cap

413

Drive gear mounting nut

 Warning

Risk of injury to skin and eyes suffering scalding from contact with hot coolantspray. Risk of poisoning from swallowing coolant.

Do not open cooling system unless coolant temperature is below 90 °C. Open cap slowly and release the pressure. Do not pour coolant into beverage containers.
Wear protective gloves, protective clothing and safety glasses.

AS20.00-Z-0001-01A



Disassemble

1

Remove air compressor from the engine.

AR13.10-Y-5810A

2

Hold the air compressor in a bench vice.

 Lock air compressor drive gear (179) using special tool locking device (180).

 Locking device

*904589036300

3

Remove drive gear lock nut (181) in clock wise direction.

4

Remove drive gear (179) from crankshaft.

 Use two jaw puller (182) and tighten drive gear (179) centering pin for removal.

5

Remove O-ring (399) and dummy cap (400) from air compressor.

6

Remove air compressor (52) from the bench vice.

7

Remove the outlet port adapter (401).

8

Remove the cylinder head (208) mounting bolts from cylinder block.

9

Remove the cylinder head inlet seal (402) from crankcase.

10

Remove the connecting rod bearing cap (116) mounting bolts from crankshaft.

11

Remove the connecting rod with piston (118) from crankcase.


Care needed to be taken during the removal of the piston.
Failure to comply may damage the piston or cylinder bore.

12

Remove the power-steering pump cover (403).

13

Remove the crankshaft (127) from air compressor housing.

14

Remove the crankshaft bush (404) from air compressor housing.

 Use suitable drift.

15

Remove O-ring (405) from power-steering pump cover.

16

Remove the cylinder head cover (406).

17

Remove seal (107) and reed valve (407) mounting bolt from cylinder head.

18

Remove the internal snap ring on both side (408) from piston pin.

19

Remove the piston pin (409) and connecting rod (117) from piston.

20

Remove the compression ring and piston ring (410) from piston.



Assemble

21

Install O-ring (405) to power-steering pump cover.

 Don't reuse O-ring, seal and snap ring.

22

Install crankshaft bush (404) to air compressor housing.

 Use suitable drift.

23

Install crankshaft (127) to air compressor housing.

24

Install power-steering pump cover (403) and tighten the mounting bolts.

25

Install the piston rings (410) and compression ring to piston by using the piston ring pliers.


Disallowance the over expansion of the ring
This may cause to damage the ring.

 Align the piston ring end gaps of all three at fixed 1200 articulation angle.

26

Install the connecting rod (117) and piston pin (409) to piston.


Care needed to be taken while installing the piston pin.
Failure to comply may damage the connecting rod or piston.

27

Install internal snap ring on both side (408) to piston pin.

28

Install piston on crankcase.


Before installing the piston, check piston rings end gap away from gudgeon pin hole.
Tapping on the top of the piston completely done with a soft material. Use nylon rod.

 Use piston ring compressor (411) and compress the piston rings and insert the piston in to cylinder bore along with rings and connecting rod.

29

Install connecting rod bearing cap (116) to crankshaft and tighten the mounting bolts.

30

Install the reed valve (407) to cylinder head and tighten the mounting bolts.

31

Install seal (107) to cylinder head.

32

Install cylinder head cover (406) and tighten the mounting bolts.

33

Install cylinder head inlet seal (402) to crankcase.

 While installing the cylinder head inlet seal, ensure the bend is exactly facing to the drive wheel side.

34

Install cylinder head (208) to cylinder block and tighten the mounting bolt.

 While installing the cylinder head, ensure the suction hole exactly facing drive gear side.

35

Install outlet port adapter (401).

 Hold the air compressor in a bench vice.

36

Install O-ring (399) to air compressor.

37

Install drive gear (179) and mounting nut (413) to the crankshaft.

 Lock the drive gear (179) using special tool locking device (180) and tighten the drive gear nut in anti clock wise direction.

 Air compressor drive gear

*BA01.10-Y-1137-02B

 Locking device

*904589036300

38

Remove the air compressor from the bench vice.

39

Install dummy cap (400) using mallet.

40

Install air compressor to engine.

AR13.10-Y-5810A

 Engine

Number

Designation

Engine 400.950/951 in model 400.204/207/212/216/231/241/243/262/281
Engine 400.954/956 in model 831.247

BA01.10-Y-1137-02B

Air compressor drive gear

Nm

270