Nippon 10 CYL (Front & Rear Head Gasket and Components)

FRONT & REAR HEAD GASKET, REED VALVE, VALVE PLATE & FRONT SHAFT SEAL REPLACE

Removal
1. Drain oil from compressor through manifold openings.
2. Clamp compressor in suitable vise, then remove clutch assembly.
3. Remove snap ring using suitable tool and clutch field coil from front of compressor.
4. Remove felt and retainer from front nose of compressor.

Fig. 9 Compressor shaft key removal:

5. Remove shaft key using tool T81P-19623-NH or equivalent, Fig. 9.
6. Remove shaft seal seat retaining snap ring using tool T81P 19703-T or equivalent.
7. Clean inner bore of compressor nose and using tool T87P-19623-B or equivalent, remove shaft seal seat.

Fig. 18 Compressor shaft seal removal:

8. Remove shaft seal using tool T87P-19623-C or equivalent, Fig. 18.
9. Holding rear head in position on compressor, remove five cylinder bolts.

Fig. 19 Disassembled view of compressor.:

10. Remove rear head, head gasket, rear valve plate, reed valve and dowel pins from compressor, Fig. 19.
11. Remove front head, head gasket, front valve plate, reed valve and dowel pins from compressor, Fig. 19.

Installation
1. Inspect cylinder bores, valve plates and reed plates for scratches, corrosion or other signs of damage or wear. Replace compressor if any of these conditions exist.
2. Install two dowel pins in front and rear cylinder assembly.
3. Lubricate O-ring and install on front and rear cylinder head assembly.
4. Lubricate front and rear reed valve with clean refrigerant oil and install them on cylinder assembly.

Fig. 20 Compressor front valve plate installation:

5. Lubricate front valve plate (marked with an ``F'') and install on cylinder assembly. The ``F'' mark must be showing when valve plate is installed, Fig. 20.
6. Lubricate rear valve plate (marked with an ``R'') and install on cylinder assembly. The ``R'' must be showing when valve plate is installed.
7. Lubricate front and rear head gaskets and install them in proper position on cylinder assemblies.
8. Install front and rear heads on cylinder assembly, aligning dowel pins with dowel pin holes in cylinder head.

Fig. 21 Cylinder head bolt tightening sequence:

9. Holding front and rear head to cylinder assembly, install cylinder bolts until snug. Torque five bolts in three steps of 12, 15 and 19 ft. lbs. using cylinder bolt tightening sequence, Fig. 21.
10. Reverse remaining procedures to install. Lubricate new seal and seal seat with clean refrigerant oil. Install new felt strip and retainer into nose of compressor.