ARB Compressor Rebuild

[Jock The Rock]

Gday

Dunno if this will help anyone but I did a search and no one else has posted one up so i thought bugger it, why not :)

First thing was first. Dropped into ARB to get a blow up diagram of the compressor and a list of part numbers

https://www.aulro.com/afvb/images/imported/2008/12/325.jpg

Heres the patient :D

https://www.aulro.com/afvb/images/imported/2008/12/351.jpg

https://www.aulro.com/afvb/images/imported/2008/12/352.jpg

Recommended Kit :)

https://www.aulro.com/afvb/images/imported/2008/12/353.jpg

Being stripped down

https://www.aulro.com/afvb/images/imported/2008/12/354.jpg

https://www.aulro.com/afvb/images/imported/2008/12/355.jpg

Just a note: One of these three bolts you cant fit a socket on, luckily I got it undone with a pair of needle nose pliers. I plan to cut a slit across the top so if there is a next time it will just be a screw driver job
https://www.aulro.com/afvb/images/imported/2008/12/356.jpg

Inlet and Exhaust valves, to get the exhaust valve out its a matter of pushing the 2 tabs together; in theory anyway. Its easier to just push one side through though. But it doesnt really matter if you break it :o cause thats one thing you'll be replacing anyway :p
https://www.aulro.com/afvb/images/imported/2008/12/357.jpg

https://www.aulro.com/afvb/images/imported/2008/12/358.jpg

https://www.aulro.com/afvb/images/imported/2008/12/359.jpg

https://www.aulro.com/afvb/images/imported/2008/12/360.jpg

Cylinder removed
https://www.aulro.com/afvb/images/imported/2008/12/361.jpg

https://www.aulro.com/afvb/images/imported/2008/12/362.jpg

I got the piston off just before, havent had a chance to take a photo yet but was a ***** of a thing. Ended up shoving a wire brush handle down beside the crank to stop it from turning.

Tomorrow Ill be going into ARB to order the parts I need. No idea when they'll be in so dont hold your breath waiting for the end of this thread :D

Any questions just fire away

Also if Ive dont anything wrong please tell me :( Im still learning :)

Thanks

[Jock The Rock]

A few questions for someone more experienced than me :D

Went into ARB today, was surprised they had all the parts I wanted in stock :o

Righto the questions:

The bearing at the bottom of the conrod/piston assembly, should this be packed with grease before I refit it?

It then says to tighten the cap screw which holds the piston to the crank to 11Nm; I dont have a torque wrench which makes it a little hard? Stupid question but how important is it to do the set torque?

Also the head bolts need to be tightened to a certain torque

What would you do?

Thanks

[Psimpson7]

I wouldn't worry too much about the torque settings. 11Nm isn't very much (@8lb/ft)

Not many torque wrenches would do that accuratley. You would need a small one.

I would just tighten it to a reasonable level with the Allen Key.

Rgds
Pete

[Slunnie]

Just do them up reasonably. 11Nm isn't a lot at all and the aluminium body will strip very quickly - if you're not happy then use a small amount of low grade (vibration blue) loctite. The hex bolt that holds the bigend bearing only does just that. The bearing is then an interference fit into the conrod - without disassembly, check that the bearing is still in there properly and not lose - if it is lose then replace it or bodgy it with loctite otherwise it will come apart while operating. I loctite the big end bolt too.

This said, the piston looks like it hasnt done much work at all.

For the bearing, its a sealed non-servicable bearing so don't sweat. if its gritty then you might washing it out with something like petrol and then soak lube back into it. If it spins freely then just leave it. IIRC I used to clean those types of bearing with WD40 spray and then I think it may have even been chain/bar lube that I used to run back in because it has some thickness and retaining properties.

[Jock The Rock]

Thanks I was thinking it wasnt too important

Is the Loctite on the head bolts important?

Havent got any :(

Thanks

[Slunnie]

Thanks I was thinking it wasnt too important

Is the Loctite on the head bolts important?

Havent got any :(

Thanks
I dont think so because the thread on those screws seem to generate a lot of friction anyway. The big end I would loctite on the thread only.

[Jock The Rock]

Might have to go and find some Loctite for the hex head then

It says to use 272 does that sound right?

Thanks

[Slunnie]

It'll be something like that. I used the Permatex red instead which I think is the equivilent, or at least similar.

[MacMan]

https://www.aulro.com/afvb/images/imported/2008/12/325.jpg

They did have to call it PUKT for a rebuild diagram didn't they!

:p:p:p

[slug_burner]

272 is designed for the permanent locking and sealing of threaded fasteners

[Jock The Rock]

Well after the past 45 mins being spent trying to find somewhere that stocks what I need; I gave up and went to Bunnings. They had 262 and 243. After reading the back I got the 243. It says the breaking torque is 20Nm, and Im only sposed to do them up to 11Nm so I thought that would do?

[Jock The Rock]

Well

Just got it finished and all put back together. Too be honest looking back, I dont think it really needed rebuilding :p Guess I now have spare parts

But I guess its an insurance policy, new Defender, (near) new compressor :D

The parts I got worked out about $70, the most expensive being the cylinder and piston.

https://www.aulro.com/afvb/images/imported/2008/12/308.jpg

https://www.aulro.com/afvb/images/imported/2008/12/309.jpg

Fitting back together

https://www.aulro.com/afvb/images/imported/2008/12/310.jpg

https://www.aulro.com/afvb/images/imported/2008/12/311.jpg

Exhaust Valve in
https://www.aulro.com/afvb/images/imported/2008/12/312.jpg

Inlet Valve in
https://www.aulro.com/afvb/images/imported/2008/12/313.jpg

Head bolts in
https://www.aulro.com/afvb/images/imported/2008/12/314.jpg

The three bolts I mentioned in the first thread
https://www.aulro.com/afvb/images/imported/2008/12/315.jpg

More precision than a hacksaw :twisted:
https://www.aulro.com/afvb/images/imported/2008/12/316.jpg

Cut and fitted (sorry forgot to take an after picture in the vice)
https://www.aulro.com/afvb/images/imported/2008/12/317.jpg

Filter on
https://www.aulro.com/afvb/images/imported/2008/12/318.jpg

All back together
https://www.aulro.com/afvb/images/imported/2008/12/319.jpg

https://www.aulro.com/afvb/images/imported/2008/12/320.jpg

And lastly next on the list :)

https://www.aulro.com/afvb/images/imported/2012/06/1088.jpg

Thanks to all those who helped

And I hope this helps someone

Sorry some of the photos are a bit blurry