Bosch RG8.0 - Page 27

F 002 DG9 H10 2018-08-21| Bosch Automotive Service Solutions GmbH
Appendix | RG8.0 / RG4.0 | 27
en
1. Loosen the four cylinder bolts.
2. Remove manifold and valve plate.
3. Remove the O-rings (Fig. 16, Pos. 1, 2), springs (Fig. 16, Pos. 3, 13) and valves (Fig. 16, Pos. 4, 5).
4. Remove the O-ring (Fig. 16, Pos. 9) from the valve plate.
5. Slide the cylinder straight up off the piston.
6. Remove the piston seal (Fig. 16, Pos. 6), O-ring (Fig. 16, Pos. 7) and two slyd rings (Fig. 16, Pos. 8) from the
piston.
7. Remove remaining O-ring (Fig. 16, Pos. 9) from main block.
8. Loosen four nuts on compressor body.
9. Remove seal plates and O-rings.
10. Remove crankshaft and inspect for any damage or foreign material. If compressor has e-clips mounted on
crankshaft remove e-clips before crankshaft removal.
11. Using a snap ring tool, remove the two snap rings.
12. Press-out the ball bearings (Fig. 16, Pos. 12).
13. Remove the shaft seals (Fig. 16, Pos. 11 ).
14. Install a new O-ring (Fig. 16, Pos. 10) unto the seal plate. Press in new bearings (Fig. 16, Pos. 12) and shaft
seals (Fig. 16, Pos. 11 ). Reinstall crankshaft.
15. Install seal plates and secure with nuts, bolts and washers.
16. Place an O-ring (Fig. 16, Pos. 9) into groove in top of main block.
17. Install the new O-ring (Fig. 16, Pos. 7) in top piston groove.
18. Install the new piston seal (Fig. 16, Pos. 6) over O-ring (Fig. 16, Pos. 7).
19. Install two new slyd rings (Fig. 16, Pos. 8).
20. Install the new O-ring (Fig. 16, Pos. 15).
21. Slide the cylinder unto the piston while holding the two slyd rings in place.
22. Install the new O-ring (Fig. 16, Pos. 9) into valve plate_
23. Install new valves (Fig. 16, Pos. 4, 5) with new springs (Fig. 16, Pos. 3, 13) unto valve plate.
24. Install new O-rings (Fig. 16, Pos. 1 ,2, 15).
25. Assemble the valve plate between cylinder body and manifold.
26. Install four cylinder bolts and tighten.
27. Reinstall the compressor into the RG8.0 / RG4.0. Pressure up and check for leaks.