PREVOST LE MIRAGE XLII BUS SHELLS Maintenance Manual Download

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To convert foot pounds to inch pounds of torque, multiply
foot pounds by 12.
Example:

1 Foot Pound x 12 = 12 Inch Pounds

CRANKCASE COVER

1. Position the crankcase cover gasket (15) on either the

crankcase or crankcase cover and install the crank-
case cover on the crankcase using the four cap screws.
"Snug" the four cap screws then torque to 62-71 inch
pounds using a crossing pattern.

CRANKCASE END COVER OR ADAPTER

1. Install the end cover o-ring (14) on the crankcase end

cover.

2. Orient the crankcase end cover or end cover adapter

to the crankcase using the reference marks made dur-
ing disassembly. Carefully install the end cover or end
cover adapter in the crankcase making certain not to
damage the crankshaft bearing surface in it.

3. Install the four end cover screws or studs. "Snug" the

screws then tighten to 195 to 213 inch pounds using a
crossing pattern.

CYLINDER HEAD

1. Note the position of the protruding alignment pins on the

cylinder block. Install the metal inlet reed valve/gasket
(13) over the alignment pins on the cylinder block.

2. Position the valve plate assembly (12) on the cylinder

block so that the alignment pins in the cylinder block fit
into the corresponding holes in the valve plate assem-
bly (12).

3. Position and install the metal gasket (11) over the align-

ment bushings protruding from the valve plate assembly
(12). When properly installed, the outline of the gasket
matches the outline of the valve plate.

4. Position and install the cylinder head over the align-

ment bushings protruding from the valve plate assembly
(12).

Note:

The alignment bushings will only fit into
two of the four cylinder head bolt holes.

5. Install the four hex head cylinder head bolts and wash-

ers and snug them, then tighten evenly to a torque of
265 to 292 inch pounds using a crossing pattern.

6. Install the unloader piston (8) with its pre-installed o-

rings in the cylinder head making certain not to damage
them in the process.

7. Install the balance piston spring (5) in the unloader pis-

ton (8), then install the small diameter of the balance
piston (4) through the center of the spring.

8. Install the unloader cover gasket (3) on the cylinder head

making certain the unloader vent passage and both
screw holes align.

9. Position the unloader cover (2) on top of the balance

piston (4) making certain the stamped logo is visible.

10. Press and hold the unloader cover (2) in place on the

cylinder head and install both unloader cover cap screws
(1). Torque the cover cap screws (1) to 62 to 71 inch
pounds.

INSTALLING THE COMPRESSOR

1. If the compressor was removed for replacement, install

the drive components.

Torque the crankshaft nut to

250 foot pounds.

2. Install any supporting bracketing on the compressor in

the same position noted and marked during removal.

3. Install the gasket on the drive flange of the compres-

sor. Make certain oil supply or return holes in the gasket
are properly aligned with the compressor and engine.
Gasket sealants are not recommended. Secure the
compressor on the engine and tighten the mounting
bolts.

4. Install the discharge, inlet and governor adapter fittings,

if applicable, in the same position on the compressor
noted and marked during disassembly. Make certain
the threads are clean and the fittings are free of corro-
sion. Replace as necessary. See the Torque
Specifications for various fitting sizes and types of thread
at the rear of this manual.

5. Inspect all air, oil, and coolant lines and fittings before

reconnecting them to the compressor. Make certain o-
ring seals are in good or new condition. Tighten all hose
clamps.

6. Clean oil supply line. Before connecting this line to the

compressor. Run the engine briefly to be sure oil is flow-
ing freely through the supply line.

7. Before returning the vehicle to service, perform the

Operation and Leakage Tests specified in this manual.
Pay particular attention to all lines reconnected during
installation and check for air, oil, and coolant leaks at
compressor connections. Also check for noisy opera-
tion.

TESTING REBUILT COMPRESSOR

In order to properly test a compressor under operating con-
ditions, a test rack for correct mounting, cooling, lubricating,
and driving the compressor is necessary. Such tests are
not compulsory if the unit has been carefully rebuilt by an
experienced person. A compressor efficiency or build up
test can be run which is not too difficult. An engine lubri-
cated compressor must be connected to an oil supply line
of at least 15 psi. pressure during the test and an oil return
line must be installed to keep the crankcase drained. Con-
nect to the compressor discharge port, a reservoir with a
volume of 1500 cubic inches, including the volume of the
connecting line. With the compressor operating at 2100

PREVOST LE MIRAGE XLII BUS SHELLS, Maintenance Manual

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