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How to Rebuild a Reciprocating Air Compressor

Reciprocating air compressor design has a lot in common with a car engine. The purpose, however, is to compress air, not capture energy from expanding gas. They have a crankshaft, rod, piston, rings, one or more cylinders and a number of bearings. The details of rebuilding a reciprocating compressor may vary as there are many designs, but conceptually, they're similar. Bearing surfaces--the parts the touch and wear due to friction--are replaced, cylinders and rings are replaced and refurbished to make airtight seals, and gaskets are replaced.

Things You'll Need

Wrenches
Gasket solvent
Gasket scraper
Replacement parts
Torque wrench

Instructions

- 1
  Disengage the power source of the compressor. Whether the power running the air compressor is an auxiliary gas engine or electric motor, disengage it for safety.
- 2
  Remove the head bolts on the compressor, then remove the head.
- 3
  Remove the cylinder bolts, then remove the cylinder or "barrel." Gently slide the cylinder off, wrapping the piston in a rag so that the piston skirts don't fall and break when they're freed from the cylinder.
- 4
  Push the wrist pin connecting the piston to the connecting rod out, removing the piston.
- 5
  Evaluate the cylinder for damage or wear. If the compressor seized due to overheating, it will have to be re-machined or possibly replaced. If it has no visible damage and the inside diameter measures within the manufacturer's specification using inside dial calipers, you may not have to do anything to the cylinder. You may just hone it with a cylinder hone.
- 6
  Machine the cylinder and any valves, if need be.
- 7
  Clean gasket residue off the joining surfaces of the cylinder head. Use gasket solvent and a gasket scraper.
- 8
  Install new rings on the old piston if it's still serviceable, or on a brand new piston. You may need a specialty ring installation tool.
- 9
  Replace the piston on the connecting rod with a new wrist pin and bearings.
- 10
  Place the gasket on the cylinder base if the compressor uses one--or use liquid gasket, if it's specified--then slide the cylinder over the reinstalled piston. Use a ring compression tool to slide the cylinder over the rings.
- 11
  Re-torque the cylinder to factory torque specifications using a torque wrench.
- 12
  Install the head gasket. Make sure that the gasket is factory specified because the height of the gasket is important to proper functioning.
- 13
  Re-torque the head to factory specifications.

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