IMPCO RK-J-2 , Model J Converter Repair Kit , Yellow Coded Diapragm
The IMPCO RK-J-2 repair kit will provide
the technician information to successfully repair the
Model J converter. Always inspect the major casting pieces for damage, corrosion or cracks before attempting a service repair. Be sure the repair kit part number you are using is correct for the regulator being serviced. Diaphragms is yellow - silicone diaphragm material is the optional upgrade material that provides excellent flexibility in cold weather climates and is more resistant to chemical contamination.
REBUILD INSTRUCTIONS
1. Under normal conditions, installation of a complete Model J Repair Kit should be necessary only at the time of a major engine overhaul or when the converter has been out of service for an extended period of time. Each kit includes the necessary gaskets, diaphragms, seals and some replacement screws.
2. Remove the 6 screws (2) from the secondary cover assembly (3).
NOTE: Identify type and location of screws removed (i.e. Torx) to ensure the same type and size screws are returned to the correct locations during reassembly.
3. Loosen the secondary cover (3) by tapping around the circumference with a plastic screw driver handle.
4. Remove the secondary cover (3) and secondary dia-phragm (4) as a unit. Note the secondary lever (6) pro-truding through the metal tab slot of the secondary dia-phragm. Slide the cover and diaphragm toward the gas inlet to free the lever from the slotted tab of the dia-phragm. Take care not to bend the lever.
5. Remove the screw (5) retaining the secondary lever fulcrum pin.
6. Remove the secondary lever (6) and fulcrum pin (7). Set aside fulcrum pin for reassembly. Remove the secondary spring (9).
7. Turn the converter over. Remove the seven screws (20) and lift off the primary cover (19).
8. Remove the primary diaphragm (18).
9. Remove the primary valve pin (17) and spring (16).
10. Remove plate (14) and the gasket (13).
11. Remove the gasket (13) from the plate (14). Clean plate as needed to ensure a good seal with a new gas-ket.
12. Remove the primary seat (12). Clean covers (3, 14, & 19), body (10) and all other metal parts as necessary with a safety solvent as needed and allow to dry prior to reassembly. Do not use harsh solvents such as brake or carburetor cleaner on any of the non-metallic components as they will damage the material.
13. Install new primary seat (12).
14. Set new plate gasket (13) on the plate (14). The pri-mary pressure hole in the gasket must line up with the hole in the body cover plate as noted in the photo at left.
15. Place the plate (14) and gasket (13) on to the body (10) and align the screw holes.
16. Insert the new primary valve pin (17) through the spring (16) and insert into the plate (14) with the larger diame-ter end of the spring resting against the plate.
17. Set the primary diaphragm (18) in place on the plate (14). Line up the screw holes to the plate.
18. Carefully place the primary cover (19) over the dia-phragm (18). Hand-thread the screws (20) through the cover and plate (14) into the converter body (10).
19. Tighten the screws (20) to 37-43 in-lb. (4.2-4.9 N•m) in a criss-cross pattern.
20. Assemble the new secondary seat (8) and new sec-ondary lever (6) by inserting the seat retaining tip to the end opening of the lever as shown. Be sure the new seat properly locks into place.
21. Position the secondary spring (9) in place on the body (10). Place the secondary lever assembly (6 & 8) into place over the spring (9).
22. Hold the lever assembly (6 & 8) with the fulcrum pin (7) in place in its locating groove and fasten in place with the retaining screw (5).
23. Tighten the screw (5) to 29-35 in.lbs. (3.3-4.0 N•m).
24. The end of the secondary lever (6) should be 1/32" be-low the level of the body casting (10). Use a straight edge to measure. Remove and gently bend the lever if necessary to obtain the correct height.
NOTE: Bending the lever while installed may result in damage to the seat (8). Remove the lever from the body, bend, reinstall, and then re-check the height.
25. Align the secondary diaphragm (4) to the secondary lever (6) as shown. The end of the lever must protrude through the tab slot on the bottom of the new dia-phragm (4) after installation. The gap from which the link is punched should be located toward the gas inlet.
26. Install the secondary cover (3) with the six screws (2).
27. Tighten the screws (2) in a crisscross pattern to 29-35 in-lb. (3.3-4.0 N•m), to complete the installation of the repair kit components.
28. Attach a 100 psi air pressure hose to the regulator "IN-LET" fitting.
29. For models with a primer button: Depress the primer button several times. Air flow should be detected when the primer is depressed.
NOTE: Not all models include a primer button. Skip this step for models without a primer button.
30. Check the primary cover for leaks using liquid leak de-tector solution.
31. Make sure one of the regulator's secondary outlets is plugged. Draw a bubble of leak solution over the other regulator outlet. The bubble should hold for several se-conds when the regulator is pressurized. If any leaks are found, the regulator must be replaced. If no leaks are found, the regulator can be reinstalled and returned to service.
