Ford Festiva. Manual — part 80

Fig. 1: Atsugi Rotary Vane Compressor

Courtesy of NISSAN MOTOR CO., U.S.A.

BOSCH 6-CYL CLUTCH R & I

Removal

1. Hold clutch plate and remove shaft nut. Using Clutch Plate Remover (64 5 00), remove clutch plate. Using snap ring pliers, remove

circlip and remove pulley assembly.

2. If pulley bearing is being replaced, remove circlip at rear of pulley. Press bearing and spacer from pulley. Press in new bearing with

spacer and replace circlip.

Installation

1. Clean all surfaces. Install pulley assembly on compressor and install circlip. Ensure clutch plate shim is in place on shaft. Install clutch

plate and nut. Tighten nut to 13-14 ft. lbs. (18-20 N.m).

2. Using a feeler gauge, check clutch plate-to-pulley clearance. Clearance should be .028-.051" (.7-1.3 mm). If clearance is not correct,

remove clutch plate and replace clutch plate shim. See

Fig. 2

.

BOSCH 6-CYL SHAFT SEAL R & I

Removal & Installation

1. Remove clutch plate. Remove shaft key and circlip. Using Seal Seat Remover/Installer (64 5 030), remove seal seat.
2. Using Seal Remover/Installer (64 5 040), remove shaft seal by turning seal slightly clockwise to disengage tangs and pull out shaft seal.

Remove "O" ring seal.

3. Coat new "O" ring seal with refrigerant oil and install. Coat new shaft seal with refrigerant oil and install shaft seal on Seal

Remover/Installer (64 5 040). Ensure alignment of shaft seal and shaft machine surfaces. Insert shaft seal and turn slightly
counterclockwise to secure on shaft.

4. Using sleeve from Seal Seat Remover/Installer (64 5 030), push seal seat into compressor and install circlip. Install shaft key and clutch

plate. Check compressor oil level before charging system.

Fig. 2: Bosch 6-Cylinder Compressor Clutch

Courtesy of BMW OF NORTH AMERICA, INC.

CALSONIC V5 CLUTCH R & I

Removal

1. Remove shaft nut while holding armature plate with clutch disk wrench. Install clutch disk puller and remove clutch plate. Remove snap

ring from center of clutch pulley.

2. Use a universal gear puller to remove clutch pulley. See

Fig. 3

.Remove screw securing clutch coil ground lead. Use puller to remove

clutch coil.

Installation

1. To install clutch coil, reverse removal procedure. Carefully press clutch coil into place. Ensure that coil lead and connector are

positioned on same side as removed coil.

2. Install a NEW clutch pulley snap ring, being careful not to damage shaft seal. Press clutch plate into place. Install shaft nut and torque

to 0.9-1.4 INCH lbs. (0.10-.12 N.m).

3. Use a feeler gauge to check clutch plate-to-pulley clearance. Clearance should be .012-.024" (0.3-0.6 mm). If clearance is too large,

remove shaft nut and again press in clutch plate. If clearance is too small, increase gap by pulling up clutch plate. Do not remove shaft
nut.

Fig. 3: Explode View of Compressor Clutch (Calsonic V5)

Courtesy of NISSAN MOTOR CO. U.S.A.

DIESEL KIKI ROTARY VANE CLUTCH R & I

Removal

1. Using Clutch Holder (KV99231010), hold clutch disc. Remove center bolt retaining clutch assembly to shaft. Thread Hub Remover

(KV99232232) into bore of clutch hub. Hold hub remover with wrench and thread center bolt inward until clutch disc is removed.

2. Remove clutch disc, collar and adjusting shims. Remove snap ring and plate. Remove pulley and bearing assembly. If assembly cannot

be removed by hand, use a puller and adapter.

3. Be careful not to scratch shaft or bend pulley. Using an impact driver, loosen 6 coil mounting screws. Remove key and clutch coil. See

Fig. 4

.

Installation

1. Install key. Position coil assembly on compressor body. Be sure that electrical terminals are installed in original position. Install and

tighten coil mounting screws to 35-52 INCH lbs. (4-6 N.m).

2. Press pulley assembly onto neck of coil assembly using Pulley Installer (KV99234160). Wipe oil thoroughly off clutch surface. Select

adjusting shims which give correct clearance between pulley and clutch disc.

3. Using a plastic mallet, tap clutch disc in place on drive shaft. Do not use excessive force with plastic mallet or press. Place spring washer

and center bolt onto drive shaft. Tighten center bolt to drive clutch wheel onto drive shaft. Tighten center bolt to 11-13 ft. lbs. (15-18
N.m).

4. Hold clutch with Clutch Holder (KV99231010). Check clearance around entire outer edge of clutch disc. Clearance should be .012-

.024" (.3-.6 mm). If specified clearance is not obtained, replace adjusting shims as required.

5. When replacing compressor clutch assembly, break-in procedure must be performed. This is accomplished by engaging and disengaging

clutch 30 times.

DIESEL KIKI 6-CYL CLUTCH COIL R & I

Removal & Installation

Using clutch holder to prevent clutch disc rotation, remove bolt. Using clutch holder and puller, remove clutch disc. Remove shims from
compressor drive shaft or clutch disc. Remove snap ring with external snap ring pliers and then remove pulley. Using a gear puller, remove
pulley. Remove coil lead wire and 6 screws. Remove coil. To install, reverse removal procedure. Adjust clutch disc-to-pulley clearance
to .010-.020" (.3-.6 mm). See

Fig. 4

.

Fig. 4: Diesel Kiki Rotary Vane Compressor

Courtesy of NISSAN MOTOR CO., U.S.A.

DIESEL KIKI 6-CYL SHAFT SEAL R & I

Removal & Installation

1. Remove clutch coil assembly. Remove retainer and felt. Discard retainer and felt. Using internal snap ring pliers, remove seal seat snap

ring. Remove seal seat and discard. Using a seal pick, remove "O" ring from inside groove of shaft seal housing. Discard "O" ring.

2. To remove shaft seal, push down and turn clockwise on seal remover to engage tangs. Slowly draw seal from bore. Discard seal. Check

shaft and inside of compressor neck for dirt or foreign material and ensure these areas are perfectly clean before installing new seal.

3. To install, reverse removal procedure. Coat "O" ring, shaft seal, and seal seat with new refrigerant oil.