Ford Festiva. Instruction — part 78

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GENERAL SERVICING

1991 Ford Compressor Overhaul

REMOVAL & INSTALLATION

FORD FS-6 6-CYL CLUTCH ASSEMBLY

Removal

1. Using Spanner (T70P-4067-A), remove compressor shaft nut. Thread Hub Remover (T80L-19703-B) into clutch plate. Tighten center

bolt in hub remover to remove clutch plate and shims.

2. Remove snap ring. Remove pulley assembly from compressor. If assembly cannot be easily removed, place Shaft Protector (T80L-

19703-G) over shaft. Using Puller (D81P-19703-B), remove pulley assembly. Remove clutch coil retaining snap ring. Remove clutch
coil.

3. If bearing replacement is required, place pulley on Support (T80L-19703-E). Drive bearing from pulley using Bearing Remover (T80L-

19703-J).

Installation

1. If bearing is to be installed, place pulley on support. Using Bearing Installer (T80L-19703-C), drive bearing into pulley. Stake pulley in

4 places to retain bearing.

2. Install clutch coil on compressor so locating pin on compressor engages with hole in clutch coil. Install snap ring. Using hammer and

Pulley Installer (T80L-19703-J), tap pulley assembly on compressor.

3. Install snap ring with beveled side away from compressor. Using Clutch Plate Installer (T80L-19703-F), install clutch plate and shims.

Install and tighten compressor shaft nut to 10-14 ft. lbs. (14-19 N.m).

4. Using feeler gauge, measure air gap between clutch plate and pulley surface in 3 locations around pulley. Rotate pulley 180 degrees and

recheck clearance. Proper clearance is .021-.036" (.05-.91 mm). Adjust shim thickness to obtain correct clearance.

FORD FS-6 6-CYL SHAFT SEAL

Removal

1. Discharge system using approved refrigerant recovery/recycling equipment and remove compressor. Drain oil from compressor and

record amount for reassembly.

2. Remove clutch assembly. See FORD FS-6 6-CYL CLUTCH ASSEMBLY R & I in this article. Ensure compressor outer surface is clean.

Attach compressor on Clamp & Holding Fixture (T81P-19623-D). Place fixture in vise.

3. Using Key Remover (T81P-19623-NH), remove key from compressor shaft. Remove front head-to-compressor retaining bolts. Remove

front head. Front valve plate assembly, inlet reed valve and shaft seal assembly come off with front head. See

Fig. 1

.

4. Remove dowel pins from front head. Lift inlet reed valve assembly from front head. Using Valve Plate Remover (T81P-19623-B),

remove front valve plate assembly from front head. Remove shaft seal assembly and felt seal from front head.

5. Place front head on cardboard. Using hammer and Shaft Seal Seat Remover (T81P-19623-OH), drive shaft seal seat from front head.

Clean components with solvent.

CAUTION:

When discharging air conditioning system, use only approved refrigerant recovery/recycling
equipment. Make every attempt to avoid discharging refrigerant into the atmosphere.

CAUTION:

DO NOT drive clutch plate on compressor. Use clutch plate installer to prevent damaging
compressor. DO NOT tighten compressor shaft nut with air tools.

Fig. 1: Exploded View of Chrysler, Ford & Nippondenso 6-Cyl Compressors

Courtesy of FORD MOTOR CO.

Installation

1. Place dowel pins in compressor. Lubricate inlet reed valve with refrigerant oil. Install inlet reed valve on compressor. Install front valve

plate assembly on compressor.

2. Lubricate shaft seal seat with refrigerant oil. Position Seat Installer (T81P-19623-C) on new seat so installer is placed on raised side of

seat. Install shaft seal seat.

3. Install shaft seal assembly in front head so sealing surface is toward en of compressor shaft. Ensure flat areas on shaft seal assembly

engage with flat areas on compressor shaft.

4. Lubricate front head "O" ring with refrigerant oil. Install front head and "O" ring. Tighten retaining bolts in a crisscross pattern to 19 ft.

lbs. (26 N.m). DO NOT use air tools to tighten retaining bolts.

5. Install clutch assembly. Add same amount new refrigerant oil to compressor as was drained. Install compressor. Evacuate and recharge

system. Perform leak test.

FORD FX-15 10-CYL CLUTCH ASSEMBLY

Removal

1. Discharge system using approved refrigerant recovery/recycling equipment. Remove compressor. Using Spanner (T70P-4067-A), remove

clutch plate retaining bolt and discard. Using an 8-mm bolt threaded into clutch plate, remove clutch plate and shims. See

Fig. 2

.

2. Remove snap ring and remove pulley assembly. Disconnect electrical wiring to clutch coil. Install Shaft Protector (T89P-19623-FH) on

nose opening of compressor.

3. Install 2-jaw puller on compressor. Ensure puller screw is engaged in center of shaft protector. Tighten puller to remove clutch coil from

compressor. DO NOT use air tools when removing clutch coil.

Installation

1. Ensure clutch coil mounting surface is clean. Install clutch coil. Ensure electrical connection is correctly positioned. Install Coil

Installer (T89P-19623-EH) over compressor nose and inner diameter of clutch coil.

2. Install 2-jaw puller on compressor and coil installer. Jaws on puller should engage with compressor front mounts and pressure screw

centered on coil installer.

3. Tighten pressure screw and install clutch coil. DO NOT use air tools when installing clutch coil.
4. Install pulley and snap ring. Install snap ring with beveled side away from compressor. Install shims and clutch plate. Install NEW

clutch plate retaining bolt and tighten to 96-120 INCH lbs. (11-14 N.m).

5. Using a feeler gauge, check clearance between clutch plate and pulley assembly mating surfaces in 3 places. Clearance should be .018-

.033" (.46-.84 mm). If clearance is not correct, add or remove shims.

6. Install compressor. Evacuate and recharge system. Perform leak test.

Fig. 2: View of Ford FX-15 10-Cyl Compressor Clutch Assembly

Courtesy of FORD MOTOR CO.

FORD FX-15 10-CYL SHAFT SEAL

Removal

CAUTION:

DO NOT dry front valve plate assembly or inlet reed valve with compressed air.

CAUTION:

DO NOT touch sealing surfaces of shaft seal or shaft seat assembly.

NOTE:

When new clutch assembly is installed, cycle clutch assembly 10 times with engine at idle to burnish
clutch and prevent slippage.

1. Discharge system using approved refrigerant recovery/recycling equipment and remove compressor. Using Spanner (T70P-4067-A),

remove clutch plate retaining bolt and discard. Using an 8-mm bolt threaded into clutch plate, remove clutch plate and shims. See

Fig.

2

.

2. Remove shaft felt seal. Thoroughly clean seal area of compressor. Using snap ring pliers, remove shaft seal retaining snap ring.
3. Position Shaft Seal Remover (T89P-19623-BH) over compressor shaft. Push shaft seal remover downward against seal. Ensure end of

shaft seal remover is engaged with inside of seal.

4. Rotate shaft seal remover handle clockwise to expand remover tip inside seal. Pull shaft seal from compressor.

Installation

1. Shaft seal protector is included with replacement seal kit. Lubricate shaft seal protector and shaft seal with refrigerant oil.
2. Install shaft seal on shaft seal protector so lip of seal is toward compressor (large end of shaft seal protector). Install shaft seal protector

on compressor shaft.

3. Using Shaft Seal Installer (T89P-19623-AH), push shaft seal down shaft seal protector until seated. Remove shaft seal installer and

protector. Install NEW shaft seal retaining snap ring.

4. Install NEW shaft seal felt. Install clutch plate. Install new clutch plate retaining bolt and tighten to 96-120 INCH lbs. (11-14 N.m).
5. Using feeler gauge, check clearance between clutch plate and pulley assembly mating surfaces in 3 places. Clearance should be .018-

.033" (.46-.84 mm). If clearance is not correct, add or remove shims.

6. Install compressor. Evacuate and recharge system. Perform leak test.

NIPPONDENSO 6E-171 & 6P-148 CLUTCH ASSEMBLY

Removal

1. Using Spanner (T81P-19623-MH), hold clutch plate and remove crankshaft nut. Using Clutch Plate Remover (T80L-19703-B), pull

clutch plate from compressor. Remove clutch plate shims.

2. Remove snap ring and clutch pulley assembly. If pulley assembly cannot be removed by hand, use Shaft Protector (T80L-19703-G) and

3-jaw puller to remove pulley. Remove snap ring. Disconnect electrical wiring and remove clutch coil.

Installation

1. Install clutch coil over locating pin and install snap ring. Connect electrical wiring.
2. Using Pulley Installer (T80L-19703-J) and hammer (if necessary), install pulley assembly. Install snap ring with beveled side away from

compressor.

3. Install clutch plate shims. Ensure clutch plate aligns with crankshaft key. Using Clutch Plate Installer (T80L-19703-F), install clutch

plate.

4. Install crankshaft nut. Using spanner, tighten nut to 10-14 ft. lbs. (13-20 N.m). DO NOT tighten nut with air tools. Using feeler gauge,

check clearance between clutch plate and pulley.

5. Rotate compressor clutch and check clearance in more than one place. Proper clearance is .021-.035" (.53-.89 mm). If clearance is not

correct, add or remove shims.

NIPPONDENSO 6E-171 & 6P-148 SHAFT SEAL

Removal

1. Discharge system using approved refrigerant recovery/recycling equipment and remove compressor. Drain oil from suction port on

compressor and record amount for reassembly.

2. Remove clutch assembly. See NIPPONDENSO 6E-171 & 6P-148 CLUTCH ASSEMBLY R & I in this article. Ensure outer surface of

compressor is clean. Attach compressor on Clamp & Holding Fixture (T81P-19623-LH). Place fixture in vise.

3. Using Key Remover (T81P-19623-NH), remove key from compressor shaft. Remove front head-to-compressor retaining bolts and front

head. Front valve plate assembly, inlet reed valve and shaft seal assembly come off with front head. See

Fig. 1

.

4. Remove dowel pins from front head. Lift inlet reed valve assembly from front head. Using Valve Plate Remover (T81P-19623-PH),

remove front valve plate assembly from front head. Remove shaft seal assembly and felt seal from front head.

5. Place front head on cardboard. Drive shaft seal seat from front head using hammer and Shaft Seal Seat Remover (T81P-19623-OH).

Clean components with solvent.

Installation

1. Place dowel pins in compressor. Lubricate inlet reed valve with refrigerant oil. Install inlet reed valve on compressor. Install front valve

plate assembly on compressor.

2. Lubricate shaft seal seat with refrigerant oil. Install Seat Installer (T81P-19623-C) on new seat so installer is placed on grooved side of

seat. Install shaft seal seat.

3. Install shaft seal assembly in front head so sealing surface is toward end of compressor shaft. Ensure flat areas on shaft seal assembly

engage with flat areas on compressor shaft.

4. Lubricate front head "O" ring with refrigerant oil. Install front head and "O" ring. Tighten retaining bolts in a crisscross pattern to 19 ft.

lbs. (26 N.m). DO NOT use air tools to tighten retaining bolts.

5. Install clutch assembly. Add same amount new refrigerant oil to compressor as was drained. Rotate compressor 10 revolutions to

distribute oil. Install compressor. Evacuate and recharge system. Perform leak test.

NOTE:

Remove compressor when clearance is not adequate for clutch assembly removal.

CAUTION:

DO NOT dry front valve plate assembly or inlet reed valve with compressed air.

CAUTION:

DO NOT touch sealing surfaces of shaft seal assembly or shaft seat assembly.

NIPPONDENSO 10P13 CLUTCH ASSEMBLY

Removal

1. Discharge system using approved refrigerant recovery/recycling equipment and remove compressor. Using Clutch Holder (1014), hold

clutch plate and remove crankshaft nut. Using Clutch Plate Remover (T80L-19703-B), pull clutch plate from compressor. Remove
clutch plate shims.

2. Remove snap ring and pulley assembly. If pulley assembly cannot be removed by hand, use Shaft Protector (T80L-19703-G) and 3-jaw

puller to remove pulley. Remove snap ring. Disconnect electrical wiring and remove clutch coil.

Installation

1. Install clutch coil over locating pin. Install snap ring with beveled side away from compressor.
2. Install pulley assembly using Pulley Installer (T80L-19703-J) and hammer (if necessary). Install snap ring with beveled side away from

compressor.

3. Install clutch plate shims. Ensure clutch plate aligns with crankshaft key. Install clutch plate using Clutch Plate Installer (T80L-19703-

F).

4. Install crankshaft nut. Using spanner, tighten nut to 10-14 ft. lbs. (13-20 N.m). DO NOT tighten nut with air tools. Using feeler gauge,

check clearance between clutch plate and pulley.

5. Rotate compressor clutch and check clearance in more than one place. Proper clearance is .021-.036" (.53-.91 mm). If clearance is not

correct, add or remove shims.

6. Add same amount new refrigerant oil to compressor as was drained. Rotate compressor 10 revolutions to distribute oil. Install

compressor. Evacuate and recharge system. Perform leak test.

NIPPONDENSO 10P13 SHAFT SEAL

Removal

1. Discharge system using approved refrigerant recovery/recycling equipment and remove compressor. Drain oil from compressor and

record amount for reassembly. Using Clutch Holder (1014), hold clutch plate and remove crankshaft nut.

2. Pull clutch plate from compressor using Clutch Plate Remover (T80L-19703-B). Remove clutch plate shims. Clean compressor area

around seal. Remove felt packing and dust seal retainer from nose of front cover. See

Fig. 3

.

3. Using Key Remover (T81P-19623-NH), remove key from compressor shaft. Remove seal seat retaining snap ring. Remove seal seat from

compressor using Seal Seat Remover/Installer (T87P-19623-B).

4. Place Seal Remover/Installer (T87P-19623-C) on compressor. Rotate seal remover/installer clockwise until tangs engage in seal. Pull

seal from compressor.

Installation

1. Lubricate shaft seal, seal seat and inside of compressor nose with refrigerant oil. Install Seal Protector (T71P-19703-H) over compressor

shaft. Using seal remover/installer, install shaft seal in compressor.

2. Rotate seal on compressor shaft to align flat areas on seal with those on compressor shaft.
3. Using seal seat remover/installer, install seal seat until it contacts seal. Install snap ring. Install key in crankshaft with rounded edge

inward.

4. Install clutch plate shims. Ensure clutch plate is aligned with crankshaft key. Using Clutch Plate Installer (T80L-19703-F), install clutch

plate.

5. Install crankshaft nut. Using spanner, tighten nut to 10-14 ft. lbs. (13-20 N.m). DO NOT tighten nut with air tools. Using feeler gauge,

check clearance between clutch plate and pulley.

6. Rotate compressor clutch and check clearance in more than one place. Proper clearance is .021-.036" (.53-.91 mm). If clearance is not

correct, add or remove shims.

7. Add same amount new refrigerant oil to compressor as was drained. Rotate compressor 10 revolutions to distribute oil in compressor.

Install compressor. Evacuate and recharge system. Perform leak test.

NOTE:

After installing new clutch, cycle clutch 10 times with engine at idle speed to prevent clutch slippage.