drain bolt FORD FESTIVA 1991 User Guide

Removal
Drain radiator and remove negative battery cable. Disconnect throttle cable. Remove air duct from throttle body. Disconnect throttle position
sensor/switch connector. Mark all coolant and vacuum hoses for reassembly reference and remove from throttle body. See Fig. 4
. Remove
intake plenum bolts and remove intake plenum and gasket.
Installation
To install, reverse removal procedure. Use NEW intake plenum-to-intake manifold gasket. Tighten bolts to specification, see TORQUE
SPECIFICATIONS at end of article.
OXYGEN (O2) SENSOR
Removal & Installation
Disconnect negative battery cable. Disconnect wire harness connector, and remove oxygen sensor. If exhaust sensor is difficult to remove, use
rust penetrant to avoid possible damage to exhaust threads. If new sensor is not pre-coated with anti-seize, apply anti-seize compound to
sensor threads. DO NOT remove anti-seize from sensor. To install, tighten sensor and attach wire harness connector.
THROTTLE BODY
Removal & Installation
Drain radiator and remove negative battery cable. Remove resonance chamber. Disconnect throttle cable. Remove air duct. Mark all coolant
and vacuum hoses for reassembly reference and remove from throttle body. Disconnect throttle position sensor/switch connector. Remove
throttle body nuts and bolts. Remove throttle body and gasket. To install, reverse removal procedure using NEW throttle body-to-intake
plenum gasket.
THROTTLE POSITION SENSOR/SWITCH
Removal & Installation
Disconnect negative battery cable. Disconnect throttle position sensor/switch connector. Remove attaching bolts. Remove sensor/switch from
throttle body. To install, reverse removal procedure.
TURBOCHARGER
Removal
1. Drain radiator and remove negative battery cable. Remove throttle body air intake tube. Disconnect intercooler hose from turbocharger
assembly. Disconnect O2 sensor. Remove lower heat shield retaining bolts and lower heat shield from turbocharger. Remove upper heat
shield retaining bolts and upper heat shield from exhaust manifold.
2. Slide O2 sensor wire and guide through upper heat shield. Remove side heat shield retaining bolts from turbocharger, and remove sid e
heat shield. Remove power steering belt. Remove power steering pump through bolt and adjuster nuts and bolts. Disconnect lower
radiator hose from water pump.
3. Pull pump from bracket, and position pump to access mounting bracket retaining nut and bolts. Remove mounting bracket-to-engine nut
and bolts and remove bracket. Remove air cleaner duct retaining screws. Loosen clamp at turbocharger and move duct tube out of way.
Disconnect coolant supply hose at turbocharger.
4. Remove bolt and sealing washers attaching oil supply line at engine block. Raise vehicle on hoist. Remove nuts and washers from
exhaust pipe flange. Remove bolts attaching exhaust hanger to engine block. Slide rubber exhaust hangers from catalytic converter. Pull
exhaust pipe downward and to left side of vehicle. Disconnect oil return hose from turbocharger. Disconnect coolant return hose fro m
turbocharger.
5. Remove turbocharger support bracket retaining bolts. Remove coolant by-pass tube outlet-to-water pump bolts. Lower vehicle. Loosen
retaining clamp bolt on coolant by-pass tube at rear of cylinder head. Remove 11 retaining nuts from exhaust manifold. Position coolant
by-pass tube out of way after pulling bracket from exhaust stud.
6. Remove exhaust manifold by pulling off studs and moving assembly towards right side of engine compartment, clearing cooling fan.
With assembly removed from vehicle, remove turbocharger-to-exhaust manifold nuts. Separate assembly and discard gasket.
Installation
1. Install NEW gasket on exhaust manifold and install turbocharger onto studs. Install turbocharger-to-exhaust manifold nuts. Remo ve o il
supply line from turbocharger. Install NEW exhaust gasket on cylinder head. Install turbocharger and exhaust manifold assembly onto
studs. Install coolant by-pass tube bracket onto exhaust stud. Install 11 retaining nuts onto exhaust manifold.
2. Securely tighten heater tube clamp bolt. Raise vehicle. Install coolant by-pass tube outlet-to-water pump bolts. Install turbocharger
support bracket retaining bolts. Connect coolant return hose to turbocharger. Connect oil return hose to turbocharger. Install exhaust
pipe onto turbocharger, and hand tighten nuts and washers. Install bolts attaching exhaust hanger to engine block.
3. Slide rubber exhaust hangers onto catalytic converter. Tighten exhaust pipe nuts and washers. Lower vehicle. Install bolt and sealing
washers attaching oil supply line at engine block. Install oil supply line onto turbocharger. To complete installation, reverse removal
procedure. Tighten bolts and nuts to specification, see TORQUE SPECIFICATIONS
at end of article. NOTE:T o prevent dust and dirt from entering intake m anifold ports, cover ports with clean cloth after
rem oving intake plenum .
WARNING:DO NOT rem ove oxygen sensor when engine is hot.
NOTE:Clean throttle body exterior before rem oval.
CAUT ION: Before installing turbocharger, put .8 oz. (25 m l) engine oil into turbocharger oil inlet.
Page 4 of 5 MITCHELL 1 ARTICLE - N - REMOVE/INSTALL/OVERHAUL 1991 ENGINE PERFORMANCE Ford/Mercury Removal, O
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ENGINES
Valve "O" ring seals damagedReplace "O" ring seals, See
ENGINES
Plugged oil drain back holesRemove restrictions
Improper PCV valve operationReplace PCV valve
Engine oil level too highRemove excess oil
Engine oil too thinReplace thicker oil
Valve stem oil deflectors damagedReplace oil deflectors
Incorrect piston ringsReplace piston rings, See
ENGINES
Piston ring gaps not staggeredReinstall piston rings, See
ENGINES
Insufficient piston ring tensionReplace rings, See ENGINES
Piston ring grooves or oil returnslots clogged Replace piston
rings, See ENGINES
Piston rings sticking in groovesReplace piston rings, See
ENGINES
Piston ring grooves excessively wornReplace piston and rings, See
ENGINES
Compression rings installed upside downReplace compression rings
correctly, See ENGINES
Worn or scored cylinder wallsRebore cylinders or replace
block
Mismatched oil ring expander and railReplace oil ring expander and
rail, See ENGINES
Intake gasket dowels too longReplace intake gasket dowels
Excessive main or connecting rod bearing clearanceReplace main or connecting
rod bearings, See ENGINES
No Oil Pressure
Low oil levelAdd oil to proper level
Oil pressure sender or gauge brokenReplace sender or gauge
Oil pump malfunctionRemove and overhaul oil
pump, See ENGINES
Oil pressure relief valve stickingR e mo ve a n d r e in st a l l va l ve
Oil pump passages blockedOverhaul oil pump, See
ENGINES
Oil pickup screen or tube blockedRemove restriction
Loose oil inlet tubeTighten oil inlet tube
Loose camshaft bearingsReplace camshaft bearings,
See ENGINES
Internal leakage at oil passagesReplace block or cylinder
head
Low Oil Pressure
Low engine oil levelAdd oil to proper level
Engine oil too thinRemove and replace with
thicker oil
Excessive oil pump clearanceReduce oil pump clearance,
See ENGINES
Oil pickup tube or screen blockedRemove restrictions
Main, rod or cam bearing clearance excessiveReplace bearing to reduce
clearance, See ENGINES
High Oil Pressure
Improper grade of oilReplace with proper oil
Oil pressure relief valve stuck closedEliminate binding
Oil pressure sender or gauge faultyReplace sender or gauge
Noisy Main Bearings
Inadequate oil supplyCheck oil delivery to main
bearings
Excessive main bearing clearanceReplace main bearings, See
ENGINES
Excessive crankshaft end playReplace crankshaft, See
ENGINES
Loose flywheel or torque converterTighten attaching bolts
Loose or damaged vibration damperTighten or replace vibration
damper
Crankshaft journals out-of-roundRe-grind crankshaft journals
Excessive belt tensionLoosen belt tension
Noisy Connecting Rods
Excessive bearing clearance or missing bearingReplace bearing, See
ENGINES
Crankshaft rod journal out-of-roundRe-grind crankshaft journal
Misaligned connecting rod or capRemove rod or cap and realign
Incorrectly tightened rod boltsRemove and re-tighten rod
Page 11 of 36 MITCHELL 1 ARTICLE - GENERAL INFORMATION Trouble Shooting - Basic Procedures
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article. Drain oil from compressor through suction and discharge ports. Measure amount of oil drained. If amount drained is more than
2.4 ounces, fill with same amount using new oil. If amount drained is less than 2.4 ounces, fill with 2.4 ounces. Install compressor and
recharge.
3. If A/C components are replaced, add refrigerant oil to system. Add 1.4 ounces if condenser is replaced. Add 2 ounces if the evaporator
is replaced. Oil does not need to be added if receiver-drier is replaced.
SANDEN SCROLL DRAIN & REFILL
Discharge system. Remove compressor from vehicle. Drain oil from compressor through inlet and outlet holes. Refill compressor with 2.8
ounces of oil through suction port. When replacing condenser, add .5 ounce. When replacing evaporator, add 1.7 ounces. When replacing
other A/C components, add .5 ounce per component replaced.
SANDEN 5-CYL DRAIN & REFILL
1. Discharge system. Remove compressor belt and loosen mounting bolts. Rotate compressor in brackets until filler plug is at top. Clean
area around filler plug and remove plug slowly. Rotate front hub plate so notch in lobe is 110 degrees from the bottom. This rotates ball
end of top piston to align with oil fill port and allows clearance for dipstick. See Fig. 1
.
2. Insert compressor dipstick diagonally from right to left until stop on dipstick contacts filler plug surface. Remove dipstick and note oil
fill level. Each increment on dipstick represents one ounce of oil. Add oil if necessary to reach 3-4 ounce level.

Fig. 1: Sanden 5
-Cylinder Oil Level Checking
Courtesy of SANDEN INTERNATIONAL U.S.A, INC.
SANDEN 7-CYL DRAIN & REFILL
1. Before checking and adjusting oil level, operate compressor at engine idle speed, and set controls at maximum cooling and high blowing
speed for 20-30 minutes to return oil to compressor.
2. Stop engine. Discharge refrigerant and remove compressor from vehicle. See SERVICING PRECAUTIONS at the beginning of this
article. Remove oil drain plug and drain oil. Measure amount of oil drained. Install drain plug with new "O" ring.
3. If amount drained is more than 3 ounces, fill with same amount using new oil. If amount drained is less than 3 ounces, fill with 3
ounces. Install filler plug. Install compressor and recharge system.
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00038952
Page 4 of 4 MITCHELL 1 ARTICLE - 1991 GENERAL SERVICING A/C Compressor Refrigerant Oil Checking
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Back To Article
GENERAL SERVICING
1991 Ford Com pressor 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. CAUT ION: When discharging air conditioning system , use only approved refrigerant recovery/recycling
equipm ent. Make every attem pt to avoid discharging refrigerant into the atm osphere.
CAUT ION: DO NOT drive clutch plate on com pressor. Use clutch plate installer to prevent dam aging
com pressor. DO NOT tighten com pressor shaft nut with air tools.
Page 1 of 7 MITCHELL 1 ARTICLE - GENERAL SERVICING 1991 Ford Compressor Overhaul
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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
CAUT ION: DO NOT dry front valve plate assem bly or inlet reed valve with com pressed air.
CAUT ION: DO NOT touch sealing surfaces of shaft seal or shaft seat assem bly.
NOTE:When new clutch assem bly is installed, cycle clutch assem bly 10 tim es with engine at idle to burnish
clutch and prevent slippage.
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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:Rem ove com pressor when clearance is not adequate for clutch assem bly rem oval.
CAUT ION: DO NOT dry front valve plate assem bly or inlet reed valve with com pressed air.
CAUT ION: DO NOT touch sealing surfaces of shaft seal assem bly or shaft seat assem bly.
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5. Using Shaft Seal Remover/Installer (T87P-19623-C), remove seal by pushing downward on shaft seal remover/installer and rotating
clockwise to engage seal tangs. Pull seal from compressor.
Installation
1. Place Shaft Seal Protector (T71P-19703-H) over compressor shaft. Lubricate shaft seal and nose of compressor with new refrigerant oil.
DO NOT touch sealing surface of seal or shaft. Engage seal tangs on shaft seal remover/installer.
2. Align flats of seal with flats on crankshaft and push new seal on compressor shaft. Push downward on shaft seal remover/installer and
turn counterclockwise to disengage seal tangs.
3. Attach shaft seal seat to shaft seal seat remover/installer and lubricate with new refrigerant oil. Install seal seat and push inward against
seal. Install seal seat retaining snap ring.
4. Install dust seal retainer and felt packing. Install clutch plate shims. Ensure clutch plate aligns with crankshaft key. Using Clutch Plate
Installer (T80L-19703-F), install clutch plate.
5. Install crankshaft nut. Using spanner to hold clutch, tighten crankshaft nut to 10-14 ft. lbs. (13-20 N.m). DO NOT tighten nut with air
tools.
6. Using feeler gauge, check clearance between clutch plate and pulley. 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. Install
compressor. Evacuate and recharge system. Perform leak test.
NIPPONDENSO 10P15A SHAFT SEAL
Removal
1. Discharge system using approved refrigerant recovery/recycling equipment and remove compressor. Drain oil from compressor and
record amount for reassembly. Remove clutch assembly. See NIPPONDENSO 10P15A CLUTCH ASSEMBLY R & I in this article.
2. Remove manifold assembly from top of compressor. Clean compressor front hub area. Using Ring Remover (T71P-19703-C), remove
retaining ring from front of compressor shaft.
3. Remove felt seal from front of compressor. Remove front head retaining bolts and front head from compressor. Remove snap ring fro m
rear of front head. Remove seal from rear of front head.
Installation
1. Install seal and snap ring in front head. Install front head on compressor. Tighten bolts to 18-20 ft. lbs. (24-27 N.m). Install felt packing
and retaining ring.
2. Install manifold assembly and tighten bolts to 18-20 ft. lbs. (24-27 N.m). Add same amount of new refrigerant oil to compressor as that
drained from compressor. Rotate compressor 10 revolutions to distribute oil in compressor. Install compressor. Evacuate and recharge
system. Perform leak test.
NIPPONDENSO 10PA17 & 10PA17A CLUTCH ASSEMBLY
Removal
1. Remove compressor shaft bolt and discard. Remove clutch plate and shims. If clutch hub cannot be removed by hand, thread a 8-mm
bolt in center of clutch plate. Tighten bolt and remove clutch plate.
2. Remove pulley assembly retaining snap ring. Remove pulley assembly. Remove snap ring and disconnect clutch coil electrical wiring.
Remove clutch coil.
Installation
1. Install clutch coil so pin in back of coil aligns with hole in front housing. Install snap ring with beveled side away from compressor.
2. Install pulley assembly. Install snap ring with beveled side away from compressor. Coat splines of compressor shaft with White grease. I
f
reusing original clutch plate and pulley, old shims can be used.
3. If installing new components, install one thin shim. Install clutch plate. Tighten compressor shaft bolt to 10 ft. lbs. (14 N.m). DO NOT
air tools to tighten bolt.
4. Using feeler gauge, measure air gap between clutch plate and pulley surface in 3 areas. Proper clearance is .014-.026" (.35-.66 mm).
Adjust shim thickness to obtain correct clearance.
5. Once compressor shaft bolt is tightened, recheck clearance between clutch plate and pulley surface in 4 places. Readjust clearance if
necessary.
NIPPONDENSO 10PA17 & 10PA17A SHAFT SEAL
Removal
1. Discharge system using approved refrigerant recovery/recycling equipment and remove compressor. Drain oil from compressor and
record amount for reassembly. Install compressor in Holding Fixture (T89P-19623-D) and clamp fixture in a vise.
2. Remove clutch assembly. See NIPPONDENSO 10PA17 & 10PA17A CLUTCH ASSEMBLY R & I in this article. Remove front head
retaining bolts. Separate front head from compressor, using care not to scratch sealing surface. See Fig. 4
.
3. Using "O" Ring Remover (T71P-19703-C), remove felt dust seal and dust seal retainer from front head. Remove shaft seal retaining snap
ring. Position front head (nose up) on cardboard placed on a flat surface. Using Shaft Seal Remover (T89P-19623-E), push shaft seal
from front head. NOTE:After installing new clutch, ensure voltage is correct and cycle clutch with 5 seconds on and 5 seconds
off. Repeat cycle for approxim ately 20 tim es with A/C on, blower fan on high speed and engine RPM at
1500-2000. T his provides better clutch torque capability.
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Fig. 4: Exploded View of Nippondenso 10PA17 & 10PA17A 10
-Cyl Compressor
Courtesy of FORD MOTOR CO.
Installation
1. Lubricate new shaft seal with refrigerant oil. DO NOT touch sealing surfaces. Using Shaft Seal Installer (T89P-19623-F), press seal into
front head and install snap ring. Install felt dust seal and dust seal retainer.
2. Lubricate Shaft Seal Protector (T89D-19623-C) and front head "O" ring with refrigerant oil. Install shaft seal protector on crankshaft.
Install a new front head "O" ring on cylinder assembly.
3. Install front head on cylinder assembly. Ensure dowel pins are aligned. Use care when guiding shaft seal protector through seal opening.
Remove shaft seal protector.
4. Install through bolts with NEW brass washers. Diagonally tighten bolts to 19 ft. lbs. (26 N.m). Install clutch assembly. Add amount of
refrigerant oil that was drained to compressor. Install compressor. Evacuate and recharge system. Perform leak test.
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00039009
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Courtesy of MAZDA MOTORS CO., U.S.A.
NIPPONDENSO 6 & 10-CYL CLUTCH R & I
Removal
1. Remove A/C compressor. Remove pressure plate shaft bolt using socket wrench and Clutch Stopper (07112-76060). Install Clutch
Remover (07112-66040) on pressure plate. Using clutch stopper and socket wrench, rotate clutch remover to remove pressure plate.
2. Remove shims from pressure plate. Remove snap ring from compressor. Tap rotor off shaft with plastic hammer. Disconnect stator wire
from housing. Remove snap ring from inside stator. Remove stator. See Fig. 12
.
Installation
To install, reverse removal procedure. Ensure snap rings are installed with beveled side up. tighten shaft bolt to 10 ft. lbs. 14 N.m). Ensure
clutch clearance is .014-.026" (.36-66 mm). adjust clearance by adding or subtracting shims as necessary.
NIPPONDENSO 6 & 10-CYL SHAFT SEAL R & I
Removal
1. Hold clutch hub stationary and remove center nut. Screw remover into center of hub. Turn center bolt to remove pressure plate.
2. Remove shims from shaft. Remove snap ring from inside of pulley. Tap pulley off of shaft with plastic mallet. Be careful not to distort
pulley while removing.
3. Disconnect clutch coil wires from compressor housing. remove snap ring inside coil and lift coil off compressor. Pry dust seal out from
around compressor shaft (if equipped).
4. Place shaft key remover on shaft and turn to remove key. Remove drain plug (if equipped). Remove service valves-to-compressor body
bolts. Remove valves. Discard "O" rings. Drain oil out of compressor.
5. Remove 6 through bolts from front head of compressor and discard washers. Tap head loose from compressor; be careful not to scratch
sealing surfaces. remove snap ring (if equipped) from front housing. Press seal plate out. Remove seal from shaft. See Fig. 14
.
Installation
1. Lubricate shaft seal with clean refrigerant oil and place on compressor shaft. Lubricate seal plate and "O" ring (if equipped) and install
in front housing. Install snap ring (if equipped).
2. Place front housing on compressor body. Install through bolts with new washers. Tighten bolts evenly and alternately to 18 ft. lbs. (24
N.m). Install shaft key using installer and plastic mallet. Insert dust seal into front of compressor.
3. Install drain plug with new gasket. Add correct amount of refrigerant oil to compressor. If service valves were removed, coat n ew "O"
rings with refrigerant oil and install service valves.
4. Place clutch coil on compressor and install snap ring. Install shims on shaft to adjust pressure plate-to-rotor clearance to .016-
.028" (.41-.71 mm). Tighten shaft nut to 12 ft. lbs. (16 N.m). CAUTION: DO NOT dam age pulley when tapping on rotor.
NOTE:Check com pressor refrigerant oil level when replacing seals. See COMPRESSOR OIL CHECKING article
in the AIR CONDIT IONING & HEAT section.
Page 13 of 18 MITCHELL 1 ARTICLE - A/C COMPRESSOR SERVICING 1991 GENERAL SERVICING Compressor Service
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Fig. 29: Condensor Fan Trouble Chart CF9

Courtesy of FORD MOTOR CO.
REMOVAL & INSTALLATION
COMPRESSOR
Removal & Installation
1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect negative battery cable. Remove compressor
drive belt. Disconnect electrical connector. Disconnect refrigerant lines, and plug openings.
2. Remove compressor mounting bolts and compressor. See Fig. 1
. To install, reverse removal procedure. If installing a new compressor,
drain 1.2 ounces of refrigerant oil from compressor before installation. Evacuate and recharge system.
CONDENSER
Removal & Installation
1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove radiator grille. Remove right-side sight glass
cover. Disconnect refrigerant line from receiver-drier. Remove refrigerant line clamp from condenser bracket. Remove hood latch and
center brace bolts.
2. Remove condenser fan (if equipped). Remove condenser mounting bolts. Lift out condenser and mounting grommets. See Fig. 1
. To
install, reverse removal procedure. Ensure mounting grommets are properly positioned. Install new "O" rings on all refrigerant line.
Evacuate and recharge system.
RECEIVER-DRIER
Removal & Installation
Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove condenser. See CONDENSER under REMOVAL &
INSTALLATION. Disconnect refrigerant lines from receiver-drier, and plug openings immediately. Remove receiver-drier mounting bolts and
receiver-drier. See Fig. 1
. To install, reverse removal procedure. Use new "O" rings. Evacuate and recharge system.
EVAPORATOR HOUSING
Removal & Installation
1. Disconnect negative battery cable. Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect
evaporator outlet tubes (refrigerant lines), and plug openings. See Fig. 1
. Remove glove box. Disconnect 2 electrical connectors from
thermostatic switch.
2. Disconnect temperature control cable. See Fig. 4
. Remove wiring harness clamps from evaporator housing. Loosen clamp screws
securing connector duct to evaporator housing. Remove evaporator drain hose. Remove air inlet duct. See Fig. 2
.
3. Remove evaporator housing-to-dash panel bolts. Remove evaporator housing. To install, reverse removal procedure. Use new "O" rings.
Evacuate and recharge system.
EVAPORATOR
Removal & Installation
1. Remove evaporator housing. See EVAPORATOR HOUSING under REMOVAL & INSTALLATION. See Fig. 1 . Remove upper and
lower evaporator case half clips. Remove upper housing. Carefully pull sensing tube from evaporator core fins while removing
thermostat. Remove evaporator from lower housing. Remove stand-off insert from between inlet and outlet tubes.
2. Remove insulator from around capillary tube and thermostatic expansion valve. Remove capillary tube-to-suction tube clamp.
Disconnect evaporator tube fitting and thermostatic expansion valve. To install, reverse removal procedure. Use new "O" rings on all
refrigerant line connections. Evacuate and recharge system.
THERMOSTATIC SW ITCH
Removal & Installation
Remove evaporator housing. See EVAPORATOR HOUSING under REMOVAL & INSTALLATION. See Fig. 1. Remove 10 clips retaining
evaporator housing halves. Remove upper housing section. Remove thermostatic switch mounting screws. Carefully pull thermostat sensing
Page 12 of 14 MITCHELL 1 ARTICLE - 1991 AIR CONDITIONING & HEAT MANUAL A/C
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