tow FORD FESTIVA 1991 Owner's Manual

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GENERAL INFORMATION
Gear T ooth Contact Patterns
* PLEASE READ THIS FIRST *
INSPECTION
Wipe lubricant from internal parts. Rotate gears and inspect for wear or damage. Mount dial indicator to housing and check backlash at several
points around ring gear. Backlash must be within specification at all points. If no defects are found, check gear tooth pattern contact.
GEAR TOOTH CONTACT PATTERN
1. Paint ring gear teeth with marking compound. Wrap cloth or rope around drive pinion flange to act as brake. Rotate gear until clear
contact pattern is obtained.
2. Contact pattern will indicate whether correct pinion bearing mounting shim has been installed and if drive gear backlash has been set
properly. Backlash between drive gear pinion must be maintained within specified limits until correct tooth pattern is obtained.
ADJUSTMENTS
GEAR BACKLASH & PINION SHIM CHANGES
1. With no change in backlash, moving pinion further from ring gear moves drive pattern toward heel and top of tooth, and moves coast
pattern toward toe and top of tooth.
2. With no change in backlash, moving pinion closer to ring gear moves drive pattern toward toe and bottom of tooth, and moves coast
pattern toward heel and bottom of tooth.
3. With no change in pinion shim thickness, an increase in backlash moves ring gear further from pinion. Both drive and coast patterns
move toward heel and top of tooth.
4. With no change in pinion shim thickness, a decrease in backlash moves ring gear closer to pinion gear. Both drive and coast patterns
move toward toe and bottom of tooth. NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For m odel-specific inform ation see appropriate articles where
available.
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For m odel-specific inform ation see appropriate articles where
available.
NOTE:Drive pattern should be well centered on ring gear teeth. Coast pattern should be centered, but m ay be
slightly toward toe of ring gear teeth.
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For m odel-specific inform ation see appropriate articles where
available.
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For m odel-specific inform ation see appropriate articles where
available.
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For m odel-specific inform ation see appropriate articles where
available.
Page 1 of 2 MITCHELL 1 ARTICLE - GENERAL INFORMATION Gear Tooth Contact Patterns
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GENERAL INFORMATION
Engine Perform ance Safety Precautions
Always refer to Emission Decal in engine compartment before servicing vehicle. If manual and decal differ, always use decal
specifications.
Do not allow or create a condition of misfire in more than one cylinder for an extended period of time. Damage to converter may occur
due to loading converter with unburned air/fuel mixture.
Always turn ignition off and disconnect negative battery cable BEFORE disconnecting or connecting computer or other electrical
components.
DO NOT drop or shock electrical components such as computer, airflow meter, etc.
DO NOT use fuel system cleaning compounds that are not recommended by the manufacturer. Damage to gaskets, diaphragm materials
and catalytic converter may result.
Before performing a compression test or cranking engine using a remote starter switch, disconnect coil wire from distributor and secure it
to a good engine ground, or disable ignition.
Before disconnecting any fuel system component, ensure fuel system pressure is released.
Use a shop towel to absorb any spilled fuel to prevent fire.
DO NOT create sparks or have an open flame near battery.
If any fuel system components such as hoses or clamps are replaced, ensure they are replaced with components designed for fuel system
use.
Always reassemble throttle body components with new gaskets, "O" rings and seals.
If equipped with an inertia switch, DO NOT reset switch until fuel system has been inspected for leaks.
We a r sa fe t y go ggl e s wh e n d r il l in g o r gr in d in g.
Wear proper clothing which protects against chemicals and other hazards.
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00002342
Page 1 of 1 MITCHELL 1 ARTICLE - GENERAL INFORMATION Engine Performance Safety Precautions
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The voltage controlled driver inside the computer operates much like a simple switch because it does not need to worry about limiting current
flow. Recall, this driver typically requires injector circuits with a total leg resistance of 12 or more ohms.
The driver is either ON, closing/completing the circuit (eliminating the voltage-drop), or OFF, opening the circuit (causing a total voltage
drop).
Some manufacturers call it a "saturated switch" driver. This is because when switched ON, the driver allows the magnetic field in the injector
to build to saturation. This is the same "saturation" property that you are familiar with for an ignition coil.
There are two ways "high" resistance can be built into an injector circuit to limit current flow. One method uses an external solenoid resistor
and a low resistance injector, while the other uses a high resistance injector without the solenoid resistor. See the left side of Fig. Fig. 1
.
In terms of injection opening time, the external resistor voltage controlled circuit is somewhat faster than the voltage controlled high resistance
injector circuit. The trend, however, seems to be moving toward use of this latter type of circuit due to its lower cost and reliability. The ECU
can compensate for slower opening times by increasing injector pulse width accordingly.

Fig. 1: Injector Driver Types
- Current and Voltage
CURRENT CONTROLLED CIRCUIT ("PEAK & HOLD")
The current controlled driver inside the computer is more complex than a voltage controlled driver because as the name implies, it has to limit
current flow in addition to its ON-OFF switching function. Recall, this driver typically requires injector circuits with a total leg resistance of
less than 12 ohms.
Once the driver is turned ON, it will not limit current flow until enough time has passed for the injector pintle to open. This period is preset by
the particular manufacturer/system based on the amount of current flow needed to open their injector. This is typically between two and six
amps. Some manufacturers refer to this as the "peak" time, referring to the fact that current flow is allowed to "peak" (to open the injector).
Once the injector pintle is open, the amp flow is considerably reduced for the rest of the pulse duration to protect the injector from
overheating. This is okay because very little amperage is needed to hold the injector open, typically in the area of one amp or less. Some
manufacturers refer to this as the "hold" time, meaning that just enough current is allowed through the circuit to "hold" the already-open
injector open.
There are a couple methods of reducing the current. The most common trims back the available voltage for the circuit, similar to turning down
a light at home with a dimmer.
The other method involves repeatedly cycling the circuit ON-OFF. It does this so fast that the magnetic field never collapses and the pintle
stays open, but the current is still significantly reduced. See the right side of Fig. Fig. 1
for an illustration.
The advantage to the current controlled driver circuit is the short time period from when the driver transistor goes ON to when the injector
actually opens. This is a function of the speed with which current flow reaches its peak due to the low circuit resistance. Also, the injector
closes faster when the driver turns OFF because of the lower holding current.
THE TWO WAYS INJECTOR CIRCUITS ARE WIRED
NOTE:Never apply battery voltage directly across a low resistance injector. T his will cause injector dam age
from solenoid coil overheating.
NOTE:Never apply battery voltage directly across a low resistance injector. T his will cause injector dam age
from solenoid coil overheating.
Page 5 of 19 MITCHELL 1 ARTICLE - GENERAL INFORMATION Waveforms - Injector Pattern Tutorial
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1991 GENERAL SERVICING
A/C Com pressor Refrigerant Oil Checking
ISOLATING COMPRESSOR
1. Connect service gauge set to the compressor service valves and open compressor valves slightly (turn in clockwise). Start engine and
operate air conditioning. Slowly turn compressor suction valve clockwise toward closed (front-seated) position.
2. When suction pressure is reduced to zero or less, turn off engine and compressor and quickly turn suction valve stem in to full front-
seated position. Suction pressure should be slightly above zero. Turn discharge valve into front-seated position.
3. To check oil level, slowly open compressor crankcase plug to relieve any remaining pressure. After oil level is corrected, cap service
gauge ports on both valves. Back-seat suction service valve to allow refrigerant to enter compressor. Open discharge valve halfway.
4. Loosen discharge service valve cap, allowing refrigerant pressure to force air out of compressor. Back-seat service valve and tighten cap.
Compressor is now ready for operation.
REFRIGERANT OIL
Only new, pure, moisture-free refrigerant oil should be used in the air conditioning system. This oil is highly refined and dehydrated to a point
where moisture content is less than 10 parts per million. The oil container must be tightly closed at all times when not in use, or moisture will
be absorbed into the refrigerant oil from the air.
SERVICING PRECAUTIONS
DISCHARGING SYSTEM PRECAUTIONS
If compressor has stem-type service valves, it can be isolated and removed without discharging entire system. See ISOLATING
COMPRESSOR at the beginning of this article. Otherwise, discharge system completely before loosening any fittings.
DISCONNECTING LINES & FITTINGS TEST
After system is discharged, carefully clean area around all fittings to be opened. Always use 2 wrenches when tightening or loosening fittings
to avoid twisting or distorting lines. Cap or plug all openings as soon as lines are removed. DO NOT remove caps until immediately before
connections are made. This will keep entry of air and moisture to a minimum.
CONNECTING LINES AND FITTINGS
A new gasket or "O" ring should be used in all instances when connecting lines or fittings. Dip "O" ring in new refrigerant oil and ensure it is
not twisted during installation. Always use 2 wrenches to prevent damage to lines and fittings.
PLACING SYSTEM IN OPERATION
After component service or replacement has been completed and all connections have been made, evacuate system thoroughly with a vacuum
pump. Charge system with proper amount of refrigerant and perform a leak test. See REFRIGERANT OIL & R-12 SPECIFICATIONS chart in
this section for system capacities. Be sure to check all fittings that have been opened. After system has been leak tested, make a system
performance check.
ATSUGI ROTARY VANE DRAIN & REFILL
1. Before checking and adjusting oil level, operate compressor at engine idling speed, with controls set for maximum cooling and high
blower speed, for 20 to 30 minutes to return oil to compressor.
2. Stop engine, discharge refrigerant and remove compressor from vehicle. See SERVICING PRECAUTIONS at beginning of article. Drain
compressor oil from compressor discharge port and measure the amount. Oil is sometimes hard to drain when compressor is cool.
Remove oil while compressor is warm.
3. If the amount drained is less than 3 ounces, conduct leak tests at system connections, and if necessary, repair or replace faulty parts.
Check purity of oil and adjust oil level as follows.
4. If amount drained was above 3 ounces, oil level is right. Pour in same amount as was drained. If amount drained was below 3 ounces,
pour in 3 ounces of new refrigerant oil.
BOSCH 6-CYL DRAIN & REFILL
1. Before checking and adjusting oil level, operate compressor at engine idling speed, with controls set for maximum cooling and high
blower speed, for 20 to 30 minutes to return oil to compressor.
2. Stop engine and discharge refrigerant. Remove refrigerant oil level inspection plug on side of compressor. Oil should be at lower lip of
threaded hole. Add necessary new refrigerant oil (if low). Replace inspection plug and tighten to 10-12 ft. lbs. (14-16 N.m). NOTE:Only com pressors with stem -type service valves can be isolated.
NOTE:Recent findings by the EPA indicate that refrigerant is harm ful to the earth's protective Ozone layer.
When discharging refrigerant, DO NOT allow refrigerant to enter the atm osphere. If available, use
refrigerant recovery/recycle system s when discharging system . Always follow m anufacturer's
instructions.
NOTE:Air conditioning system s will not norm ally need addition of refrigerant oil unless definite oil loss has
occurred due to ruptured lines, leaking com pressor seals, com pressor overhaul or com ponent
replacem ent.
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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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A/C COMPRESSOR SERVICING
1991 GENERAL SERVICING Com pressor Service
ISOLATING COMPRESSOR
1. Connect service gauge set to the compressor service valves and open compressor valves slightly (turn in clockwise). Start engine and
operate air conditioning. Slowly turn compressor suction valve clockwise toward closed (front-seated) position.
2. When suction pressure is reduced to zero or less, turn off engine and compressor and quickly turn suction valve stem in to full front-
seated position. Suction pressure should be slightly above zero. Turn discharge valve into front-seated position.
3. To check oil level, slowly open compressor crankcase plug to relieve any remaining pressure. After oil level is corrected, cap service
gauge ports on both valves. Back-seat suction service valve to allow refrigerant to enter compressor. Open discharge valve halfway.
4. Loosen discharge service valve cap, allowing refrigerant pressure to force air out of compressor. Back-seat service valve and tighten cap.
Compressor is now ready for operation.
REFRIGERANT OIL
Only new, pure, moisture-free refrigerant oil should be used in the air conditioning system. This oil is highly refined and dehydrated to a point
where moisture content is less than 10 parts per million. The oil container must be tightly closed at all times when not in use, or moisture will
be absorbed into the refrigerant oil from the air.
DISCHARGING SYSTEM PRECAUTIONS
If compressor has stem-type service valves, it can be isolated and removed without discharging entire system. Otherwise, discharge system
completely using approved refrigerant recovery/recycling equipment before loosening any fittings.
DISCONNECTING LINES & FITTINGS TEST
After system is discharged, carefully clean area around all fittings to be opened. Always use 2 wrenches when tightening or loosening fittings
to avoid twisting or distorting lines. Cap or plug all openings as soon as lines are removed. Do not remove caps until immediately before
connections are made. This will keep entry of air and moisture to a minimum.
CONNECTING LINES AND FITTINGS
A new gasket or "O" ring should be used in all instances when connecting lines or fittings. Dip "O" ring in new refrigerant oil and ensure it is
not twisted during installation. Always use 2 wrenches to prevent damage to lines and fittings.
PLACING SYSTEM IN OPERATION
After component service or replacement has been completed and all connections have been made, evacuate system thoroughly with a vacuum
pump. Charge system with proper amount of refrigerant and perform a leak test. See REFRIGERANT OIL & R-12 SPECIFICATIONS chart in
this section for system capacities. Be sure to check all fittings that have been opened. After system has been leak tested, make a system
performance check.
ATSUGI ROTARY VANE CLUTCH R & I
Removal
When replacing compressor clutch, be careful not to scratch shaft or bend pulley. When removing center bolt, hold clutch disc with Clutch
Holder (KV99231010). Using Hub Puller (KV998VR001 & KV99231010), remove clutch disc. When removing pulley, remove lock nut with
Hub Socket (KV99235160).
Installation
Wipe oil off clutch surface. Adjust disc pulley clearance to .012-.024" (.3-.6 mm). Tighten center bolt to 80-104 INCH lbs. (9.1-11.8 N.m).
Tighten clutch lock nut to 22-29 ft. lbs. (29-39 N.m). See Fig. 1
. 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.
NOTE:Only com pressors with stem -type service valves can be isolated.
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.
NOTE:Air conditioning system s will not norm ally need addition of refrigerant oil unless definite oil loss has
occurred due to ruptured lines, leaking com pressor seals, com pressor overhaul or com ponent
replacem ent.
Page 1 of 18 MITCHELL 1 ARTICLE - A/C COMPRESSOR SERVICING 1991 GENERAL SERVICING Compressor Service
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Fig. 5: Diesel Kiki 6
-Cylinder Compressor
Courtesy of MITSUBISHI MOTOR SALES OF AMERICA.
FORD FX-15 CLUTCH R & I
Removal
1. Using Clutch Holder (00 41 0812 05), remove clutch plate retaining bolt and discard. Using an 8 mm bolt threaded into clutch plate,
remove clutch plate and shim(s). See Fig. 6
.
2. Remove snap ring and pulley assembly. Install Shaft Protector (49 UN01 47) over shaft seal opening. Use a 2-jaw puller to remove
clutch coil from compressor.
Installation
1. Ensure clutch coil mounting surface is clean. Use Coil Installer (49 UN01 046) and 2-jaw puller engaged to rear side of compressor
front mounts to press coil into place.
2. Install pulley assembly. Install pulley assembly snap ring with bevel side of snap ring facing out. Install shim(s) and clutch plate. Install
a NEW clutch plate retaining bolt and tighten to 96-120 INCH lbs. (11-14 N.m).
3. Use a feeler gauge to check clearance between clutch plate and pulley assembly. Clearance should be .018-.033" (.46-.84 mm). If
clearance is incorrect, add or remove shims as necessary.
FORD FX-15 SHAFT SEAL R & I
Removal
1. Using Clutch Holder (000 41 0812 05), remove clutch plate retaining bolt and discard. Using an 8 mm bolt threaded into clutch plate,
remove clutch plate and shim(s). See Fig. 6
.
2. Remove shaft felt seal. Thoroughly clean seal area of compressor. Remove shaft seal retaining snap ring. Position Shaft Seal Remover
(49 UN01 044) over compressor shaft.
3. Push shaft seal remover downward against seal. Ensure end of shaft seal remover is engaged with inside of seal. Rotate shaft seal
remover clockwise to expand remover tip inside seal. Pull shaft seal from compressor.
Installation
1. Lubricate shaft seal protector and shaft seal with refrigerant oil. Install shaft seal on shaft seal protector so lip seal is toward compressor
(large end of shaft seal protector).
2. Install shaft seal protector on compressor shaft. Using shaft seal installer (49 UN01 043), push shaft seal down seal protector until seal
is seated.
3. Remove shaft seal installer and protector. Install a NEW shaft seal retaining snap ring and shaft seal felt. Install shim(s) and clutch plate.
Install a NEW clutch plate retaining bolt and tighten to 91-120 INCH lbs. (11-14 N.m).
4. Use a feeler gauge to check clearance between clutch plate and pulley assembly. Clearance should be .018-.033" (.46-.84 mm). If
clearance is incorrect, add or remove shims as necessary.
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1991 GENERAL SERVICING
A/C System Specifications - Applications & Oil/R-12 Capacities
COMPRESSOR APPLICATIONS - PASSENGER CARS
COMPRESSOR APPLICATIONS - PASSENGER CARS
COMPRESSOR APPLICATIONS - LIGHT TRUCKS & VANS
COMPRESSOR APPLICATIONS - LIGHT TRUCKS & VANS
BODY CODE DESIGNATIONS - LIGHT TRUCKS & VANS
BODY CODE DESIGNATIONS - LIGHT TRUCKS & VANS
REFRIGERANT OIL & R-12 CAPACITY - PASSENGER CARS
PASSENGER CAR REFRIGERANT OIL & R-12 CAPACITY
ApplicationCompressor
ContinentalFord FX-15 10-Cyl.
Cougar & ThunderbirdFord FX-15 10-Cyl.
Crown Victoria, Grand Marquis & Town CarFord FX-15 10-Cyl.
Escort & TracerNippondenso 10P13 10-Cyl.
Mark VIINippondenso 10PA17 10-Cyl.
Mustang
2.3L EngineNippondenso 10P15 10-Cyl.
5.0L EngineNippondenso 6P-148 6-Cyl.
Probe
2.2L EngineNippondenso 10P15A 10-Cyl.
3.0L EngineNippondenso 10P15 10-Cyl.
Sable & Taurus
2.5L EngineFord FS-6 6-Cyl.
3.0L & 3.8L EnginesFord FX-15 10-Cyl.
3.0L SHO EngineNippondenso 10P15F 10-Cyl.
Tempo & TopazNippondenso 10P15 10-Cyl.
ApplicationCompressor
AerostarFord FX-15 10-Cyl.
BroncoFord FX-15 10-Cyl.
"E " SeriesFord FS-6 6-Cyl.
ExplorerFord FX-15 10-Cyl.
"F" Series
7.3L DieselFord FS-6 6-Cyl.
Gas Engine ModelsFord FX-15 10-Cyl.
Ranger
2.3L EngineFord FX-15 10-Cyl.
2.9L EngineFord FS-6 6-Cyl.
4.0L EngineFord FX-15 10-Cyl.
ModelDesignation
Aerostar"A" Series
Bronco & Explorer"U" Series
Pickups (Full Size)"F" Series
Ranger"R" Series
Vans (Full Size)"E " Series
Application(1) Oil OuncesR-12 Ounces
Continental8.040
Cougar & Thunderbird7.040
Crown Victoria, Grand Marquis & Town Car7.040-48
Escort & Tracer8.036
Mark VII8.040
Mustang
10P15 Compressor8.040
6P148 Compressor10.040
Probe
10P15 Compressor8.040
10P15A Compressor3.340
Sable & Taurus
FS-6 Compressor10.044
FX-15 Compressor7.044
10P15 Compressor8.040
Page 1 of 2 MITCHELL 1 ARTICLE - 1991 GENERAL SERVICING A/C System Specifications - Applications & Oil/R-12 Capacities
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MAINTENANCE INFORMATION
1988-93 MAINT ENANCE Ford Motor Co. Maintenance Inform ation
MODEL IDENTIFICATION
VIN LOCATION
The Vehicle Identification Number (VIN) is located on the left side of the dash panel at the base of the windshield. The VIN chart explains the
code characters.
VIN CODE ID EXPLANATION
Numbers preceding the explanations in the legend below refer to the sequence of characters as listed on VIN identification label. See VIN
example below.

Fig. 1: VIN Code ID Explanation

MAINTENANCE SERVICE INFORMATION
SEVERE & NORMAL SERVICE DEFINITIONS
Service is recommended at mileage intervals based on vehicle operation. Service schedules are based on the following primary operating
conditions:
Severe Service
Short Trips (About 10 Miles) In Freezing Temperatures
Towing Or Heavily Loaded
Severe Dust Conditions
Hot Weather, Stop-And-Go Driving
Extensive Idling Conditions (Taxi Or Delivery Type Service)
Normal Service
NOTE:For scheduled m aintenance intervals and the related fluid capacities, fluid specifications and labor
tim es for m ajor service intervals, see SCHEDULED SERVICES article in this section. Warranty
inform ation and specifications for fluid capacities, lubrication specifications, wheel and tire size, and
battery type are covered in this article.
NOTE:Use the Severe Service schedule if the vehicle to be serviced is operated under ANY (one or m ore) of
these conditions:
Page 1 of 9 MITCHELL 1 ARTICLE - MAINTENANCE INFORMATION 1988-93 MAINTENANCE Ford Motor Co. Maintenance Inform...
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