1991 FORD FESTIVA Service Manual

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 tim es with engine at idle speed to prevent clutch slippage.
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Fig. 3: View of 10P13, 10P15 & 10P15F 10
-Cyl Compressor
Courtesy of FORD MOTOR CO.
NIPPONDENSO 10P15, 10P15F 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. 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. Install pulley assembly, using Pulley Installer (T80L-19703-J) and hammer (if necessary). Install snap ring with beveled side outward.
Install clutch plate shims.
3. Ensure clutch plate aligns with crankshaft key. Using Clutch Plate Installer (T80L-19703-F), install clutch plate. Install crankshaft nut.
Using spanner, tighten nut to 10-14 ft. lbs. (13-20 N.m). DO NOT tighten nut with air tools.
4. 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.
NIPPONDENSO 10P15A CLUTCH ASSEMBLY
Removal
1. Hold pulley assembly with Strap Wrench (D85L-6000-A). Apply battery voltage to clutch coil assembly and remove crankshaft nut.
Screw Clutch Plate Remover (T88C-19703-BH) into clutch plate and remove clutch plate from compressor. Remove clutch plate shims.
2. Remove snap ring and clutch pulley assembly. If pulley cannot easily be removed, use plastic hammer and tap pulley from shaft.
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. Install pulley.
2. Ensure pulley bearing is aligned with compressor head. Gently tap pulley on shaft with plastic hammer (if necessary). Install pulley
retaining snap ring.
3. Install shims and clutch plate. Install crankshaft nut and tighten to 10-12 ft. lbs. (14-16 N.m). DO NOT tighten nut with air tools. Using
feeler gauge, measure clearance between clutch plate and pulley in several different areas. Proper clearance is .016-.028" (.41-.71 mm).
If clearance is not correct, add or remove shims.
NIPPONDENSO 10P15, 10P15F 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. Mount compressor in vise claMFIng on mounting ears. Using Spanner (T81P-19623-MH), hold clutch plate and remove crankshaft nut.
Pull clutch plate from compressor using Clutch Plate Remover (T80L-19703-B). Remove clutch plate shims.
3. Clean compressor front hub area. Remove felt packing and dust seal retainer from inside compressor nose. See Fig. 3
. Using Shaft Key
Remover (T81P-19623-NH), remove key from shaft.
4. Remove seal seat retaining snap ring. Clean inner bore of compressor nose. Using Shaft Seat Remover/Installer (T87P-19623-B), remove
seal seat.
NOTE:Rem ove com pressor when clearance is not adequate for clutch assem bly rem oval.
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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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Back To Article
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.
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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, remo ve
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.
Remo ve "O" rin g 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.
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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. Remo ve sn ap
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 remo ve sh aft
nut.
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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 disengagin g
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
.
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