1991 FORD FESTIVA adding oil

CALSONIC V5 5-CYLINDER
1. Before checking and adjusting oil level, operate compressor at 1000-1500 engine RPM, and set controls at maximum cooling and
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. Drain compressor oil from compressor discharge port and measure oil amount. Oil may be hard to drain if compressor is cool.
Drain oil while compressor is warm.
3. If amount drained is less than 3.2 ounces, conduct leak tests at system connections. Repair or replace faulty parts as necessary. Check
purity of oil and oil level as follows.
4. If amount drained is more than 3.2 ounces, oil level is okay; fill with same amount drained using new oil. If amount drained is less than
3.2 ounces, pour in 3.2 ounces of new refrigerant oil.
DIESEL KIKI 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 the beginning of this
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 is less than 2.4 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 2.4 ounces, oil level is right. Pour in same amount as was drained. If amount drained was below 2.4
ounces, pour in 2.4 ounces of new refrigerant oil.
DIESEL KIKI 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, 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 was more than 2 ounces (4.4 ounces for Infinity), refill with same amount of new oil. If amount drained was less than
2 ounces (4.4 ounces for Infinity), refill with 2 ounces (4.4 ounces for Infinity). Install filler plug and recharge system.
FORD FX-15 6-CYLINDER DRAIN & REFILL
1. Slowly discharge system. Remove A/C compressor. Drain compressor oil from suction and discharge ports. Measure amount drained and
discard oil.
2. If amount drained from removed (old) compressor is between 3 and 5 ounces, add drained amount of new SUNINSO 5GS refrigerant oil
into the NEW compressor through suction port.
3. If amount drained is less than 3 ounces, add 3 ounces to the NEW compressor. If amount drained is more than 5 ounces, add 5 ounces.
Use new "O" rings on refrigerant lines. Install A/C compressor. Evacuate and recharge system. Perform leak test.
HARRISON 4-CYL DRAIN & REFILL
The Harrison 4-cyl compressor is charged (new) with 6 ounces of refrigerant oil. Because compressor does not have an oil sump, it should not
have to be removed for oil measurement (it retains very little oil). Note the following situations for checking and adding oil to this compressor.
NO OIL LEAK; REPLACING COMPONENTS
If only the compressor is to be replaced, remove, drain oil, measure and reinstall an equal amount of new oil. If evaporator is being replaced,
add 3 ounces of new oil. If condenser is being replaced, add one ounce.
LOSS OF REFRIGERANT OVER EXTENDED PERIOD
When a loss of refrigerant has occurred over an extended period of time and a component is being replaced to correct the leak, add an
appropriate amount of refrigerant oil to the component.
SIGNS OF EXCESSIVE OIL LEAKAGE
If system has lost excessive oil, remove accumulator. Drain and measure oil. If more than 3 ounces is measured, replace the same amount of
new oil as was drained. If less than 3 ounces is measured, add 3 ounces of new oil. Add and additional 2 ounces of new oil to compensate for
that lost by replacing the accumulator (held in desiccant).
HARRISON V5 5-CYLINDER DRAIN & REFILL
1. If system is operable, run for several minutes to stabilize system before performing repairs. Turn off engine. Discharge system and
remove compressor. See SERVICING PRECAUTIONS at the beginning of this article. Remove drain plug. Drain and measure oil. NOTE:Replacem ent FX-15 com pressors contain 7 ounces of refrigerant oil. Prior to installing com pressor,
drain refrigerant oil and determ ine proper am ount of refrigerant oil to be added.
NOTE:T he Harrison com pressor DOES NOT have an oil sum p. It's crucial that the com pressor rem ains well
oiled. It takes very little tim e to destroy this com pressor if it runs dry.
NOTE:If the exact oil charge is in doubt, drain and flush system . Add a new 6-ounce charge of refrigerant oil to
the system .
Page 2 of 4 MITCHELL 1 ARTICLE - 1991 GENERAL SERVICING A/C Compressor Refrigerant Oil Checking
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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. 14: Nippondenso 6
-Cylinder Compressor
Courtesy of CHRYSLER MOTORS.
PANASONIC ROTARY VANE CLUTCH R & I
Removal
1. Insert two 5 mm bolts into threaded holes in armature. Using screwdriver as a lever in between bolts, remove center bolt. Remove
armature and shims from shaft.
2. remove snap ring. Using puller, remove pulley. Disconnect electrical leads from field coil. Remove 3 field coil mounting bolts. Remove
field coil.
Inspection
Check friction surfaces for damage from excessive heat or grooving caused by slippage. Replace parts as necessary. Check coil winding for
shorted or open winding. Clean surfaces with solvent and dry rag.
Installation
To install, reverse removal procedure. Tighten field coil retaining screws to 30-56 INCH lbs. (3.4-6.4 N.m). Ensure pulley-to-armature gap
is .016-.024" (.4-.6 mm). If gap is not as specified, adjust by adding or removing shims. Tighten center bolt to 96-108 INCH lbs. (11-13 N.m).
See Fig. 15
.
Page 14 of 18 MITCHELL 1 ARTICLE - A/C COMPRESSOR SERVICING 1991 GENERAL SERVICING Compressor Service
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compressor label before adding refrigerant oil to A/C compressor/system. See Fig. 2 . The following R-134a refrigerant oils are currently
available.
Lexus
PAG Refrigerant Oil (ND-OIL 8) with 10P/10PA swashplate (piston) compressor. Synthetic Refrigerant Oil (ND-OIL 9) with through-va n e
(rotary vane) compressor.
Mercedes-Benz
PAG Refrigerant Oil (001 989 08 03).
Nissan
PAG Refrigerant Oil (KLH00-PAGR0) with rotary vane compressor. PAG Refrigerant Oil (KLH00-PAGS0) with piston (swashplate)
compressor.
Saab
PAG Refrigerant Oil (40 74 787).
SERVICE EQUIPMENT
Because R-134a is not interchangeable with R-12, separate sets of hoses, manifold gauge set and recovery/recycling equipment are required to
service vehicles. This is necessary to avoid cross-contaminating and damaging system.
All equipment used to service systems using R-134a must meet SAE standard J1991. The service hoses on the manifold gauge set must have
manual (turn wheel) or automatic back-flow valves at the service port connector ends. This will prevent refrigerant from being released into
the atmosphere.
For identification purposes, R-134a service hoses must have a Black stripe along its length and be clearly labeled SAE J2196/R-134a. The low
pressure test hose is Blue with a Black stripe. The high pressure test hose is Red with a Black stripe, and the center test hose is Yellow with a
Black stripe.
R-134a manifold gauge sets can be identified by one or all of the following.
Labeled FOR USE WITH R-134a on set
Labeled HFC-134 or R-134a on gauge face
Light Blue color on gauge face
In addition, pressure/temperature scales on R-134a gauge sets are different from R-12 manifold gauge sets.
SYSTEM SERVICE VALVES
SCHRADER-TYPE VALVES
Schrader valve is similar in construction and operation to a tire valve. When a test gauge hose with built-in valve core depressor is attached,
Schrader stem is pushed inward to the open position and allows system pressure to reach gauge.
If test hose does not have a built-in core depressor, an adapter must be used. Never attach hose or adapter to Schrader valve unless it is first
connected to manifold gauge set.
Refrigerant R-12 Schrader-type valve cores have TV5 thread size. Refrigerant R-134a Schrader-type valve cores use M6 (Metric) threads. R-
134a valve cores can be easily identified by use of "O" rings and external spring. See Fig. 1
.
SERVICE VALVE LOCATIONS
SERVICE VALVE LOCATIONS NOTE:Synthetic/PAG oils absorb m oisture very rapidly, 2.3-5.6% by weight, as com pared to a m ineral oil
absorption rate of .005% by weight.
NOTE:Refrigerant R-12 service hoses will ONLY be labeled SAE J2196.
NOTE:Although sim ilar in construction and operation to a tire valve, NEVER replace a Schrader-type valve
with a tire valve.
VehicleHighLow
Audi(14) (15)
Acura(2) (3)
BMW(4) (5)
Chrysler, Eagle & Mitsubishi
Colt, Mirage & Summit(10) (11)
Colt Vista & Summit Wagon(10) (11)
Diamante(1) (1)
Eclipse & Expo(10) (11)
Galant(10) (11)
Page 4 of 6 MITCHELL 1 ARTICLE - 1991-92 AIR CONDITIONING & HEATING A/C System General Servicing
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Fig. 25: Measuring Differential Bearing Preload

Courtesy of FORD MOTOR CO.
3. Unthread gauge tool until differential bearings are seated. Install Differential Rotator into differential assembly. Using INCH lb. torque
wrench, rotate differential assembly while unthreading gauge tool. Unthread gauge tool until 4.3 INCH lbs. (.5 N.m) of turning torque is
obtained.
4. Using feeler gauge, measure gap of gauge tool. Select correct thrust shim(s) by adding .006" (.15 mm) to measured gauge tool ga p . S h ims
are available from in thicknesses of .043" (1.08 mm) to .079" (2.00 mm) in .040 mm increments.
5. Disassemble case halves. Remove gauge set and spacers. Install selected shim(s) in transaxle case. DO NOT exceed 3 shims. Remove
bearing race from gauge tool and install race in transaxle case. Reassemble transaxle case halves. Install bolts and tighten bolts to
specification. See TORQUE SPECIFICATIONS
.
6. Install Differential Rotator (T88C-77000-L) into differential assembly. Using INCH lb. torque wrench, rotate differential assembly to
confirm correct bearing preload. Turning torque should be 18-25 INCH lbs. (21.-2.8 N.m). If turning torque is not within specification,
repeat steps 1) through 6).
FINAL REASSEMBLY
1. Install low-reverse brake piston by applying even pressure on perimeter of piston while rotating slowly. Install 20 return springs and
low-reverse brake hub. Using appropriate compressor, compress return spring and install snap ring. See Fig. 9
.
2. Install dished plate with small end of dish facing away from piston. Install clutch discs, retainer ring and one-way clutch. Install one-
way clutch machined surface toward retainer ring. Install snap ring.
3. Using a feeler gauge, ensure clearance between one-way clutch and retainer plate is .031-.041" (.80-1.05 mm). If clearance is not within
specification, select correct retainer plate to obtain correct clearance. Retainer plates are available in thicknesses of .063" (1.60 mm)
to .102" (2.60 mm) in .20 mm increments. Apply air pressure to low-reverse oil passage and check for proper clutch operation. See Fig.
10 .
4. Place converter housing on bench with output shaft facing upward. Install needle bearing over output shaft. Install drum hub assembly
onto output shaft spline. Install needle bearing with thrust washer in recess of drum hub. Install rear planetary carrier onto one-way
clutch race. Install snap ring. Install rear planetary assembly into drum hub. Install oil tubes into transaxle case.
5. Install governor into transaxle case. Ensure alignment mark on governor sleeve is aligned with mark on transaxle case. Install go ve r n o r
cover.Tighten bolts to specification. Refer to TORQUE SPECIFICATIONS
. Apply appropriate gasket sealant to converter housing
and install transaxle case. Once case halves are secured in place, ensure all parts previously installed rotate without resistance.
6. Lubricate servo piston with ATF. Assembly servo retainer, piston, piston large seal and spring. Insert assembly into transaxle. Usin g "C"
clamp and socket, compress assembly and install snap ring.
7. Install thrust bearing and thrust washer. Install sun gear shell with sun gear spacer and sun gear. See Fig. 8
. Install front planetary
carrier with thrust washer onto sun gear. Install thrust washer and thrust bearing onto front of front planetary carrier.
8. Install seal sleeve to center of front planetary carrier. Install front ring gear. Install front ring gear needle bearing with rollers facing
upward. Install thrust washer. Match tangs on thrust washer with mating holes in rear clutch assembly.
9. Install rear clutch assembly. Install needle bearing. Companion thrust washer is fitted to oil pump support later in reassembly procedure.
Install front clutch assembly. Install band, band strut and band adjusting stop. Tighten band adjusting stop until band is secured in
place.
TOTAL END PLAY ADJUSTMENT
1. Remove oil pump cover from oil pump housing. Set oil pump housing aside. Coat pump support thrust washer with petroleum jelly and
install on end of pump support. Ensure washer tangs mate with holes in pump support.
2. Install pump cover in front clutch drum. DO NOT have front drum adjusting thrust shim installed. Place a straightedge across transaxle
NOTE:Low/reverse snap ring m ay not have been installed during production. Snap ring is required
during overhaul reassem bly.
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