Ford Festiva. Instruction - part 79

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:

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

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 from

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. If

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 approximately 20 times with A/C on, blower fan on high speed and engine RPM at
1500-2000. This provides better clutch torque capability.

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.

Article GUID: A00039009

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A/C COMPRESSOR SERVICING

1991 GENERAL SERVICING Compressor 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

CAUTION:

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

NOTE:

Only compressors with stem-type service valves can be isolated.

CAUTION:

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

NOTE:

Air conditioning systems will not normally need addition of refrigerant oil unless definite oil loss has
occurred due to ruptured lines, leaking compressor seals, compressor overhaul or component
replacement.

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