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A/c Compressor Servicing: Removal & Installation Ford Contour I

General Servicing - All Makes 3 illustrations ~1031 words

Removal

  1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove compressor. Using Spanner (T94P-19703-AH), remove clutch plate bolt. Discard bolt. Thread an 8-mm bolt into clutch plate, and remove clutch plate and shims.
  2. Remove snap ring. Remove pulley assembly. (Scheme 21) Disconnect clutch coil lead. Install Shaft Protector (T89P-19623-FH) over compressor shaft.
  3. Install 2-jaw puller on compressor. Tighten puller to remove clutch coil from compressor. DO NOT use air-powered tools when removing clutch coil.

Installation

Note. When installing new clutch assembly, cycle clutch assembly 10 times with engine at idle to burnish clutch and prevent slippage.

  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. Engage jaws on puller with compressor front mounts.
  3. Tighten pressure screw, and install clutch coil. DO NOT use air-powered tools when installing clutch coil. Ensure clutch coil seats against compressor head at all contact points of mounting surface.
  4. Install pulley and snap ring. Install snap ring with beveled side away from compressor. Install shims and clutch plate. Install NEW clutch plate bolt, and tighten it 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 as specified, add or remove shims to obtain proper clearance.

Scheme 21

Scheme 21
Scheme 21
  1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove compressor. Using Spanner (T70P-4067-A), remove clutch plate bolt. Discard bolt. Thread an 8-mm bolt into clutch plate and remove clutch plate and shims.
  2. Remove shaft felt seal. Thoroughly clean seal area of compressor. Using Snap Ring Remover (T89P-19623-DH), rotate eye of snap ring. Pull up snap ring while holding snap ring at an angle.
  3. Position Shaft Seal Remover (T89P-19623-BH) over compressor shaft. Push shaft seal remover downward against seal. Ensure end of shaft seal remover engages inside of seal.
  4. Rotate shaft seal remover handle clockwise to expand remover tip inside seal. Pull shaft seal from compressor.
  1. Lubricate shaft seal protector and shaft seal with refrigerant oil. Replacement Seal Kit (19D665) includes Shaft Seal Protector (T94P-19623-F).
  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 down shaft seal until it is seated. Remove shaft seal installer and protector. Install NEW shaft seal snap ring.
  4. Install NEW shaft seal felt. Install clutch plate. Install new clutch plate bolt, and tighten it 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 as specified, add or remove shims to obtain proper clearance.
  1. Using Spanner (1014 on 10P13 or T81P-19623-MH on 10P15C and 10P15F), hold clutch plate and remove compressor shaft 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 clutch coil lead, and remove clutch coil.
  1. Install clutch coil over locating pin, and install snap ring. Connect clutch coil lead.
  2. Install pulley assembly using Pulley Installer (T80L-19703-J) and hammer (if necessary). Install snap ring with beveled side out. Install clutch plate shims.
  3. Ensure clutch plate aligns with compressor shaft key. Using Clutch Plate Installer (T80L-19703-F), install clutch plate. Install compressor shaft nut. Using spanner, tighten nut to 10-14 ft. lbs. (14-19 N.m). DO NOT tighten nut using air-powered 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 as specified, add or remove shims to correct clearance.
  1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove compressor. Drain oil from compressor, and measure drained amount.
  2. Mount compressor in vise, clamping it by mounting ears. Remove clutch plate and clutch plate shims. Remove front head from cylinder assembly.
  3. Clean compressor front hub area. Remove felt packing and dust seal retainer from inside compressor nose. (Scheme 22) Using Shaft Key Remover (T81P-19623-NH), remove key from shaft.
  4. Remove seal seat snap ring. Clean inner bore of compressor nose. Using Shaft Seat Remover/Installer (T87P-19623-BH), remove seal seat.
  5. Using Shaft Seal Remover/Installer (T87P-19623-AH), remove seal by pushing downward on shaft seal remover/installer and rotating clockwise to engage seal tangs. Pull seal from compressor.
  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 compressor shaft, and push new seal onto compressor shaft. Push downward on shaft seal remover/installer, and turn it counterclockwise to disengage seal tangs.
  3. Attach shaft seal seat to shaft seal seat remover/installer, and lubricate seal seat with new refrigerant oil. Install seal seat and push inward against seal. Install shaft seal seat snap ring.
  4. Install dust seal retainer and felt packing. Install clutch plate. Using new refrigerant oil, add to compressor the same amount of oil drained from it. Rotate compressor 10 revolutions to distribute oil. Install compressor. Evacuate and recharge system. Perform leak test.

Scheme 22

Scheme 22
Scheme 22

Removal & Installation

  1. Remove Allen head bolt from clutch hub. Remove clutch hub. Using snap ring pliers, remove clutch pulley snap ring. Remove clutch pulley from compressor shaft. (Scheme 23)
  2. Disconnect clutch coil lead. Release lead from safety clip (if equipped). Using Phillips screwdriver, remove clutch coil screws. Remove clutch coil. To install, reverse removal procedure. Tighten clutch hub bolt to 10 ft. lbs. (14 N.m).
  1. Remove compressor clutch assembly. Using scribe or small screwdriver, remove compressor shaft felt dust seal. Use Remover/Installer (T92C-19623-AH) to remove compressor shaft seal.
  2. Using Remover/Installer (T92C-19623-BH), carefully remove compressor shaft seal. Inspect compressor shaft for scratches or score marks. Repair or replace compressor as necessary. To install, reverse removal procedure.

Scheme 23

Scheme 23
Scheme 23

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