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A/c Compressor Overhaul - 10-cyl Ford Tempo I

General Servicing - All Makes 15 illustrations ~2162 words

DESCRIPTION

The Nippondenso/Ford 10-cyl. compressor is a reciprocating piston type. The pistons are operated by a swashplate which moves the pistons back and forth in the cylinders as the shaft is rotated. There are 10 separate cylinders, 5 at the rear of the compressor and 5 at the front. Reed valves are provided for each cylinder.

Note. This article covers shaft seal, pulley bearing and clutch coil replacement procedures for Ford & Nippondenso 10-cyl. compressors. The shaft seal assembly is precision-machined with its critical parts finished to extremely close tolerance and as such must be handled with great care. Its slip face demands particularly careful handling.

FORD FX-15 10-CYLINDER

  1. Using Spanner (T70P-4067-A), remove clutch plate retaining bolt and discard. Using an 8 mm bolt threaded into clutch plate, remove clutch plate. Remove clutch plate shims.
  2. Remove snap ring and remove pulley assembly. Remove snap ring. Disconnect electrical wiring and remove clutch coil. To install, reverse removal procedure. Install pulley assembly snap ring with beveled side out.
  3. Install new clutch plate retaining bolt and tighten to 96-120 INCH lbs. (11-14 N.m). Using a feeler gauge, rotate clutch assembly and check clearance in 3 places. Proper clearance is .018-.038" (.46-.97 mm). If clearance is not correct, add or remove shims.

Exploded View of FX-15 10-Cylinder Compressor Clutch Assembly. Scheme 11

Scheme 11: Exploded View of FX-15 10-Cylinder Compressor Clutch Assembly
Scheme 11: Exploded View of FX-15 10-Cylinder Compressor Clutch Assembly

NIPPONDENSO 10P15, 10P15F

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

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.
  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.
  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.

Scheme 12

Scheme 12
Scheme 12
  1. Remove clutch plate retaining bolt and discard. Using 8 mm bolt, thread bolt into crankshaft and remove clutch plate. Remove clutch plate shims.
  2. Remove pulley assembly snap ring. Remove pulley assembly. Remove snap ring and disconnect clutch coil electrical wiring. Remove clutch coil.
  1. Install clutch coil over locating tab. Install snap ring. Install pulley assembly and install snap ring. Apply a thin coat of White grease to compressor shaft splines.
  2. Install clutch plate spacer shims. Slide compressor clutch on crankshaft and install new retaining bolt. Tighten bolt to 96-120 INCH lbs. (11-14 N.m). Using a feeler gauge, rotate clutch assembly and check clearance in 3 places. Proper clearance is .014-.026" (.36-.66 mm). If clearance is not correct, add or remove shims.

Exploded View of Nippondenso 10PA17A 10-Cyl. Compressor. Scheme 13

Scheme 13: Exploded View of Nippondenso 10PA17A 10-Cyl. Compressor
Scheme 13: Exploded View of Nippondenso 10PA17A 10-Cyl. Compressor
  1. Remove clutch hub. Using "O" Ring Remover (T71P-19703-C) remove shaft seal felt. Thoroughly clean seal area of compressor. Using snap ring pliers, remove shaft seal snap ring.
  2. Position Shaft Seal Remover (T89P-19623-BH) over compressor shaft and push remover down against seal. Ensure end of remover is in seal and turn remover handle clockwise to expand remover tip. Pull shaft seal straight out.
  1. Place a well lubricated Shaft Seal Protector (T89P-19623-CH) over crankshaft. Dip shaft seal in new refrigerant oil and position seal with lip pointing toward compressor.
  2. Using Shaft Seal Installer (T89P-19623-AH), slowly push shaft seal down protector until seated. Remove installer and protector. Install shaft seal snap ring. Using seal installer, push on snap ring until it snaps into snap ring groove. Install new shaft seal felt. To complete installation, reverse removal procedure.
  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. (Scheme 12) 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.
  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.
  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.
  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 under 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.
  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.
  1. Install compressor in Holding Fixture (T89P-19623-D) and clamp fixture in a vise. Remove clutch plate, pulley assembly and clutch coil. Using a 6 mm Allen wrench, remove 5 compressor through bolts. Pull front head from compressor using care not to scratch sealing surface.
  2. Reach down inside front head and remove felt seal and retainer. Using "O" Ring Remover (T71P-19703-C), remove "O" ring. Position compressor front head nose up on cardboard on flat surface. Using Shaft Seal Remover (T89P-19623-E), push shaft seal from head. Inspect front head for damage to sealing surface. Replace if needed.
  1. Lubricate new "O" ring with refrigerant oil and install. Using Shaft Seal Installer (T89P-19623-F), press seal into front head. Install felt seal and retainer.
  2. Install a well lubricated Shaft Seal Protector T89D-19623-C) on crankshaft. Install a new front head "O" ring on compressor housing and coat with refrigerant oil.
  3. Position front head on compressor aligning dowel pins. Use care when guiding shaft seal protector through seal opening. Remove shaft seal protector. Install 5 compressor through bolts using new brass washers. Diagonally tighten bolts to 19 ft. lbs. (26 N.m). To complete installation, reverse removal procedure.

Scheme 14

Scheme 14: NIPPONDENSO EXCEPT 10PA17A
Scheme 14: NIPPONDENSO EXCEPT 10PA17A

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18

Scheme 19

Scheme 19
Scheme 19
  1. Remove Clutch Coil - Refer to CLUTCH COIL REPLACEMENT in this article. Remove inner felt with needle nose pliers. (Scheme 14): Nippondenso 10-Cylinder Compressor (Except 10PA17A) (Scheme 15): Removing Felt - Nippondenso Except 10PA17A Compressor
  2. Remove Internal Snap Ring - Remove the internal snap ring with internal snap ring pliers. (Scheme 16): Removing Internal Snap Ring - Nippondenso Except 10PA17A Compressor
  3. Remove Key - Using fingers or side cutters, remove shaft key and save it for later reassembly. (Scheme 17): Removing Key - Nippondenso Except 10PA17A Compressor
  4. Apply Oil - Apply compressor oil to the inner bore of the compressor.
  5. Remove Shaft Plate - Insert shaft plate remover against the shaft. Then push the holder ring downward. Pull the remover bar up and remove the shaft plate. NOTE: Tool using the prefix "J" are Kent-Moore tool numbers. (Scheme 18): Removing Shaft Plate With Shaft Plate Remover (J-9393-A) - Nippondenso Except 10PA17A Compressor
  6. Remove Shaft Seal - Remove shaft seal by inserting shaft seal remover against the shaft and turn it to the right while pressing on the remover. (Scheme 19): Removing Shaft Seal With Shaft Seal Remover (J-34897) - Nippondenso Except 10PA17A Compressor
  7. Clean - Clean the sealed section of the compressor.
  8. Apply Oil - Apply clean compressor oil to new shaft seal and drive shaft. If the slip faces are dirty, clean them with thinner. After drying the cleaned face, apply clean compressor oil to them.
  9. Install Shaft Seal - Using Shaft Seal Installer (J-33941), install the new shaft seal on the drive shaft, matching the chamfered portion of the shaft seal retainer to the corresponding chamfered part of the drive shaft.
  10. Install "O" Ring - Install new "O" ring into the groove inside the compressor neck.
  11. Apply Oil - Apply clean compressor oil to the seal seat.
  12. Install Shaft Plate - Using Shaft Plate Installer (J-33942), install the shaft plate.
  13. Install Snap Ring - Using internal snap ring pliers, install the snap ring. Install clutch coil. Refer to CLUTCH COIL REPLACEMENT in this article.

NIPPONDENSO EXCEPT 10PA17A

  1. Remove Pulley & Bearings - Remove the bearing snap ring from the rotor.
  2. Remove Snap Ring - Using snap ring pliers, remove the bearing snap ring from the rotor.
  3. Press Out 2 Bearings - Using a driver handle, press out the 2 bearings.
  4. Inspect - Inspect the pressure plate and rotor surfaces for wear and scoring. Check the rotor bearings for wear and leakage of grease. Replace parts as needed.
  5. Installation - Press new bearings into place and replace snap ring. Reinstall pulley and bearings.

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24
  1. Remove Shaft Nut - Using holder and socket, remove the pressure plate and shaft nut. see scheme 10: Nippondenso 10-Cylinder Compressor (Except 10PA17A) (Scheme 20): Removing Shaft Nut Using Holder (J-33939) - Nippondenso Except 10PA17A Compressor
  2. Remove Shims - Remove the shims from the shaft.
  3. Remove Snap Ring - Using snap ring pliers, remove the snap ring securing the pulley. (Scheme 21): Removing Snap Ring - Nippondenso Except 10PA17A Compressor
  4. Remove Key - Remove key from inside diameter shaft groove.
  5. Remove Pulley - Using a plastic hammer, gently tap the pulley off the shaft. (Scheme 22): Removing Pulley - Nippondenso Except 10PA17A Compressor
  6. Disconnect Wires - Disconnect the stator lead wires from the compressor housing. (Scheme 23): Disconnect Wires - Nippondenso Except 10PA17A Compressor (Scheme 24): Removing Snap Ring - Nippondenso Except 10PA17A Compressor
  7. Remove Snap Ring - Using snap ring pliers, remove the snap ring and then the coil.
  8. Install Coil - To install the coil, reverse steps 1 through 7) After tightening the bolt, check to be sure the pulley rotates smoothly. Check to be sure that the clutch clearance is between.016-.028" (.4-.7 mm). Adjust the clearance using shim(s) as necessary. Shims are available in sizes from.0039" (.1 mm) to.0197" (.5 mm).

Installing Coil - Nippondenso Except 10PA17A Compressor. Scheme 25

Scheme 25: Installing Coil - Nippondenso Except 10PA17A Compressor
Scheme 25: Installing Coil - Nippondenso Except 10PA17A Compressor

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