Ford Festiva. Instruction - part 84

Fig. 18: Sanden 5-Cylinder Compressor

Courtesy of CHRYSLER MOTORS.

SANDEN 7-CYL CLUTCH COIL & BEARING R & I

Removal

1. Hold clutch hub stationary and remove shaft nut. Remove clutch plate using Clutch Plate Puller (09977-21110). Remove clutch shims

and bearing dust cover. Remove external front housing snap ring.

2. Install puller, and pull drive pulley assembly off. Detach clutch coil lead from compressor housing. Remove clutch coil snap ring and

clutch coil. If necessary, invert drive pulley assembly and remove snap ring and bearing.

Installation

1. Ensure clutch coil protrusion aligns with hole in compressor housing, and install clutch coil snap ring. Install drive pulley assembly

using Drive Pulley Installer (09977-21811).

2. install external bearing snap ring. Using Seal Installer (09977-21800), install bearing dust cover. After dust cover installation, ensure

there is no contact between cover and front housing.

3. Install clutch shims and clutch plate. Tighten shaft nut to 12-14 ft. lbs. (17-19 N.m). Using a dial indicator, apply voltage to clutch coil

to check air gap between clutch plate and drive pulley assembly. Ensure air gap is .016-.032" (.41-.80 mm).

SANDEN 7-CYL SHAFT SEAL R & I

Removal

1. Hold clutch hub stationary and remove shaft nut. Remove clutch plate using Clutch Plate Puller (09977-21110). Tap shaft key out of

slot in compressor shaft. Remove clutch shims.

2. Remove seal retainer felt ring. Remove shaft seal seat snap ring with snap ring pliers. Insert Seal Seat Remover/Installer (09977-21400)

into front housing and turn to engage tangs on seat. Lift seal seat out.

3. Insert seal Remover/Installer (09977-21510) into front housing and turn to engage tangs on seal. carefully lift seal seat out without

scratching compressor shaft.

Installation

1. Install Shaft Seal Guide Sleeve (09977-21700) over compressor shaft. Dip seal in refrigerant oil and install seal on sleeve. Using seal

remover/installer, rotate seal clockwise until seal is engaged. Remove seal remover/installer by turning it counterclockwise.

2. Coat seal seat with refrigerant oil and install seal with seal seat remover/installer. Remove shaft seal guide sleeve. Install snap ring.

Install seal retainer felt ring using seal seat remover/installer. Install clutch shims and shaft key.

3. Install clutch plate. Tighten shaft nut to 12-14 ft. lbs. (17-19 N.m). Using dial indicator, apply voltage to clutch coil to check air gap

between clutch plate and drive pulley assembly. Ensure air gap is .016-.032" (.41-.80 mm).

NOTE:

Check compressor refrigerant oil level when replacing seals.

Article GUID: A00038955

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1991-92 AIR CONDITIONING & HEATING

A/C System General Servicing

HANDLING/SAFETY PRECAUTIONS

1. Always work in a well-ventilated, clean area. Refrigerant R-134a is colorless and is invisible as a gas. Refrigerant (R-12 or R-134a) is

heavier than oxygen and will displace oxygen in a confined area. Avoid breathing refrigerant vapors. Exposure may irritate eyes, nose
and throat.

2. The system's high pressure can cause severe injury to eyes and skin if a hose were to burst. Always wear eye protection when working

around A/C system and refrigerant. If necessary, wear rubber gloves or other protective clothing.

3. Refrigerant evaporates quickly when exposed to atmosphere, freezing anything it contacts. If liquid refrigerant contacts eyes or skin, DO

NOT rub eyes or skin. Immediately flush affected area with cool water for 15 minutes and consult a doctor or hospital.

4. Never use R-134a in combination with compressed air for leak testing. Pressurized R-134a in the presence of oxygen (air concentrations

greater than 60% by volume) may form a combustible mixture. DO NOT introduce compressed air into R-134a containers (full or
empty), A/C system components or service equipment.

5. DO NOT expose A/C system components to high temperatures, steam cleaning for example, as excessive heat will cause

refrigerant/system pressure to increase. Never expose refrigerant directly to open flame. If refrigerant needs to be warmed, place bottom
of refrigerant tank in warm water. Water temperature MUST NOT exceed 125°F (52°C).

6. Use care when handling refrigerant containers. DO NOT drop, strike, puncture or incinerate containers. Use Department Of

Transportation (DOT) approved, DOT 4BW or DOT 4BA, refrigerant containers.

7. Never overfill refrigerant containers. The safe filling level of a refrigerant container MUST NOT exceed 60% of the container's gross

weight rating. Store refrigerant containers at temperature less than 125°F (52°C).

8. R-12 refrigerant (Freon) will be sold and stored in White containers, while R-134a refrigerant will be sold and stored in 30- or 50-

pound Light Blue containers.

9. R-12 and R-134a refrigerants must never be mixed, as their desiccants and lubricants are not compatible. If the refrigerants are mixed,

system cross-contamination or A/C system component failure may occur. Always use separate servicing and refrigerant
recovery/recycling equipment.

10. Follow equipment manufacturer instructions of all service equipment to be used. The Material Safety Data Sheet (MSDS), provided by

refrigerant manufacturer/suppliers, contains valuable information regarding the safe handling of R-12 or R-134a refrigerants.

IDENTIFYING R-134A SYSTEMS & COMPONENTS

To prevent refrigerant cross-contamination, use following methods to identify R-134a based systems and components.

Fittings & "O" Rings

All R-134a based A/C systems use 1/2" - 16 ACME threaded fittings (identifiable by square threads) and quick-connect service couplings. See

Fig. 1

. Besides the use of these fittings, most manufacturers will use Green colored "O" rings in R-134a systems.

CAUTION:

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

Fig. 1: Identifying R-134a Fittings & Quick Connect Service Couplings

Courtesy of AUDI OF AMERICA, INC.

Underhood A/C Specification Labels

Most R-134a based systems will be identified through the use of Green or Light Blue underhood labels, or with R-134a refrigerant clearly
printed on labels. See

Fig. 2

. Some manufacturers will identify R-12 based systems with White, Red, Silver or Gold underhood labels. Before

servicing an A/C system, always determine which refrigerant is being used.

Fig. 2: Underhood A/C Specification Labels (Typical)

Courtesy of NISSAN MOTOR CO., U.S.A.

Other Means Of Identification

Refrigerant R-134a, when viewed through a sight glass, may have a "milky" appearance due to the mixture of refrigerant and lubricating oil. As
the refrigerant and oil DO NOT exhibit a "clear" sight glass on a properly charged A/C system, R-134a systems have no sight glass.

Audi, Mercedes-Benz and Volkswagen use Green bands/labels on condenser, refrigerant lines, receiver-drier and expansion valve. Lexus A/C
system hoses and line connectors have a groove, a White line and "R-134a" marked on them. See

Fig. 3

Fig. 3: Identifying R-134a Hose & Line Connectors (Lexus)

Courtesy of TOYOTA MOTOR SALES, U.S.A., INC.

REFRIGERANT OILS

Refrigerant R-12 based systems use mineral oil, while R-134a systems use synthetic/Polyalkylene Glycol (PAG) oils. Using a mineral oil based
lubricant with R-134a will result in A/C compressor failure due to lack of proper lubrication.

Use ONLY specified oil for the appropriate system and A/C compressor. Always check the underhood A/C specification label or A/C

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