Condenser; Compressor; Compressor Components; Valve Plate And Head Gasket - Ford COUGAR 1968 Shop Manual

GROUP 16
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Ventilating, Heating, And Accessories
5. Remove the radiator grille and
hood latch support from the vehicle
as an assembly.
6. Disconnect and cap the high
pressure hoses from the condenser and
the receiver tank.
7. Remove four condenser attach-
ing screws and remove the condenser.
8. Remove the receiver tank from
the condenser.
INSTALLATION
1. Install the receiver tank on the
condenser.
2. Position the condenser to the
vehicle and install the four attaching
screws.
3. Connect the hoses to the re-
ceiver tank and the condenser.
4. Position the grille and hood
latch support to the vehicle and in-
stall the grille attaching screws.
.
5. Install the hood latch support
attaching bolts.
6. Install the horns.
7. Leak test, evacuate, and charge
the A / C system (Section 3).
COMPRESSOR
REMOVAL
1. Isolate the compressor (See
Common Adjustments and Repairs)
and disconnect the two service valves
and hoses from the compressor (Fig.
23). Energize the clutch and loosen
and remove the clutch mounting bolt.
2. Install a 518-1 1 bolt in the
clutch drive shaft hole. With the clutch
still energized, tighten the bolt to
loosen the clutch from the shaft. Dis-
connect the clutch wire a t the bullet
connector.
3. Loosen the idler pulley or al-
ternator and remove the drive belt
and the clutch and then remove the
mounting bolts and the compressor.
.
INSTALLATION
Before installing the compressor,
see Cleaning and Inspection in this
part.
1. Mount the clutch on the shaft
and install the mounting screw and
washer finger-tight. Place the com-
pressor on the mounting bracket and
install the four mounting bolts finger-
tight.
2. Connect the clutch wire, ener-
gize the clutch and torque the clutch
mounting bolt to specification. In-
stall and tighten the mounting bolts
to specification (Part 16-5).
3. Install the belt and adjust and
tighten the idler pulley.
4. Install the service valves on the
compressor using new seals. Be cer-
tain to remove the rubber shipping
plugs first. Tighten the service valve
nuts to specification (Part 16-5). Do
not over tighten. The new ROTO-
LOK service valves can be rotated
slightly on their seat without breaking
the high pressure seal. This is not an
indication of a loose valve. Leak test
the compressor, then evacuate it and
connect it back into the system.
5. Check the oil level in the com-
pressor and add or remove oil i f
necessary (Section 3).
COMPRESSOR COMPONENTS
All compressor removal and in-
stallation operations, except belt re-
placement, can be performed only
after the unit has been isolated from
the rest of the system. (See Common
Adjustments and Repairs.)
VALVE PLATE AND
HEAD GASKET
The procedure for replacing a
blown head gasket is identical to the
procedure for replacing the valve
plate except that the old valve plate
is used. If a defective valve plate has
caused the cylinder walls to become
scored or has imbedded pieces of
metal in the pistons, the compressor
should be replaced.
Removal
1. Remove the compressor from the
vehicle.
2. Remove the cylinder head bolts.
3. Remove the valve plate and
cylinder head from the compressor
by tapping upward with a fiber ham-
mer on the overhanging edge of the
valve plate.
4. Remove the valve plate from
the cylinder head by holding the head
and tapping against the valviplate.
5. Remove all particles of gasket,
dirt and foreign material from the sur-
face of the cylinder head and cylinder
face. Be extremely careful not to
scratch or nick the mating surfaces
or any edges.
Installation (York Compressor-
Fig. 24)
1.
Apply a thin film of clean re-
frigeration oil to each side of the
valve plate gasket (Fig. 24).
2. Place the new valve plate gas-
ket in position on the crankcase so
that the crankcase dowel pins go
through the dowel pin holes in the
gasket (Fig. 24).
3. Place the valve plate in posi-
tion on the cylinder so that the dowel
pins go through the dowel pin holes
(Fig. 24).
4. Apply a light film of clean re-
frieeration oil on each side of the
cy;nder head gasket. Then, place the
FIG.
24-Valve Plate and Crankshaft Seal Installation-York Compressor
gasket and cylinder head on the cyl-