1991 FORD FESTIVA Service Manual

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GENERAL INFORMATION
Clutch Trouble Shooting
* PLEASE READ THIS FIRST *
ALL MODELS
CLUTCH TROUBLE SHOOTING NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For m odel-specific inform ation see appropriate articles where
available.
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For m odel-specific inform ation see appropriate articles where
available.
Problem & Possible CauseAction
Clutch Chatters/Grabs
Incorrect Pedal AdjustmentAdjust Free Play
Worn Input Shaft SplineReplace Input Shaft
Binding Pressure PlateReplace Pressure Plate
Binding Throw-Out LeverCheck Throw-Out Lever,
Check Throw-Out
Bearing, Check Bearing
Retainer
Uneven Pressure Plate Contact With FlywheelAlign/Replace Worn Parts
Transmission MisalignedAlign Transmission
Worn Pressure PlateReplace Clutch Assembly
Oil-Saturated DiscReplace Clutch Assembly,
Repair Oil Leak
Loose Engine MountsReplace Engine Mounts
Clutch Pedal Sticks Down
Clutch Cable BindingReplace Clutch Cable
Weak Pressure Plate SpringsReplace Clutch Assembly
Binding Clutch LinkageLubricate Linkage
Broken Clutch Pedal Return SpringReplace Return Spring
Clutch Will Not Release
Oil-Saturated DiscReplace Clutch Assembly,
Repair Oil Leak
Defective Disc FaceReplace Clutch Assembly
Disc Sticking on Input Shaft SplinesReplace Disc/Input Shaft
Binding Pilot BearingReplace Pilot Bearing
Faulty Clutch Master CylinderReplace Master Cylinder
Faulty Clutch Slave CylinderReplace Slave Cylinder
Blown Clutch HoseReplace Hose
Sticky Throw-Out Bearing SleeveClean/Lube Sleeve
Clutch Cable BindingReplace Clutch Cable
Broken/Loose BellhousingCheck Bellhousing
Rattling/Squeaking
Broken Throw-Out Lever Return SpringReplace Return Spring
Faulty Throw-Out BearingReplace Throw-Out
Bearing
Faulty Clutch DiscReplace Clutch Disc
Faulty Pilot BearingReplace Pilot Bearing
Worn Throw-Out BearingReplace Throw-Out
Bearing
Dry Bearing Retainer Slide For Throw-Out Bearing SleeveLubricate Slide
Slipping
Faulty Pressure PlateReplace Clutch Assembly
Worn Clutch DiscReplace Clutch Assembly
Incorrect AlignmentRealign Clutch Assembly
Faulty Clutch Slave CylinderReplace Slave Cylinder
No Pedal Pressure
Leaky Hydraulic SystemCheck Clutch Master
Cylinder, Check Clutch
Slave Cylinder
Check Clutch Hose
Broken Clutch CableReplace Clutch Cable
Faulty Throw-Out LeverReplace Throw-Out Lever
Broken Clutch LinkageRepair Clutch Linkage
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Noisy Clutch Pedal
Faulty Safety SwitchCheck/Replace Switch
Noisy Self-Adj. RatchetReplace Ratchet
Dry Throw-Out BearingReplace Throw-Out
Bearing
Dry Pilot BearingReplace Pilot Bearing
Worn Input ShaftReplace Input Shaft
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00091461
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GENERAL INFORMATION
Electrostatic Discharge (ESD) Warning - Basic Inform ation
* PLEASE READ THIS FIRST *
INTRODUCTION
All Electrostatic Discharge (ESD) sensitive components contain solid state circuits (transistors, diodes, semiconductors) that may become
damaged when contacted with an electrostatic charge. The following information applies to all ESD sensitive devices. The ESD symbol shown
in Fig. Fig. 1
may be used on schematics to indicate which components are ESD sensitive. See Fig. 1. Although different manufactures may
display different symbols to represent ESD sensitive devices, the handling and measuring precautions and procedures are the same.

Fig. 1: Sample ESD Symbol

HANDLING STATIC-SENSITIVE CIRCUITS/DEVICES
When handling an electronic part that is ESD sensitive, the technician should follow these guidelines to reduce any possible electrostatic
charge build-up on the technician's body and the electronic part.
1. Always touch a known good ground source before handling the part. This should be repeated while handling the part and more
frequently after sitting down from a standing position, sliding across the seat or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed by a diagnostic procedure.
3. DO NOT open the package of a new part until it is time to install the part.
4. Before removing the part from its package, ground the package to a known good ground source.
CHECKING STATIC-SENSITIVE CIRCUITS/DEVICES
1. Solid State circuits in electronic devices are shown greatly simplified in schematics. See Fig. 2. Due to the simplification of the NOTE:T his article is intended for general inform ation purposes only. Contents are generic in nature and all
inform ation m ay or m ay not apply to all vehicles.
NOTE:T his article is intended for general inform ation purposes only. Contents are generic in nature and all
inform ation m ay or m ay not apply to all vehicles.
NOTE:T his article is intended for general inform ation purposes only. Contents are generic in nature and all
inform ation m ay or m ay not apply to all vehicles.
NOTE:T his article is intended for general inform ation purposes only. Contents are generic in nature and all
inform ation m ay or m ay not apply to all vehicles.
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electronic devices on the schematic, resistance measurements could be misleading or could lead to an electrostatic discharge. Always
follow the recommended diagnostic procedure.

Fig. 2: Sample Schematic Showing Typical ESD Sensitive Device

2. Only measure resistance at the terminals of the devices when instructed by the recommended diagnostic procedure.
3. When using a voltmeter, be sure to connect the ground lead first.
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00130228
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EMISSION CONT ROL VISUAL INSPECT ION PROCEDURES
1983-93 GENERAL INFORMAT ION Em ission Control Visual Inspection Procedures
EMISSION CONTROL LABELS
This article is provided for general information only. Not all information applies to all makes and models. For more complete information, see
appropriate article(s) in the ENGINE PERFORMANCE Section.
The vehicle manufacturer's emission control label, also known as the underhood tune-up label or Vehicle's Underhood Emission Control
System (VECI) label, is located in the engine compartment. Information regarding year model of vehicle, engine size, number of cylinders,
emission equipment or type, engine tune-up specifications, whether vehicle was manufactured for sale in California or is a Federal vehicle,
vacuum hose routing schematic, etc., can be found on this label. See Fig. 1
.
In addition to the VECI label, some emission control inspection and maintenance programs may require an additional label to be affixed to the
vehicle in special circumstances. For example, in California, a Bureau Of Automotive Repair (BAR) engine label may be affixed to the left
door post. A BAR engine label is only used when the vehicle has an engine change, approved modification or is a Specially Constructed
(SPCN) or an acceptable Gray market vehicle. Check your state's emission control inspection and maintenance laws to determine if a simil ar
label is used.

Fig. 1: Typical Emission Control Label

Courtesy of GENERAL MOTORS CORP.
FORD CALIBRATION LABELS
Ford Motor Co. uses an emission calibration label in addition to the emission control label. The emission calibration label is located on either
the engine valve cover, the driver-side door or the left door post pillar.
The calibration label identifies the engine year, calibration design and design revision level. These numbers are also used to identify service
parts and engine specifications that make up the emission system designed for the vehicle. See Fig. 2 , Fig. 3 , Fig. 5 and Fig. 6 .

Fig. 2: Identifying Vehicle Calibration Label (1975
-81 Ford Models)
Courtesy of FORD MOTOR CO.
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Fig. 3: Identifying Vehicle Calibration Label (1982
-83 Ford Models)
Courtesy of FORD MOTOR CO.

Fig. 4: Identifying Vehicle Calibration Label (1984
-88 Ford Models)
Courtesy of FORD MOTOR CO.
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Fig. 5: Identifying Vehicle Calibration Label (1989
-93 Ford Models)
Courtesy of FORD MOTOR CO.
EMISSION CONTROL VISUAL INSPECTION
A visual inspection is made to determine if any required emission control devices are missing, modified or disconnected. Missing, mo d ifie d o r
disconnected systems must be made fully operational before a vehicle can be certified.
POSITIVE CRANKCASE VENTILATION (PCV)
PCV controls the flow of crankcase fumes into the intake manifold while preventing gases and flames from traveling in the opposite direction.
PCV is either an open or closed system. See Fig. 4
.
Ensure PCV system is installed as required. Verify valve, required hoses, connections, flame arresters, etc., are present, routed properly and in
serviceable condition.

Fig. 6: Typical Open & Closed Type PCV System

THERMOSTATIC AIR CLEANER (TAC)
The TAC supplies warm air to air intake during cold engine operation. This system is active during cold engine warm-up only. Under all other
operating conditions, air cleaner function is the same as any non-thermostatic unit.
Ensure required exhaust shroud, hot air duct, vacuum hoses and air cleaner components are present and installed properly. See Fig. 7
. Ensure
any required thermostatic vacuum switches are in place and vacuum hoses are installed and in serviceable condition. Also ensure air cleaner
lid is installed right side up. Check for oversized air filter elements and for additional holes in the air cleaner housing.
NOTE:T he following em ission control visual inspection procedures should be used as a guide only. When
perform ing a visual inspection, always follow your state's recom m ended inspection procedures.
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Fig. 7: Typical Thermostatic Air Cleaner System

FUEL EVAPORATIVE SYSTEM (EVAP)
The EVAP system allows for proper fuel system ventilation while preventing fuel vapors from reaching the atmosphere. This means that vapors
must be caught and stored while the engine is off, which is when most fuel evaporation occurs. When the engine is started, these fuel vapors
can be removed from storage and burned. In most systems, storage is provided by an activated charcoal (or carbon) canister. See Fig. 8
. On a
few early systems, charcoal canisters are not used. Instead, fuel vapors are vented into the PCV system and stored inside the crankcase.
The main components of a fuel evaporation system are a sealed fuel tank, a liquid-vapor separator and vent lines to a vapor-storing canister
filled with activated charcoal. The filler cap is normally not vented to the atmosphere, but is fitted with a valve to allow both pressure and
vacuum relief.
Although a few variations do exist between manufacturers, basic operation is the same for all systems. Check for presence of vapor storage
canister or crankcase storage connections when required. Ensure required hoses, solenoids, etc., are present and connected properly. Check
for proper type fuel tank cap. Check for any non-OEM or auxiliary fuel tanks for compliance and the required number of evaporation
canisters.

Fig. 8: Typical Fuel Evaporative System

CATALYTIC CONVERTERS
Oxidation Catalyst (OC)
This type of converter is the most common. It may use pellets or monolith medium, depending upon application. See Fig. 9 . Platinum and
palladium (or platinum alone) are used as catalyst in this type of converter.
Visually check for presence of catalytic converter(s). Check for external damage such as severe dents, removed or damaged heat shields, etc.
Also check for pellets or pieces of converter in the tailpipe.
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