1991 FORD FESTIVA Service Manual

tube from evaporator core fins while removing thermostatic switch. To install, reverse removal procedure. Evacuate and recharge system.
THERMOSTATIC EXPANSION VALVE
Removal & Installation
1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove evaporator housing. See EVAPORATOR
HOUSING under REMOVAL & INSTALLATION. Remove air inlet duct. See Fig. 1 .
2. Remove insulation from sensing bulb. Disconnect thermostatic expansion valve at evaporator tube fitting and inlet tube fitting (from
receiver-drier). See Fig. 3
. Remove thermostatic expansion valve. To install, reverse removal procedure. Use new "O" rings. Evacuate
and recharge system.
A/C RELAYS
Removal & Installation
A/C relays are located in left front corner of engine compartment, near battery. Unclip relay holder from its mounting bracket. Disconnect
relay wiring. DO NOT pull on wiring connector to remove relay from holder. Remove relay from holder. To install, reverse removal procedure.
A/C-HEATER CONTROL ASSEMBLY
Removal & Installation
1. A/C control module is located above radio. Remove accessory bezel. Remove radio (if necessary) and glove box. Disconnect
recirculated/fresh air cable from door lever. See Fig. 5
. Disconnect mode select cable from door lever. See Fig. 6 .
2. Disconnect temperature control cable from door lever. See Fig. 4
. Pull control assembly away from dash, and disconnect wiring
connectors. Remove control assembly.
3. To install, reverse removal procedure. Check and adjust temperature control, recirculated/fresh air and mode cables. See
ADJUSTMENTS. Test control assembly operation.
BLOWER MOTOR
Removal & Installation
Disconnect negative battery cable. Remove A/C air outlet duct located below steering column. See Fig. 2 . Disconnect blower motor wiring.
Remove blower motor attaching screws and blower motor. Remove blower wheel attaching nut. Remove blower wheel and washer. To install,
reverse removal procedure.
BLOWER MOTOR RESISTOR
Removal & Installation
Disconnect negative battery cable. Remove air duct located below steering column. See Fig. 2 . Disconnect blower motor resistor wiring.
Remove blower resistor attaching screws and resistor. To install, reverse removal procedure.
AIR DISTRIBUTION PLENUM
Removal & Installation
1. Remove instrument panel. See INSTRUMENT PANEL under REMOVAL & INSTALLATION. Drain cooling system. Disconnect
heater hoses in engine compartment. Disconnect wiring for blower motor and blower resistor. Disengage wiring harness and antenna
lead from bracket on front of air distribution housing.
2. Loosen connector duct-to-air inlet clamp screw. Remove upper and lower mounting nuts from plenum. Disengage and remove plenum
from defroster ducts. To install, reverse removal procedure. Refill cooling system, and check for leaks.
HEATER CORE
Removal & Installation
1. Remove air distribution plenum. See AIR DISTRIBUTION PLENUM under REMOVAL & INSTALLATION. Disconnect linkage
connecting defroster doors. Remove attaching screw located near blower resistor. Turn housing around and remove attaching screw
located near blower motor opening.
2. Remove clips retaining blower housing halves. Separate blower housing halves. Remove heater core. Remove tube insert from heater
core. To install, reverse removal procedure. Test system for proper operation.
INSTRUMENT PANEL
Removal & Installation
1. Disconnect negative battery cable. Remove steering wheel, steering column covers and multifunction switch assembly. Disconnect
electrical connectors from switches on instrument panel. Remove instrument cluster hood.
2. Disconnect speedometer cable from transmission. Remove 4 instrument cluster screws. Pull instrument cluster out from instrument
panel cluster enough to disconnect wiring and speedometer cable. Remove instrument cluster.
3. Remove steering column shield. Remove shield bracket. Remove glove box. Remove fuse panel cover and 4 fuse panel screws. Pull fu se
panel out, but DO NOT remove. Remove shift lever console and mount brackets. CAUTION: DO NOT rem ove screw in front of blower resistor, or blower resistor m ounting plate will fall into air
distribution plenum . T o retrieve plate, disassem ble instrum ent panel.
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4. Remove radio and A/C-heater control assembly. See A/C-HEATER CONTROL ASSEMBLY under REMOVAL &
INSTALLATION. Disconnect cigarette lighter connector. Remove snap-in trim inserts concealing instrument panel attaching bolts.
Remove 7 instrument panel attaching bolts.
5. Remove 2 lower instrument panel-to-body bracket stud nuts. Disconnect remaining electrical connectors from instrument panel.
Remove instrument panel. To install, reverse removal procedures.
WIRING DIAGRAM

Fig. 30: Manual A/C Heater System Wiring Diagram (Festiva)

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1971-96 MAINT ENANCE & SERVICE INFORMAT ION
Interference Verification Check For OHC Engine - T im ing Belt Inform ation
TIMING BELT INTERFERENCE VERIFICATION INFORMATION
TIMING BELT INTERFERENCE CAUTION
Crack Or Tears In Belt Surface
Missing, Damaged, Cracked Or Rounded Teeth
Oil Contamination
Damaged Or Faulty Tensioners
Incorrect Tension Adjustment
TIMING BELT REPLACEMENT INTERVAL & INTERFERENCE VERIFICATION
TIMING BELT REPLACEMENT INTERVAL & INTERFERENCE VERIFICATION (FORD PASSENGER CARS)
(1)
TIMING BELT REPLACEMENT INTERVAL & INTERFERENCE VERIFICATION (MERCURY PASSENGER CARS)
(1) CAUT ION: T he condition of cam shaft tim ing belts should always be checked on vehicles which have m ore than
50,000 m iles. Although som e m anufacturers do not recom m end replacem ent at a specified m ileage,
others require it at 60,000-100,000 m iles. A cam shaft drive belt failure m ay cause extensive dam age to
internal engine com ponents on m ost engines, although som e designs do not allow piston-to-valve
contact. T hese designs are often called "Free Wheeling". Many m anufacturers changed their
m aintenance and warranty schedules in the m id-1980's to reflect tim ing belt inspection and/or
replacem ent at 50,000-60,000 m iles. Most service interval schedules shown in this section reflect these
changes. Belts or com ponents should be inspected and replaced if any of the following conditions
exist:
ApplicationYear SpanEngineReplacement Interval (Miles)
Aspire1994-961.3L 4-Cyl.60,000
Contour1995-962.0L 4-Cyl.60,000
Escort1981-851.6L 4-Cyl.60,000
Escort1985-961.9L 4-Cyl.60,000
Escort1984-87(2) 2.0L 4-Cyl. Diesel(4) 100,000
Escort1991-961.8L 4-Cyl.60,000
EXP1981-851.6L 4-Cyl.60,000
EXP1985-961.9L 4-Cyl.60,000
Fairmont1978-832.3L 4-Cyl.(3) 60,000
Festiva1988-931.3L 4-Cyl.60,000
Granada1981-822.3L 4-Cyl.(3) 60,000
LTD1983-862.3L 4-Cyl.(3) 60,000
Mustang1974-932.3L 4-Cyl.(3) 60,000
Pinto1971-742.0L 4-Cyl.(3) 60,000
Pinto1974-802.3L 4-Cyl.(3) 60,000
Probe1989-92(2) 2.2L 4-Cyl.60,000
Probe1993-96(2) 2.0L 4-Cyl.60,000
Probe1993-962.5L V660,000
Taurus SHO1989-953.0L V6100,000
Taurus SHO1993-953.2L V6100,000
Tempo1984-87(2) 2.0L 4-Cyl. Diesel(4) 100,000
Thunderbird1983-882.3L 4-Cyl.(3) 60,000
(1)Other interference engine applications may exist which are not indicated here.
(2)Interference engine. Check for possible damage to piston(s) or valve(s) if there has been a timing belt failure.
(3)Although the vehicle manufacturer does not recommend a specific scheduled maintenance interval, aftermarket belt manufacturers
suggest the belt be replaced at 60,000 mile intervals.
(4)Vehicle manufacturer recommends replacing all belts at the same time.
ApplicationYear SpanEngineReplacement Interval (Miles)
Bobcat1974-802.3L 4-Cyl.(3) 60,000
Capri1971-721.6L 4-Cyl.(3) 60,000
Capri1971-742.0L 4-Cyl.(3) 60,000
Capri1974-842.3L 4-Cyl.(3) 60,000
Capri1991-941.6L 4-Cyl.60,000
Cougar1984-862.3L 4-Cyl.(3) 60,000
LN71981-85(2) 1.6L 4-Cyl.(3) 60,000
Lynx1981-85(2) 1.6L 4-Cyl.(3) 60,000
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TIMING BELT REPLACEMENT INTERVAL & INTERFERENCE VERIFICATION (LIGHT TRUCKS) (1)
Lynx1984-871.9L 4-Cyl.(3) 60,000
Lynx1984-872.0L 4-Cyl. Diesel(4) 100,000
Marquis1983-862.3L 4-Cyl.(3) 60,000
Mystique1995-962.0L 4-Cyl.60,000
Topaz1984-86(2) 2.0L 4-Cyl. Diesel(4) 100,000
Tracer1987-901.6L 4-Cyl.60,000
Tracer1991-961.8L 4-Cyl.60,000
Tracer1991-961.9L 4-Cyl.60,000
Tracer (Canadian)1987, 19901.6L 4-Cyl.(3) 60,000
Zephyr1978-832.3L 4-Cyl.(3) 60,000
Villager1993-96(2) 3.0L V6105,000
(1)Other interference engine applications may exist which are not indicated here.
(2)Interference engine. Check for possible damage to piston(s) or valve(s) if there has been a timing belt failure.
(3)Although the vehicle manufacturer does not recommend a specific scheduled maintenance interval, aftermarket belt manufacturers
suggest the belt be replaced at 60,000 mile intervals.
(4)Vehicle manufacturer recommends replacing all belts at the same time.
ApplicationYear SpanEngineReplacement Interval (Miles)
Aerostar1986-872.3L 4-Cyl.(3) 60,000
Courier1977-822.3L 4-Cyl.(3) 60,000
Ranger1986-882.0L 4-Cyl.60,000
Ranger1983-962.3L 4-Cyl.(3) 60,000
Ranger1985-87(2) 2.3L 4-Cyl. Diesel(3) (4) 60,000
(1)Other interference engine applications may exist which are not indicated here.
(2)Interference engine. Check for possible damage to piston(s) or valve(s) if there has been a timing belt failure.
(3)Although the vehicle manufacturer does not recommend a specific scheduled maintenance interval, aftermarket belt manufacturers
suggest the belt be replaced at 60,000 mile intervals.
(4)Vehicle manufacturer recommends replacing all belts at the same time.
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00062912
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MAINTENANCE INFORMATION
1988-93 MAINT ENANCE Ford Motor Co. Maintenance Inform ation
MODEL IDENTIFICATION
VIN LOCATION
The Vehicle Identification Number (VIN) is located on the left side of the dash panel at the base of the windshield. The VIN chart explains the
code characters.
VIN CODE ID EXPLANATION
Numbers preceding the explanations in the legend below refer to the sequence of characters as listed on VIN identification label. See VIN
example below.

Fig. 1: VIN Code ID Explanation

MAINTENANCE SERVICE INFORMATION
SEVERE & NORMAL SERVICE DEFINITIONS
Service is recommended at mileage intervals based on vehicle operation. Service schedules are based on the following primary operating
conditions:
Severe Service
Short Trips (About 10 Miles) In Freezing Temperatures
Towing Or Heavily Loaded
Severe Dust Conditions
Hot Weather, Stop-And-Go Driving
Extensive Idling Conditions (Taxi Or Delivery Type Service)
Normal Service
NOTE:For scheduled m aintenance intervals and the related fluid capacities, fluid specifications and labor
tim es for m ajor service intervals, see SCHEDULED SERVICES article in this section. Warranty
inform ation and specifications for fluid capacities, lubrication specifications, wheel and tire size, and
battery type are covered in this article.
NOTE:Use the Severe Service schedule if the vehicle to be serviced is operated under ANY (one or m ore) of
these conditions:
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Driven More Than 10 Miles Daily
No Operating Conditions From Severe Service Schedule
CAMSHAFT TIMING BELT
The condition of camshaft drive belts should always be checked on vehicles which have more than 50,000 miles. Although some
manufacturers do not recommend belt replacement at a specified mileage, others require it at 60,000-100,000 miles. A camshaft drive belt
failure may cause extensive damage to internal engine components on most engines, although some designs do not allow piston-to-va l ve
contact. These designs are often called "Free Wheeling".
Many manufacturers changed their maintenance and warranty schedules in the mid-1980's to reflect timing belt inspection and/or replacement
at 50,000-60,000 miles. Most service interval schedules in this manual reflect these changes.
Belts or components should be inspected and replaced if any of the following conditions exist:
Cracks Or Tears In Belt Surface
Missing, Damaged, Cracked Or Rounded Teeth
Oil Contamination
Damaged Or Faulty Tensioners
Incorrect Tension Adjustment
Replace camshaft timing belt every 60,000 miles.
COOLING SYSTEM
Replace engine coolant every 36 months or 30,000 miles. Check condition of hoses and clamps every 12 months or 15,000 miles, whichever
comes first. Replace hoses and clamps if necessary.
SERVICE POINT LOCATIONS

Fig. 2: Engine Service Point Locations (1988
-89 1.3L 2V Carb.)
Courtesy of FORD MOTOR CO. CAUT ION: Failure to replace a faulty cam shaft tim ing belt m ay result in serious engine dam age.
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Fig. 3: Engine Service Point Locations (1989
-93 1.3L EFI)
Courtesy of FORD MOTOR CO.

Fig. 4: Jacking & Hoisting Points

Courtesy of FORD MOTOR CO.
ALIGNING CAMSHAFT TIMING MARKS
NOTE:For m ore inform ation regarding vehicle lifting refer to the JACKING & HOISTING article in the WHEEL
ALIGNMENT section.
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Fig. 5: Aligning Camshaft & Crankshaft Timing Marks (1.3L)

Courtesy of FORD MOTOR CO.
VALVE CLEARANCE ADJUSTMENT (1988-89 CARBURETOR ENGINES)
IDENTIFICATION LABEL LOCATIONS
NOTE:For m ore inform ation regarding cam shaft tim ing belt service refer to the 1.3L 4-CYL - VINS [H,K] article
in the ENGINE MECHANICAL section.
NOTE:For m ore inform ation regarding valve clearance adjustm ents refer to the 1.3L 4-CYL - VINS [H,K] article
in the ENGINE MECHANICAL section.
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