1991 FORD FESTIVA engine oil capacity

levels to proper level.
Removal (1.6L & 1.6L Turbo)
1. Relieve fuel pressure and discharge air conditioning system (if equipped). See FUEL PRESSURE RELEASE under REMOVAL &
INSTALLATION. Disconnect and remove battery, battery tray and battery tray support bracket.
2. Release wiring harness retaining straps from battery support tray. Disconnect windshield washer supply hose between fluid reservoir and
hood. Mark hinge locations and remove hood.
3. Disconnect intake air tube and wiring to ignition coil and vane airflow meter. Remove air cleaner/vane airflow meter assembly. Remove
air cleaner assembly support brackets. Disconnect intercooler hoses from turbocharger (if equipped).
4. Drain engine coolant and remove radiator. Disconnect accelerator cable, and remove retaining bracket from cam cover. Position cable to
one side.
5. Disconnect and plug fuel lines at fuel filter and pressure regulator. Disconnect power brake booster manifold vacuum hose from
manifold. Disconnect heater hoses at heater core tubes. Label and remove vacuum hoses located at throttle body.
6. For manual transaxle turbocharged vehicles, disconnect clutch cable and remove support bracket and cable from transmission. On non-
turbo vehicles, disconnect clutch slave hydraulic line. For automatic transaxle, remove transaxle cooler lines.
7. Disconnect starter wiring at starter. Remove harness from locating strap on bracket. Disconnect alternator wiring. Disconnect wiring
from engine coolant sensors located on rear of engine block. Remove ground connection at bracket on thermostat cover. Disconnect O2
sensor wire, main wiring harness connector, TPS connector (turbocharged only), knock sensor connector, distributor wiring and
transaxle wiring. Disconnect ground wire and strap at front of engine, and reinstall lifting eye.
8. Remove engine oil dipstick and retaining clip. Remove power steering pump from mounting bracket. Remove power steering pump
mounting bracket. With hoses attached, position pump aside. Remove upper air conditioning compressor retaining bolts (if equipped).
9. Raise vehicle on hoist. Drain engine oil and cooling system. On vehicles with air conditioning, remove lower air conditioning
compressor mounting bolts, and position compressor out of way.
10. Remove front wheels and tires. Remove front ball joints-to-ste e r in g kn u c kl e s r e t a in in g b o l t s. R e mo ve sp l a sh gu a r d s. Dr a in t ransmission
oil and remove half shafts from differential. Remove front exhaust pipe bracket located on lower side of engine. Disconnect front
exhaust pipe from exhaust manifold, or turbocharger (if equipped).
11. Remove frame support bar-to-engine support bolt. Loosen right control arm bolt and, pivot support bar downward. Disengage rubber
exhaust hangers located directly behind catalytic converter. Allow exhaust system to hang down 6 inches, and support system with
mechanic's wire. Unbolt shift linkage and stabilizer bar at transaxle. Remove nuts from front and rear engine mounts, and lower vehicle.
12. Attach chains onto lift eyes at ends of cylinder head, and support engine with hoist. Remove RH engine mount through bolt. Raise
engine off mounts and slightly pivot engine/transaxle assembly. Disconnect oil pressure sensor and route starter/alternator wiring
harness from engine. Carefully lift engine/transaxle assembly, turn assembly while raising to clear brake master cylinder, shift linkage
universal joint, radiator support and air conditioning lines (if equipped).
13. Remove intake manifold support bracket. Remove gusset plate(s) (if equipped). Remove starter. Remove transaxle-to-engine retaining
bolts. Identify bolts to ensure correct installation. Separate transaxle from engine. On manual transaxle, remove pressure plate, clutch
disc and flywheel. On automatic transaxle, remove flexplate.
Installation (1.6L & 1.6L Turbo)
1. Install transaxle to engine in reverse order of removal. Attach hoist to engine/transaxle assembly and position assembly in vehicle.
Before engine contacts mounts, route starter, alternator and oil pressure sensor wiring, and connect oil pressure sensor. Lower engine
until front mount seats on crossmember. Install through bolt on RH engine mount. DO NOT tighten bolt.
2. Remove hoist. Raise vehicle and support with jackstands. Align rear engine mount to crossmember, and install retaining nuts to front
and rear engine mounts. Tighten nuts to specification. See TORQUE SPECIFICATIONS
table at end of article.
3. On manual transaxles, connect shift coupling and stabilizer. Tighten to specification. On automatic transaxles, connect shift linkage and
oil cooler lines. Tighten linkage retaining bolt, shift cable pivot and oil cooler hose clamps to specification. Connect front exhaust pipe
to manifold (or turbocharger). Install exhaust pipe to support bracket. Tighten bolts to specification. Tighten manifold (or turbocharger)
to specification. Attach rubber exhaust hangers. Position cross brace. Tighten retaining nut and bolt and right control arm front bolt.
4. Install drive axles. Install ball joint retaining bolts and tighten to specification. Mount A/C Compressor to engine (if equipped). Tighten
lower retaining bolts to specification. Install splash guards. Install tire and wheel assemblies. Tighten retaining nuts to specification.
5. Lower vehicle. Install upper A/C compressor retaining bolts (if equipped). Tighten bolts to specification. Tighten RH engine mo u n t
through bolt to specification. Connect alternator wiring.
6. Position power steering pump bracket on stud. Lower pump into engine compartment. Install power steering pump bracket retaining
bolts and nut. Tighten to specification. Install power steering pump and belt. Tighten adjustment nut and pivot bolt to specification.
7. Install engine oil dipstick and retaining clip. Install ground strap and ground wire to cylinder head. Install clutch cable (if equipped).
Connect clutch hydraulic line if equipped with manual transaxle or naturally aspirated. Connect transmission electrical connectors.
Connect fuel lines to fuel filter and pressure regulator. Install intake air tube to throttle body.
8. Install intercooler hoses on turbocharged models. Install air cleaner assembly brackets. Install air cleaner assembly with airflow meter
attached. Install intake air tube. Install coil and airflow meter connectors. Connect coolant crankcase and air bypass hoses. Install
vacuum hoses as noted in disassembly.
9. Connect accelerator cable. Install retaining bracket. Install power brake booster hose. Remove speedometer cable from transaxle. Fill
transaxle to specification. See CAPACITIES in SERVICE & ADJUSTMENT SPECIFICATIONS article. Install speedometer cable.
Connect speedometer cable connector. Fill engine oil to capacity.
10. Install radiator/fan assembly. Tighten bracket retaining bolts to specification. Connect coolant hoses and fan electrical connector. Fill
coolant to specification.
11. Install hood and connect washer hose. Install battery tray support, battery tray, battery and battery hold-down. Connect battery
terminal. Evacuate and charge air conditioning system (if equipped). Road test vehicle and inspect for leaks.
INTAKE MANIFOLD
Removal (1.3L)
CAUT ION: DO NOT allow com pressor to hang by hoses. T ie up com pressor with m echanic's wire.
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2. Remove main bearing cap bolts. Remove cap and lower bearing insert. Use bearing remover or fabricated cotter key to remove upper
bearing insert. Insert bearing remover in journal lubrication hole. Rotate crankshaft in normal direction of operation only. Repeat
procedure for remaining main bearings.
3. Check bearings for abnormal wear. Check crankshaft for grooves, scratches and pitting. Using Plastigage method, check clearance of
main bearing-to-crankshaft. Always keep at least 2 bearings and caps tight during clearance check. See, at end of article,
CRANKSHAFT MAIN & CONNECTING ROD BEARINGS
table under ENGINE SPECIFICATIONS.
4. Lubricate and install new bearings in cap and block. Match bearing tangs with notch in cap and block. Position cap in its proper
location and position. Install cap bolts and tighten to specification. See TORQUE SPECIFICATIONS
table at end of article. Repeat
procedure for remaining main bearings.
CRANKSHAFT END PLAY
Check crankshaft end play with dial indicator. End play should be .0031-.0111" (.08-.282 mm). Service limit is .012" (.30 mm). If end play is
not within specification, replace thrust bearings as necessary.
CYLINDER BLOCK
1. Using straightedge and feeler gauge, check entire cylinder head surface of cylinder block. Ensure warpage does not exceed .006" (.15
mm). If warpage exceeds specification, cylinder block surface can be machined a maximum of .008" (.20 mm).
2. Replace cylinder block if it needs to be machined more than .008" (.20 mm). Check cylinder bore for wear, out-of-round, taper and
piston fit. See CYLINDER BORE SPECIFICATIONS
table. Oversize pistons are available in .010" and .020" (.25 mm and .50 mm).
CYLINDER BORE SPECIFICATIONS
LUBRICATION
ENGINE OILING SYSTEM
Oiling system is force-feed type and uses a full-flow oil filter. Oil is retrieved from oil pan by oil pump pick-up tube and distributed to oil
filter. Oil is then filtered and routed throughout engine.
Crankcase Capacity
1.3 L crankcase capacity is 3.2 qts. (3.0 L) without filter change and 3.6 qts. (3.4 L) with filter change. For 1.6 L vehicles, capacity is 3.2 qts
(3.2 L) without filter and 3.72 qts. (3.5 L) with filter.
Normal Oil Pressure (Hot)
Normal oil pressure is 50-64 psi (3.5-4.5 kg/cm2 ) at 3000 RPM.
Pressure Regulator Valve
Pressure regulator valve is located in oil pump body and is nonadjustable.
OIL PUMP
Removal
Remove oil pan, pick-up tube and screen, timing belt and crankshaft sprocket. Remove front engine cover bolts and remove front cover.
R e mo ve b o l t s r e t a in in g p u mp c o ve r t o b a c k sid e o f fr o n t c o ve r h o u sin g.
2) Remove pump cover and inner and outer gears. Pry out front seal from front cover. Remove cotter pin. Remove pressure regulator retainer,
spring and valve.
OIL PUMP SPECIFICATIONS or replacem ent.
ApplicationIn. (mm)
Cylinder Diameter
Standard Bore
1.3L2.7953-2.7960 (71.000-71.019)
1.6L3.0709-3.0716 (78.000-78.019)
Maximu m Bo re
1.3L2.8020 (71.17)
1.6L3.0905-3.0913 (78.500-78.519)
Maximu m Ou t -Of-Ro u n d & Tap er.0007 (.019)
Piston-To-Bore Clearance.006 (.15)
ApplicationIn. (mm)
Inner Gear-To-Outer Gear
1.3L.008 (.20)
1.6L.0008-.0063 (.02-.16)
Outer Gear-To-Housing
1.3L.009 (.22)
1.6L.0035-.0071 (.09-.18)
End Play
1.3L.006 (.14)
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AIR CONDITIONING & HEAT
AIR CONDITIONING TROUBLE SHOOTING
BASIC AIR CONDITIONING TROUBLE SHOOTING CHART
HEATER SYSTEM TROUBLE SHOOTING
BASIC HEATER SYSTEM TROUBLE SHOOTING CHART
Broken lead or loose soldered connectionsRepair wire or wire
connections as necessary
Solenoid Plunger Vibrates When Switch is Engaged
Weak batteryCharge or replace battery as
necessary
Solenoid contacts corrodedClean contacts or replace
solenoid
Faulty wiringCheck all wiring leading to
solenoid
Broken connections inside switch coverRepair connections or replace
solenoid
Open hold-in wiresolenoid
Low Current Draw
Worn brushes or weak brush springsReplace brushes or brush
springs as necessary
High Pitched Whine During Cranking Before Engine Fires but Engine Fires and Cranks Normally
Distance too great between starter pinion and flywheelAlign starter or check that
correct starter and flywheel are
being used
High Pitched Whine After Engine Fires With Key released. Engine Fires and Cranks Normally
Distance too small between starter pinion and flywheelFlywheel runout contributes to
the intermittent nature
WARNING:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
CONDITIONPOSSIBLE CAUSE
Compressor Not WorkingCompressor clutch circuit open.
.....Compressor clutch coil inoperative.
.....Poor clutch ground connection.
.....Fan belts loose.
.....Thermostatic switch inoperative.
.....Thermostatic switch not adjusted.
.....Ambient temperature switch open.
.....Superheat fuse blown.
Excessive Noise or VibrationMissing or loose mounting bolts.
.....Bad idler pulley bearings.
.....Fan belts not tightened correctly.
.....Compressor clutch contacting body.
.....Excessive system pressure.
.....Compressor oil level low.
.....Damaged clutch bearings.
.....Damaged reed valves.
.....Damaged compressor.
In su fficien t o r No Co o l in g; Co mp resso r
WorkingExpansion valve inoperative.
.....Heater control valve stuck open.
.....Low system pressure.
.....Blocked condenser fins.
.....Blocked evaporator fins.
.....Vacuum system leak.
.....Vacuum motors inoperative.
.....Control cables improperly adjusted.
.....Restricted air inlet.
.....Mode doors binding.
.....Blower motor inoperative.
.....Temperature above system capacity.
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to DIAGNOST IC,
or T EST ING articles available in the section(s) you are accessing.
Page 6 of 36 MITCHELL 1 ARTICLE - GENERAL INFORMATION Trouble Shooting - Basic Procedures
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1991 GENERAL SERVICING
A/C System Specifications - Applications & Oil/R-12 Capacities
COMPRESSOR APPLICATIONS - PASSENGER CARS
COMPRESSOR APPLICATIONS - PASSENGER CARS
COMPRESSOR APPLICATIONS - LIGHT TRUCKS & VANS
COMPRESSOR APPLICATIONS - LIGHT TRUCKS & VANS
BODY CODE DESIGNATIONS - LIGHT TRUCKS & VANS
BODY CODE DESIGNATIONS - LIGHT TRUCKS & VANS
REFRIGERANT OIL & R-12 CAPACITY - PASSENGER CARS
PASSENGER CAR REFRIGERANT OIL & R-12 CAPACITY
ApplicationCompressor
ContinentalFord FX-15 10-Cyl.
Cougar & ThunderbirdFord FX-15 10-Cyl.
Crown Victoria, Grand Marquis & Town CarFord FX-15 10-Cyl.
Escort & TracerNippondenso 10P13 10-Cyl.
Mark VIINippondenso 10PA17 10-Cyl.
Mustang
2.3L EngineNippondenso 10P15 10-Cyl.
5.0L EngineNippondenso 6P-148 6-Cyl.
Probe
2.2L EngineNippondenso 10P15A 10-Cyl.
3.0L EngineNippondenso 10P15 10-Cyl.
Sable & Taurus
2.5L EngineFord FS-6 6-Cyl.
3.0L & 3.8L EnginesFord FX-15 10-Cyl.
3.0L SHO EngineNippondenso 10P15F 10-Cyl.
Tempo & TopazNippondenso 10P15 10-Cyl.
ApplicationCompressor
AerostarFord FX-15 10-Cyl.
BroncoFord FX-15 10-Cyl.
"E " SeriesFord FS-6 6-Cyl.
ExplorerFord FX-15 10-Cyl.
"F" Series
7.3L DieselFord FS-6 6-Cyl.
Gas Engine ModelsFord FX-15 10-Cyl.
Ranger
2.3L EngineFord FX-15 10-Cyl.
2.9L EngineFord FS-6 6-Cyl.
4.0L EngineFord FX-15 10-Cyl.
ModelDesignation
Aerostar"A" Series
Bronco & Explorer"U" Series
Pickups (Full Size)"F" Series
Ranger"R" Series
Vans (Full Size)"E " Series
Application(1) Oil OuncesR-12 Ounces
Continental8.040
Cougar & Thunderbird7.040
Crown Victoria, Grand Marquis & Town Car7.040-48
Escort & Tracer8.036
Mark VII8.040
Mustang
10P15 Compressor8.040
6P148 Compressor10.040
Probe
10P15 Compressor8.040
10P15A Compressor3.340
Sable & Taurus
FS-6 Compressor10.044
FX-15 Compressor7.044
10P15 Compressor8.040
Page 1 of 2 MITCHELL 1 ARTICLE - 1991 GENERAL SERVICING A/C System Specifications - Applications & Oil/R-12 Capacities
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ST EERING SYST EM - POWER
1991-92 ST EERING Ford Motor Co. - Steering - Power Rack & Pinion
DESCRIPTION & OPERATION
Power steering system consists of a rack and pinion steering gear, valve body, power steering pump, fluid reservoir and interconnecting
hydraulic lines. Pressure and return lines from pump are connected to valve body. A vane-type power steering pump draws fluid from the
steering reservoir. Fluid is compressed by rotor and vanes inside steering pump and sent to steering gear. Pressure is monitored and controlled
by a pressure switch and a control valve located inside of steering pump.
TROUBLE SHOOTING
Refer to TROUBLE SHOOTING - BASIC PROCEDURES article in the GENERAL TROUBLE SHOOTING section.
LUBRICATION
CAPACITY
Information is not available.
FLUID TYPE
Use Dexron-II ATF type fluid.
FLUID LEVEL CHECK
Check fluid level before engine is started, while fluid is still cool. Remove reservoir cap fluid indicator on steering pump. Check fluid level.
Fluid should be between the "L" and "H" marks on the level gauge dipstick. If fluid is needed, fill to the "L" mark on dipstick. Run engine until
warm and turn steering wheel fully in both directions about 10 times. Return steering to straight-ahead position and shut engine off. Ensure
fluid level is between "L" and "H" marks. Add fluid if necessary.
HYDRAULIC FLUID BLEEDING
1. Raise and support front of vehicle. Ensure pump reservoir is filled to specified level. With ignition coil wire disconnected, crank engine
and add fluid to steering pump until fluid level remains constant. While cranking engine, rotate steering from stop to stop. Recheck and
add fluid as necessary.
2. Start engine and allow to idle for several minutes. Turn steering wheel completely lock-to-lock several times. Check fluid level. Add
fluid as necessary. Continue this procedure until there is no bubbling or decrease in fluid level.
ADJUSTMENTS
BELT TENSION
On Festiva, remove air duct and air cleaner. On all models, loosen steering pump mounting pivot bolt and the adjusting bolt lock nut. Using
Belt Tension Gauge (021-0028A), fit gauge to longest available belt span for testing. Adjust belt to specification. See BELT TENSION
SPECIFICATIONS . Tighten adjuster lock nut to 32-45 ft. lbs. (43-61 N.m) on Capri or 27-38 ft. lbs. (37-52 N.m) on Festiva.
BELT TENSION SPECIFICATIONS
REMOVAL & INSTALLATION
STEERING GEAR
Removal
1. Disconnect negative battery cable. On Capri, mark and loosen intermediate lower U-joint. On Festiva, mark and remove steering gear
intermediate shaft connecting steering gear to column shaft. On all models, disconnect high pressure and return lines and plug them.
Loosen front wheel lug nuts.
2. Raise vehicle. Remove front wheels. Remove tie rod end cotter pins and nuts. Separate tie rod ends from steering knuckles using Tie
Rod Remover (T85M-3395-A). Remove tie rod end splash shields. Remove right fender splash shield. Remove front catalytic converter
nuts and separate converter from inlet pipe.
3. Place reference marks on tie rod end and tie rod for reassembly reference. Loosen tie rod jam nut and remove right tie rod end. Remove
steering gear mounting bolts and washers. Slide steering gear to the left and pull right tie rod through fender opening. Remove steering
gear by sliding it to the right.
Installation
Application
(1) Deflection: In.
(mm)Gauge Tension:
Lbs. (kg)
New Belt
Capri & Festiva.31-.35 (8-9)110-132 (50-60)
Used Belt
Capri.31-.35 (8-9)110-132 (50-60)
Festiva.35-.39 (9-10)95-110 (43-50)
(1)Apply approximately 22 lbs. (9.9 kg) of pressure.
Page 1 of 9 MITCHELL 1 ARTICLE - STEERING SYSTEM - POWER 1991-92 STEERING Ford Motor Co. - Steering - Power Rack & Pi
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