1991 FORD FESTIVA oil dipstick

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ENGINE OVERHAUL
1991-92 FORD MOT OR CO. ENGINES 1.3L & 1.6L 4-Cylinder
ENGINE IDENTIFICATION
Engine can be identified by Vehicle Identification Number (VIN) on metal tab attached to instrument panel. Tab is close to windshield on
driver's side and is visible through windshield. VIN has 17 characters. The 8th character identifies engine.
ENGINE IDENTIFICATION CODES
ADJUSTMENTS
VALVE ARRANGEMENT
Firewall Side
In t ake val ves.
Radiator Side
Exhaust valves.
VALVE CLEARANCE ADJUSTMENT
Hydraulic lifters are used. Adjustment is NOT possible nor necessary.
REMOVAL & INSTALLATION
FUEL PRESSURE RELEASE
Remove rear seat. Remove fuel pump access panel. Disconnect fuel pump electrical connector. Start engine and allow to idle until engine dies.
ENGINE
Removal (1.3L)
1. Remove battery and battery tray. Index hood-to-hinge and remove hood. Drain coolant. Drain engine oil and transaxle fluid. Disconnect
vane airflow meter connector, vane airflow meter and hose.
2. Remove oil dipstick, cooling fan and radiator assembly. Disconnect accelerator cable from mounting bracket and throttle lever.
Disconnect speedometer cable at transaxle. Mark and disconnect fuel lines at fuel pump. Plug fuel lines. Remove heater hoses. Remove
brake booster vacuum hose. Disconnect transaxle vacuum hose.
3. Remove charcoal canister hoses from engine. Disconnect engine wiring harness. Remove alternator and brackets. Remove engine ground
strap. Raise vehicle and remove catalytic converter.
4. Disconnect A/C compressor without removing hoses, and set compressor aside. Disconnect distributor wiring at coil. On automatic
transaxle models, remove shift lever-to-manual shaft assembly nut. Remove shift cable from transaxle. Loosen front wheel bolts. Raise
vehicle and remove wheel assemblies.
5. Remove stabilizer mounting nuts and brackets. Remove lower arm clamp bolts and nuts. Pull lower arms downward, separating lower
arms from knuckles. Separate halfshafts and install Differential Plugs (T87C-7025-C) between differential side gears. See FWD AXLE
SHAFTS article in DRIVE AXLES Section.
6. On manual transaxle vehicles, disconnect clutch control cable and shift control cable rod. Remove stabilizer bar from transaxle. Remove
catalytic converter inlet pipe. Support engine assembly with hoist. Remove rear crossmember mount bolts. Remove front and rear engine
mount nuts.
7. Remove crossmember. Lower vehicle and attach engine lift hooks. Remove right engine mount bolt. Remove engine/transaxle assembly.
Remove gusset plates. Remove starter and flywheel cover. Remove torque converter bolts on automatic transaxle. Remove engine-to-
transaxle bolts. Separate transaxle from engine.
Installation (1.3L)
1. Install transaxle to engine in reverse order of removal. Attach hoist to engine/transaxle assembly and position in vehicle. Support engine
in chassis and install engine mount bolts. Raise vehicle and install front engine mount nut. Tighten nuts to specification. See TORQUE
SPECIFICATIONS table at end of article.
2. Position crossmember onto mounts and chassis. Tighten rear nut. Install mount-to-crossmember nuts and tighten. Remove differential
plugs and install halfshafts. To complete installation, reverse removal procedure. Tighten all bolts/nuts to specifications. Fill all fluid NOTE:For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES
-
GENERAL INFORMATION
article in the GENERAL INFORMAT ION section.
ApplicationVIN Code
Festiva
1.3L SOHC PFIH
Capri
1.6L DOHC PFIZ
1.6L DOHC PFI TURBO6
NOTE:When rem oving engine m ounts, m ark and note location and position to ensure proper installation.
Engine and transaxle are rem oved as an assem bly.
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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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article. Install timing belt and covers. Install cam cover. On non-turbo engines, connect front exhaust pipe to exhaust manifold. Tighten
nuts to specification.
4. On turbocharged engines, install exhaust manifold and turbocharger assembly. Install ground wire and strap to cylinder head with
retaining bolts. Connect intercooler tubes (if equipped). Connect O2 sensor connector, and install ground wires to bracket on cylinder
head with retaining screw. Connect main engine harness connector. Connect fuel lines to fuel filter and pressure regulator. Install
throttle cable and retaining brackets.
5. Install coolant hoses and vacuum lines to intake manifold and throttle body. Install coolant hose to thermostat cover. Install intake air
tube to air cleaner. Install spark plug wires and retainers. Install intake air tube to throttle body, and connect by-pass hoses. Fill cooling
system. Connect negative battery terminal. Start engine, check for leaks and system operation.
TIMING BELT COVER
Removal & Installation (1.3L)
Remove accessory belts. Remove water pump pulley. Remove crankshaft damper. Remove bolts retaining upper and lower cover halves to
engine front. Remove both covers. To install, reverse removal procedure.
Removal & Installation (1.6L)
Raise vehicle on hoist. Remove RF tire and wheel assembly. Remove RF splash guard. Lower vehicle. Remove spark plugs and set camsh aft
timing to TDC No. 1 cylinder. Remove oil dipstick. Remove water pump pulley. Remove crankshaft pulley, damper and baffle plate. Remove
upper timing belt cover. Remove center and lower timing belt covers. To install, reverse removal procedure.
TIMING BELT
Removal (1.3L)
Remove accessory belts, water pump pulley, crankshaft damper and upper and lower timing belt covers. Mark timing belt direction of rotation
for installation reference. Remove timing belt tensioner pulley bolt. Remove tensioner pulley, spring and spring cover. Remove timing belt.
Installation (1.3L)
1. Ensure timing belt and sprockets are clean and not worn or damaged. Align crankshaft and camshaft timing marks. See Fig. 3 . No. 1
cylinder must be at TDC of compression stroke.
2. Position belt on camshaft sprocket. Install timing belt tensioner spring, spring cover and pulley. Tighten tensioner pulley bolt to
specification. See TORQUE SPECIFICATIONS
table at end of article. To complete installation, reverse removal procedure. Tighten
all bolts and nuts to specification.

Fig. 3: Aligning Camshaft & Crankshaft Timing Marks (1.3L)

Courtesy of FORD MOTOR CO.
Removal (1.6L)
NOTE:Always rotate engine in direction of norm al operation. Rotating crankshaft backwards m ay cause belt to
jump timing.
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Remove timing belt covers, See TIMING BELT COVER procedure to remove timing belt from this engine.
Installation (1.6L)
1. Ensure timing belt and sprockets are clean and not worn or damaged. Ensure timing marks are properly positioned on camshafts and
crankshaft. Intake cam should have letter "I" aligned with arrow on belt cover. Exhaust cam should have letter "E" aligned with arrow on
belt cover. Crankshaft key should align with arrow. See Fig. 4
.
2. Tighten tension pulley with tension spring fully extended. Install timing belt. Keep tension on opposite side of tensioner as tight as
possible. Ensure rotation mark on belt is correct.
3. Turn crankshaft 2 full turns. Check alignment of timing marks. If any mark is not aligned, remove timing belt and reset timing. Lo o se n
tension pulley retaining bolt allowing tension spring to tighten belt. Tighten tension pulley to specification and rotate engine 2 full
turns. Verify timing mark alignment.
4. Measure timing belt tension between camshaft pulleys. Belt deflection should be 0.33-0.45" (8.5-11.5 mm). If incorrect, loosen tension
pulley and repeat procedure. If correct tension cannot be achieved, replace tension spring.
5. Install lower, center and upper timing belt covers, and tighten bolts to specification. See TORQUE SPECIFICATIONS
table at end of
article. Install RH engine mount. Lower engine. Tighten retaining nuts to specification. Install crankshaft pulley, damper and baffle.
Tighten baffle and damper screws and pulley retaining bolts to specification. Install water pump pulley and tighten retaining bolts to
specification.
6. Install alternator and power steering belts. Install oil dipstick. Raise vehicle and install splash guard and RF wheel and tire assembly.
Lower vehicle, install spark plugs and start engine. Inspect for leaks and check operation.

Fig. 4: Aligning Camshaft & Crankshaft Timing Marks (1.6L)

Courtesy of FORD MOTOR CO.
FRONT COVER & OIL SEAL
Removal & Installation
Front cover is the housing for the oil pump. See OIL PUMP under ENGINE OILING.
CAMSHAFT
Removal (1.3L)
Remove cylinder head. Remove rocker arm assemblies if not previously removed. Carefully remove camshaft thrust plate. Remove camsh aft
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bearing oil seal. To complete installation, reverse removal procedure.
WATER PUMP
Removal & Installation (1.3L)
Remove timing belt. Drain cooling system. Remove lower radiator hose and heater return hose from water pump. Remove water pump
retaining bolts and water pump. Clean gasket mounting surface and replace gasket. To install, reverse removal procedure.
Removal (1.6L)
1. Remove timing belt. See TIMING BELT . Drain cooling system. Remove timing belt tensioner and idler pulleys. Remove oil dipstick
bracket retaining bolt.
2. Remove power steering pump from retaining bracket, leaving hoses attached. Remove power steering bracket and position power
steering pump to one side. Remove water pump outlet. Remove water pump retaining bolts and water pump.
Installation (1.6L)
1. Clean all gasket surfaces. Transfer rubber belt cover seal to new water pump (if required). Position water pump with new gasket and
install retaining bolts. Install pump outlet with new gasket and "O" ring. See TORQUE SPECIFICATIONS
table at end of article.
2. Install oil dipstick retaining bolt. Install timing belt tensioner and idler pulleys. Install power steering pump bracket. Install power
steering pump. Tighten all bolts and nuts to specification. See TORQUE SPECIFICATIONS
table at end of article.
3. Install timing belt. Fill cooling system. Start engine and check for leaks and proper system function.
OIL PAN
Removal (1.3L)
Disconnect battery ground cable. Raise vehicle and drain engine oil. Remove flywheel housing dust cover. Remove oil pan retaining bolts,
nuts and stiffeners. Rotate crankshaft while removing oil pan. Remove baffle plate from oil pan. Clean gasket mating surfaces thoroughly.
Installation (1.3L)
Ensure gasket surfaces are clean. Apply oil resistant sealer to front and rear engine covers and across joint line of cylinder block.
Removal (1.6L)
1. Raise vehicle and drain engine oil. Remove frame brace retaining bolt. Loosen RH "A" arm front bolt, and pivot brace downward.
Disconnect front exhaust pipe from exhaust manifold (or turbocharger). Remove exhaust pipe bracket retaining bolts. Loosen rubber
exhaust hangers at catalytic converter.
2. Allow exhaust to hang supported by mechanic's wire. Disconnect turbocharger oil return hose (if equipped). Remove oil pan retaining
bolts. Carefully pry oil pan loose from cylinder block.
Installation (1.6L)
1. Clean pan and block gasket surfaces. Apply Gasket Sealant (E3AZ-19562-A) to new front and rear pan seals. Install seals to cylinder
block. Apply Gasket Sealant (E3AZ-19562-A) to oil pan gasket surface. See Fig. 8
. Install oil pan and tighten pan retaining bolts to
specification. See TORQUE SPECIFICATIONS
table at end of article.
2. Connect turbocharger oil return hose (if equipped). Install rubber exhaust hanger to brackets. Install new gasket and connect fro n t
exhaust pipe to exhaust manifold (or turbocharger). Install front exhaust pipe bracket. Tighten nuts and bolts to specification.
3. Pivot frame brace into position. Tighten retaining bolt to crossmember and RH "A" arm front retaining bolt to specification. Lower
vehicle, fill with oil and start engine. Check for oil leaks and system operation. NOTE:Raise engine slightly with floor jack, if required, to gain clearance for water pum p rem oval.
CAUT ION: DO NOT force a pry tool between cylinder block and oil pan.
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Fig. 1: Testing Canister Purge Solenoid

Courtesy of FORD MOTOR CO.
Carbon Canister
1. Start and run engine until it is at operating temperature. Stop engine. Remove carbon canister. Carbon canister on 1.3L is located under
brake booster. Carbon canister is located in right side of engine compartment near cowl panel on 1.6L.
2. Inspect carbon canister for presence of liquid fuel, as evidenced by odor or weight. Blow into air vent and ensure air exits fro m fu el
vapor inlet. Replace carbon canister if it contains fuel, or if air does not pass freely through it.
POSITIVE CRANKCASE VENTILATION (PCV)
1. Remove PCV valve from valve cover and disconnect it from PCV h o se . S h a ke va l ve vigo r o u sl y t o e n su r e p l u n ge r is fr e e t o mo ve .
Replace PCV valve if plunger is not free.
2. Idle engine until it is warm. Remove fresh air hose at inlet end. Plug nipple immediately to prevent stalling. Verify presence of vacuum at
inlet end of hose. If vacuum is not present, replace PCV valve or service hoses or loose oil dipstick.
THROTTLE CONTROLS
Dashpot
Disconnect PCV valve. Remove resonance chamber. Push dashpot rod in and then release it. Replace dashpot if rod does not go in slowly and
return quickly.
MISCELLANEOUS CONTROLS
A/C CLUTCH
A/C Clutch Relay
Remove relay from its socket near left headlight, in front of battery. Connect ohmmeter to contact terminals (Blue/Red and Black/White wires
on mating connector). Ohmmeter should indicate continuity. Supply 12 volts to remaining terminals (Green/Yellow and Yellow wires on
mating connector). Ohmmeter should indicate no continuity.
COOLING FAN
Cooling Fan
Unplug connector from cooling fan. Apply 12 volts to one terminal of fan connector. Ground remaining fan connector terminal. Replace fan if
it does not run.
Cooling Fan Control Relay
Remove relay from its socket near left headlight. Connect ohmmeter to contact terminals. Wire colors are Yellow/Red and Black on mating
connector on Festiva; Yellow/Green and Black on Capri. Ohmmeter should indicate continuity. Supply 12 volts to remaining 2 relay
terminals. Ohmmeter should indicate no continuity.
NOTE:Although som e of the controlled devices listed here are not technically engine perform ance
com ponents, they can affect driveability if they m alfunction.
Page 6 of 7 MITCHELL 1 ARTICLE - I - SYSTEM/COMPONENT TESTS 1991 ENGINE PERFORMANCE Ford Motor Co. - Ford/Merc
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article. Drain oil from compressor through suction and discharge ports. Measure amount of oil drained. If amount drained is more than
2.4 ounces, fill with same amount using new oil. If amount drained is less than 2.4 ounces, fill with 2.4 ounces. Install compressor and
recharge.
3. If A/C components are replaced, add refrigerant oil to system. Add 1.4 ounces if condenser is replaced. Add 2 ounces if the evaporator
is replaced. Oil does not need to be added if receiver-drier is replaced.
SANDEN SCROLL DRAIN & REFILL
Discharge system. Remove compressor from vehicle. Drain oil from compressor through inlet and outlet holes. Refill compressor with 2.8
ounces of oil through suction port. When replacing condenser, add .5 ounce. When replacing evaporator, add 1.7 ounces. When replacing
other A/C components, add .5 ounce per component replaced.
SANDEN 5-CYL DRAIN & REFILL
1. Discharge system. Remove compressor belt and loosen mounting bolts. Rotate compressor in brackets until filler plug is at top. Clean
area around filler plug and remove plug slowly. Rotate front hub plate so notch in lobe is 110 degrees from the bottom. This rotates ball
end of top piston to align with oil fill port and allows clearance for dipstick. See Fig. 1
.
2. Insert compressor dipstick diagonally from right to left until stop on dipstick contacts filler plug surface. Remove dipstick and note oil
fill level. Each increment on dipstick represents one ounce of oil. Add oil if necessary to reach 3-4 ounce level.

Fig. 1: Sanden 5
-Cylinder Oil Level Checking
Courtesy of SANDEN INTERNATIONAL U.S.A, INC.
SANDEN 7-CYL DRAIN & REFILL
1. Before checking and adjusting oil level, operate compressor at engine idle speed, and set controls at maximum cooling and high blowing
speed for 20-30 minutes to return oil to compressor.
2. Stop engine. Discharge refrigerant and remove compressor from vehicle. See SERVICING PRECAUTIONS at the beginning of this
article. Remove oil drain plug and drain oil. Measure amount of oil drained. Install drain plug with new "O" ring.
3. If amount drained is more than 3 ounces, fill with same amount using new oil. If amount drained is less than 3 ounces, fill with 3
ounces. Install filler plug. Install compressor and recharge system.
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00038952
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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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