FORD FESTIVA 1991 Service Manual

Fig. 3: Cross
-Sectional View of Thermostatic Expansion Valve
Courtesy of FORD MOTOR CO.
ADJUSTMENTS
TEMPERATURE CONTROL CABLE
Temperature control cable is located at left base of evaporator housing. See Fig. 4
. Release cable retaining clip. Position temperature control
knob in maximum cool position. While holding thermostat cable in maximum cool position, secure cable casing using retaining clip.
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Fig. 4: Adjusting Temperature Control Cable

Courtesy of FORD MOTOR CO.
RECIRCULATED/FRESH AIR DOOR CABLE
Remove glove box retaining screws and glove box. Release cable retaining clip. See Fig. 5
. Move control knob to recirculation position. Hold
door lever in recirculation position, and secure cable casing using retaining clip. Install glove box.

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Fig. 5: Adjusting Recirculated/Fresh Air Door Cable
Courtesy of FORD MOTOR CO.
MODE SELECTOR CABLE
1. Remove air distribution plenum and instrument panel brace. See AIR DISTRIBUTION PLENUM
under REMOVAL &
INSTALLATION. Release cable retaining clip. See Fig. 6
.
2. Move control knob to vent position. While holding lever downward against stop, secure cable using retaining clip.
3. Disconnect defrost door link at defrost door lever. While holding defrost door upward against its stop, adjust defrost door link to a free
fit in defrost door lever. Install air distribution duct. Install instrument panel brace.

Fig. 6: Adjusting Mode Select Cable

Courtesy of FORD MOTOR CO.
TROUBLE SHOOTING
COMPRESSOR CLUTCH TROUBLE CHARTS

Fig. 7: Compressor Clutch Trouble Chart CC1

Courtesy of FORD MOTOR CO.
NOTE:Use the following trouble shooting charts to diagnose air conditioning system problem s.
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Fig. 8: Compressor Clutch Trouble Chart CC2

Courtesy of FORD MOTOR CO.

Fig. 9: Compressor Clutch Trouble Chart CC3

Courtesy of FORD MOTOR CO.

Fig. 10: Compressor Clutch Trouble Chart CC4

Courtesy of FORD MOTOR CO.

Fig. 11: Compressor Clutch Trouble Chart CC5

Courtesy of FORD MOTOR CO.
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Fig. 12: Compressor Clutch Trouble Chart CC6

Courtesy of FORD MOTOR CO.

Fig. 13: Compressor Clutch Trouble Chart CC7

Courtesy of FORD MOTOR CO.

Fig. 14: Compressor Clutch Trouble Chart CC8

Courtesy of FORD MOTOR CO.

Fig. 15: Compressor Clutch Trouble Chart CC9

Courtesy of FORD MOTOR CO.
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Fig. 16: Compressor Clutch Trouble Chart CC10

Courtesy of FORD MOTOR CO.

Fig. 17: Compressor Clutch Trouble Chart CC11

Courtesy of FORD MOTOR CO.

Fig. 18: Compressor Clutch Trouble Chart CC12

Courtesy of FORD MOTOR CO.

Fig. 19: Compressor Clutch Trouble Chart CC13

Courtesy of FORD MOTOR CO.
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Fig. 20: Compressor Clutch Trouble Chart CC14

Courtesy of FORD MOTOR CO.
CONDENSOR FAN TROUBLE CHARTS

Fig. 21: Condensor Fan Trouble Chart CF1

Courtesy of FORD MOTOR CO.

Fig. 22: Condensor Fan Trouble Chart CF2

Courtesy of FORD MOTOR CO.
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Fig. 23: Condensor Fan Trouble Chart CF3

Courtesy of FORD MOTOR CO.

Fig. 24: Condensor Fan Trouble Chart CF4

Courtesy of FORD MOTOR CO.

Fig. 25: Condensor Fan Trouble Chart CF5

Courtesy of FORD MOTOR CO.
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Fig. 26: Condensor Fan Trouble Chart CF6

Courtesy of FORD MOTOR CO.

Fig. 27: Condensor Fan Trouble Chart CF7

Courtesy of FORD MOTOR CO.

Fig. 28: Condensor Fan Trouble Chart CF8

Courtesy of FORD MOTOR CO.
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Fig. 29: Condensor Fan Trouble Chart CF9

Courtesy of FORD MOTOR CO.
REMOVAL & INSTALLATION
COMPRESSOR
Removal & Installation
1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect negative battery cable. Remove compressor
drive belt. Disconnect electrical connector. Disconnect refrigerant lines, and plug openings.
2. Remove compressor mounting bolts and compressor. See Fig. 1
. To install, reverse removal procedure. If installing a new compressor,
drain 1.2 ounces of refrigerant oil from compressor before installation. Evacuate and recharge system.
CONDENSER
Removal & Installation
1. Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove radiator grille. Remove right-side sight glass
cover. Disconnect refrigerant line from receiver-drier. Remove refrigerant line clamp from condenser bracket. Remove hood latch and
center brace bolts.
2. Remove condenser fan (if equipped). Remove condenser mounting bolts. Lift out condenser and mounting grommets. See Fig. 1
. To
install, reverse removal procedure. Ensure mounting grommets are properly positioned. Install new "O" rings on all refrigerant line.
Evacuate and recharge system.
RECEIVER-DRIER
Removal & Installation
Discharge A/C system using approved refrigerant recovery/recycling equipment. Remove condenser. See CONDENSER under REMOVAL &
INSTALLATION. Disconnect refrigerant lines from receiver-drier, and plug openings immediately. Remove receiver-drier mounting bolts and
receiver-drier. See Fig. 1
. To install, reverse removal procedure. Use new "O" rings. Evacuate and recharge system.
EVAPORATOR HOUSING
Removal & Installation
1. Disconnect negative battery cable. Discharge A/C system using approved refrigerant recovery/recycling equipment. Disconnect
evaporator outlet tubes (refrigerant lines), and plug openings. See Fig. 1
. Remove glove box. Disconnect 2 electrical connectors from
thermostatic switch.
2. Disconnect temperature control cable. See Fig. 4
. Remove wiring harness clamps from evaporator housing. Loosen clamp screws
securing connector duct to evaporator housing. Remove evaporator drain hose. Remove air inlet duct. See Fig. 2
.
3. Remove evaporator housing-to-dash panel bolts. Remove evaporator housing. To install, reverse removal procedure. Use new "O" rings.
Evacuate and recharge system.
EVAPORATOR
Removal & Installation
1. Remove evaporator housing. See EVAPORATOR HOUSING under REMOVAL & INSTALLATION. See Fig. 1 . Remove upper and
lower evaporator case half clips. Remove upper housing. Carefully pull sensing tube from evaporator core fins while removing
thermostat. Remove evaporator from lower housing. Remove stand-off insert from between inlet and outlet tubes.
2. Remove insulator from around capillary tube and thermostatic expansion valve. Remove capillary tube-to-suction tube clamp.
Disconnect evaporator tube fitting and thermostatic expansion valve. To install, reverse removal procedure. Use new "O" rings on all
refrigerant line connections. Evacuate and recharge system.
THERMOSTATIC SW ITCH
Removal & Installation
Remove evaporator housing. See EVAPORATOR HOUSING under REMOVAL & INSTALLATION. See Fig. 1. Remove 10 clips retaining
evaporator housing halves. Remove upper housing section. Remove thermostatic switch mounting screws. Carefully pull thermostat sensing
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