engine FORD FESTIVA 1991 Service Manual

Fig. 1: Exploded View of Chrysler, Ford & Nippondenso 6-Cyl Compressors
Courtesy of FORD MOTOR CO.
Installation
1. Place dowel pins in compressor. Lubricate inlet reed valve with refrigerant oil. Install inlet reed valve on compressor. Install front valve
plate assembly on compressor.
2. Lubricate shaft seal seat with refrigerant oil. Position Seat Installer (T81P-19623-C) on new seat so installer is placed on raised side of
seat. Install shaft seal seat.
3. Install shaft seal assembly in front head so sealing surface is toward en of compressor shaft. Ensure flat areas on shaft seal assembly
engage with flat areas on compressor shaft.
4. Lubricate front head "O" ring with refrigerant oil. Install front head and "O" ring. Tighten retaining bolts in a crisscross pattern to 19 ft.
lbs. (26 N.m). DO NOT use air tools to tighten retaining bolts.
5. Install clutch assembly. Add same amount new refrigerant oil to compressor as was drained. Install compressor. Evacuate and recharge
system. Perform leak test.
FORD FX-15 10-CYL CLUTCH ASSEMBLY
Removal
1. Discharge system using approved refrigerant recovery/recycling equipment. Remove compressor. Using Spanner (T70P-4067-A), remove
clutch plate retaining bolt and discard. Using an 8-mm bolt threaded into clutch plate, remove clutch plate and shims. See Fig. 2
.
2. Remove snap ring and remove pulley assembly. Disconnect electrical wiring to clutch coil. Install Shaft Protector (T89P-19623-FH) on
nose opening of compressor.
3. Install 2-jaw puller on compressor. Ensure puller screw is engaged in center of shaft protector. Tighten puller to remove clutch coil from
compressor. DO NOT use air tools when removing clutch coil.
Installation
1. Ensure clutch coil mounting surface is clean. Install clutch coil. Ensure electrical connection is correctly positioned. Install Coil
Installer (T89P-19623-EH) over compressor nose and inner diameter of clutch coil.
2. Install 2-jaw puller on compressor and coil installer. Jaws on puller should engage with compressor front mounts and pressure screw
centered on coil installer.
3. Tighten pressure screw and install clutch coil. DO NOT use air tools when installing clutch coil.
4. Install pulley and snap ring. Install snap ring with beveled side away from compressor. Install shims and clutch plate. Install NEW
clutch plate retaining bolt and tighten to 96-120 INCH lbs. (11-14 N.m).
5. Using a feeler gauge, check clearance between clutch plate and pulley assembly mating surfaces in 3 places. Clearance should be .018-
.033" (.46-.84 mm). If clearance is not correct, add or remove shims.
6. Install compressor. Evacuate and recharge system. Perform leak test.

Fig. 2: View of Ford FX
-15 10-Cyl Compressor Clutch Assembly
Courtesy of FORD MOTOR CO.
FORD FX-15 10-CYL SHAFT SEAL
Removal
CAUT ION: DO NOT dry front valve plate assem bly or inlet reed valve with com pressed air.
CAUT ION: DO NOT touch sealing surfaces of shaft seal or shaft seat assem bly.
NOTE:When new clutch assem bly is installed, cycle clutch assem bly 10 tim es with engine at idle to burnish
clutch and prevent slippage.
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NIPPONDENSO 10P13 CLUTCH ASSEMBLY
Removal
1. Discharge system using approved refrigerant recovery/recycling equipment and remove compressor. Using Clutch Holder (1014), hold
clutch plate and remove crankshaft nut. Using Clutch Plate Remover (T80L-19703-B), pull clutch plate from compressor. Remove
clutch plate shims.
2. Remove snap ring and pulley assembly. If pulley assembly cannot be removed by hand, use Shaft Protector (T80L-19703-G) and 3-jaw
puller to remove pulley. Remove snap ring. Disconnect electrical wiring and remove clutch coil.
Installation
1. Install clutch coil over locating pin. Install snap ring with beveled side away from compressor.
2. Install pulley assembly using Pulley Installer (T80L-19703-J) and hammer (if necessary). Install snap ring with beveled side away from
compressor.
3. Install clutch plate shims. Ensure clutch plate aligns with crankshaft key. Install clutch plate using Clutch Plate Installer (T80L-19703-
F).
4. Install crankshaft nut. Using spanner, tighten nut to 10-14 ft. lbs. (13-20 N.m). DO NOT tighten nut with air tools. Using feeler gauge,
check clearance between clutch plate and pulley.
5. Rotate compressor clutch and check clearance in more than one place. Proper clearance is .021-.036" (.53-.91 mm). If clearance is not
correct, add or remove shims.
6. Add same amount new refrigerant oil to compressor as was drained. Rotate compressor 10 revolutions to distribute oil. Install
compressor. Evacuate and recharge system. Perform leak test.
NIPPONDENSO 10P13 SHAFT SEAL
Removal
1. Discharge system using approved refrigerant recovery/recycling equipment and remove compressor. Drain oil from compressor and
record amount for reassembly. Using Clutch Holder (1014), hold clutch plate and remove crankshaft nut.
2. Pull clutch plate from compressor using Clutch Plate Remover (T80L-19703-B). Remove clutch plate shims. Clean compressor area
around seal. Remove felt packing and dust seal retainer from nose of front cover. See Fig. 3
.
3. Using Key Remover (T81P-19623-NH), remove key from compressor shaft. Remove seal seat retaining snap ring. Remove seal seat from
compressor using Seal Seat Remover/Installer (T87P-19623-B).
4. Place Seal Remover/Installer (T87P-19623-C) on compressor. Rotate seal remover/installer clockwise until tangs engage in seal. Pull
seal from compressor.
Installation
1. Lubricate shaft seal, seal seat and inside of compressor nose with refrigerant oil. Install Seal Protector (T71P-19703-H) over compressor
shaft. Using seal remover/installer, install shaft seal in compressor.
2. Rotate seal on compressor shaft to align flat areas on seal with those on compressor shaft.
3. Using seal seat remover/installer, install seal seat until it contacts seal. Install snap ring. Install key in crankshaft with rounded edge
inward.
4. Install clutch plate shims. Ensure clutch plate is aligned with crankshaft key. Using Clutch Plate Installer (T80L-19703-F), install clutch
plate.
5. Install crankshaft nut. Using spanner, tighten nut to 10-14 ft. lbs. (13-20 N.m). DO NOT tighten nut with air tools. Using feeler gauge,
check clearance between clutch plate and pulley.
6. Rotate compressor clutch and check clearance in more than one place. Proper clearance is .021-.036" (.53-.91 mm). If clearance is not
correct, add or remove shims.
7. Add same amount new refrigerant oil to compressor as was drained. Rotate compressor 10 revolutions to distribute oil in compressor.
Install compressor. Evacuate and recharge system. Perform leak test. NOTE:After installing new clutch, cycle clutch 10 tim es with engine at idle speed to prevent clutch slippage.
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5. Using Shaft Seal Remover/Installer (T87P-19623-C), remove seal by pushing downward on shaft seal remover/installer and rotating
clockwise to engage seal tangs. Pull seal from compressor.
Installation
1. Place Shaft Seal Protector (T71P-19703-H) over compressor shaft. Lubricate shaft seal and nose of compressor with new refrigerant oil.
DO NOT touch sealing surface of seal or shaft. Engage seal tangs on shaft seal remover/installer.
2. Align flats of seal with flats on crankshaft and push new seal on compressor shaft. Push downward on shaft seal remover/installer and
turn counterclockwise to disengage seal tangs.
3. Attach shaft seal seat to shaft seal seat remover/installer and lubricate with new refrigerant oil. Install seal seat and push inward against
seal. Install seal seat retaining snap ring.
4. Install dust seal retainer and felt packing. Install clutch plate shims. Ensure clutch plate aligns with crankshaft key. Using Clutch Plate
Installer (T80L-19703-F), install clutch plate.
5. Install crankshaft nut. Using spanner to hold clutch, tighten crankshaft nut to 10-14 ft. lbs. (13-20 N.m). DO NOT tighten nut with air
tools.
6. Using feeler gauge, check clearance between clutch plate and pulley. Rotate compressor clutch and check clearance in more than one
place. Proper clearance is .021-.036" (.53-.91 mm). If clearance is not correct, add or remove shims.
7. Add same amount new refrigerant oil to compressor as was drained. Rotate compressor 10 revolutions to distribute oil. Install
compressor. Evacuate and recharge system. Perform leak test.
NIPPONDENSO 10P15A SHAFT SEAL
Removal
1. Discharge system using approved refrigerant recovery/recycling equipment and remove compressor. Drain oil from compressor and
record amount for reassembly. Remove clutch assembly. See NIPPONDENSO 10P15A CLUTCH ASSEMBLY R & I in this article.
2. Remove manifold assembly from top of compressor. Clean compressor front hub area. Using Ring Remover (T71P-19703-C), remove
retaining ring from front of compressor shaft.
3. Remove felt seal from front of compressor. Remove front head retaining bolts and front head from compressor. Remove snap ring fro m
rear of front head. Remove seal from rear of front head.
Installation
1. Install seal and snap ring in front head. Install front head on compressor. Tighten bolts to 18-20 ft. lbs. (24-27 N.m). Install felt packing
and retaining ring.
2. Install manifold assembly and tighten bolts to 18-20 ft. lbs. (24-27 N.m). Add same amount of new refrigerant oil to compressor as that
drained from compressor. Rotate compressor 10 revolutions to distribute oil in compressor. Install compressor. Evacuate and recharge
system. Perform leak test.
NIPPONDENSO 10PA17 & 10PA17A CLUTCH ASSEMBLY
Removal
1. Remove compressor shaft bolt and discard. Remove clutch plate and shims. If clutch hub cannot be removed by hand, thread a 8-mm
bolt in center of clutch plate. Tighten bolt and remove clutch plate.
2. Remove pulley assembly retaining snap ring. Remove pulley assembly. Remove snap ring and disconnect clutch coil electrical wiring.
Remove clutch coil.
Installation
1. Install clutch coil so pin in back of coil aligns with hole in front housing. Install snap ring with beveled side away from compressor.
2. Install pulley assembly. Install snap ring with beveled side away from compressor. Coat splines of compressor shaft with White grease. I
f
reusing original clutch plate and pulley, old shims can be used.
3. If installing new components, install one thin shim. Install clutch plate. Tighten compressor shaft bolt to 10 ft. lbs. (14 N.m). DO NOT
air tools to tighten bolt.
4. Using feeler gauge, measure air gap between clutch plate and pulley surface in 3 areas. Proper clearance is .014-.026" (.35-.66 mm).
Adjust shim thickness to obtain correct clearance.
5. Once compressor shaft bolt is tightened, recheck clearance between clutch plate and pulley surface in 4 places. Readjust clearance if
necessary.
NIPPONDENSO 10PA17 & 10PA17A SHAFT SEAL
Removal
1. Discharge system using approved refrigerant recovery/recycling equipment and remove compressor. Drain oil from compressor and
record amount for reassembly. Install compressor in Holding Fixture (T89P-19623-D) and clamp fixture in a vise.
2. Remove clutch assembly. See NIPPONDENSO 10PA17 & 10PA17A CLUTCH ASSEMBLY R & I in this article. Remove front head
retaining bolts. Separate front head from compressor, using care not to scratch sealing surface. See Fig. 4
.
3. Using "O" Ring Remover (T71P-19703-C), remove felt dust seal and dust seal retainer from front head. Remove shaft seal retaining snap
ring. Position front head (nose up) on cardboard placed on a flat surface. Using Shaft Seal Remover (T89P-19623-E), push shaft seal
from front head. NOTE:After installing new clutch, ensure voltage is correct and cycle clutch with 5 seconds on and 5 seconds
off. Repeat cycle for approxim ately 20 tim es with A/C on, blower fan on high speed and engine RPM at
1500-2000. T his provides better clutch torque capability.
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A/C COMPRESSOR SERVICING
1991 GENERAL SERVICING Com pressor Service
ISOLATING COMPRESSOR
1. Connect service gauge set to the compressor service valves and open compressor valves slightly (turn in clockwise). Start engine and
operate air conditioning. Slowly turn compressor suction valve clockwise toward closed (front-seated) position.
2. When suction pressure is reduced to zero or less, turn off engine and compressor and quickly turn suction valve stem in to full front-
seated position. Suction pressure should be slightly above zero. Turn discharge valve into front-seated position.
3. To check oil level, slowly open compressor crankcase plug to relieve any remaining pressure. After oil level is corrected, cap service
gauge ports on both valves. Back-seat suction service valve to allow refrigerant to enter compressor. Open discharge valve halfway.
4. Loosen discharge service valve cap, allowing refrigerant pressure to force air out of compressor. Back-seat service valve and tighten cap.
Compressor is now ready for operation.
REFRIGERANT OIL
Only new, pure, moisture-free refrigerant oil should be used in the air conditioning system. This oil is highly refined and dehydrated to a point
where moisture content is less than 10 parts per million. The oil container must be tightly closed at all times when not in use, or moisture will
be absorbed into the refrigerant oil from the air.
DISCHARGING SYSTEM PRECAUTIONS
If compressor has stem-type service valves, it can be isolated and removed without discharging entire system. Otherwise, discharge system
completely using approved refrigerant recovery/recycling equipment before loosening any fittings.
DISCONNECTING LINES & FITTINGS TEST
After system is discharged, carefully clean area around all fittings to be opened. Always use 2 wrenches when tightening or loosening fittings
to avoid twisting or distorting lines. Cap or plug all openings as soon as lines are removed. Do not remove caps until immediately before
connections are made. This will keep entry of air and moisture to a minimum.
CONNECTING LINES AND FITTINGS
A new gasket or "O" ring should be used in all instances when connecting lines or fittings. Dip "O" ring in new refrigerant oil and ensure it is
not twisted during installation. Always use 2 wrenches to prevent damage to lines and fittings.
PLACING SYSTEM IN OPERATION
After component service or replacement has been completed and all connections have been made, evacuate system thoroughly with a vacuum
pump. Charge system with proper amount of refrigerant and perform a leak test. See REFRIGERANT OIL & R-12 SPECIFICATIONS chart in
this section for system capacities. Be sure to check all fittings that have been opened. After system has been leak tested, make a system
performance check.
ATSUGI ROTARY VANE CLUTCH R & I
Removal
When replacing compressor clutch, be careful not to scratch shaft or bend pulley. When removing center bolt, hold clutch disc with Clutch
Holder (KV99231010). Using Hub Puller (KV998VR001 & KV99231010), remove clutch disc. When removing pulley, remove lock nut with
Hub Socket (KV99235160).
Installation
Wipe oil off clutch surface. Adjust disc pulley clearance to .012-.024" (.3-.6 mm). Tighten center bolt to 80-104 INCH lbs. (9.1-11.8 N.m).
Tighten clutch lock nut to 22-29 ft. lbs. (29-39 N.m). See Fig. 1
. CAUT ION: When discharging air conditioning system , use only approved refrigerant recovery/recycling
equipm ent. Make every attem pt to avoid discharging refrigerant into the atm osphere.
NOTE:Only com pressors with stem -type service valves can be isolated.
CAUT ION: When discharging air conditioning system , use only approved refrigerant recovery/recycling
equipm ent. Make every attem pt to avoid discharging refrigerant into the atm osphere.
NOTE:Air conditioning system s will not norm ally need addition of refrigerant oil unless definite oil loss has
occurred due to ruptured lines, leaking com pressor seals, com pressor overhaul or com ponent
replacem ent.
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A/C SYST EM PRECAUT IONS
A/C GENERAL SERVICING A/C System Servicing cautions
BEFORE OPENING THE SYSTEM
Before disconnecting any lines or fittings, the system must be completely discharged using approved refrigerant recovery/recycling equipment.
DISCHARGING A/C SYSTEM
1. Remove service valve caps and install gauges. For high side gauge hose, Adapter (D81L-19703-A) must be used to connect to high side
service valve.
2. Place open end of center hose in garage exhaust outlet or in a well ventilated area. Slightly open low side gauge valve and let refrigerant
escape slowly without loosing refrigerant oil.
3. When system is nearly discharged, using approved refrigerant recovery/recycling equipment, open high side gauge valve to release any
pressure trapped in compressor. Close valves immediately after discharging to prevent entry of moisture.
DISCONNECTING LINES & FITTINGS
1. After system is discharged, using approved refrigerant recovery/recycling equipment, carefully clean entire area around coupling nut to
prevent dirt entering system. Always use two wrenches to avoid twisting or distorting lines and fittings (hold fitting with one wrench
while loosening coupling nut with second wrench).
2. Ford spring-coupling fittings require a special coupling tool (Motorcraft YT-1056) to open or close. See procedure under Connecting
Lines and Fittings.
3. Cap or plug all LINES and FITTINGS immediately to prevent entry of air and moisture into system. Do not remove these caps until
connections are being made.
COMPONENT REPLACEMENT
When components are replaced, system oil level must be adjusted. Add refrigeration oil to replacement component. See Compressor oil Check
article, as well as COMPONENT OIL REPLACEMENT QUANTITIES chart under A/C SYSTEM SPECS article in this section.
USING R-12 REFRIGERANT - SAFETY PRECAUTIONS
1. Always work in a well-ventilated, clean area. Refrigerant (R-12) is heavier than oxygen, and will displace oxygen in a confined area.
Always wear eye protection when working around air conditioning systems and R-12. The system's high pressure can cause severe injury
to eyes and skin if a hose were to burst. R-12 evaporates quickly when exposed to atmosphere, freezing anything it contacts.
2. Use care when handling refrigerant containers. DO NOT drop or strike containers or expose refrigerant containers to excessive heat.
Containers must never be heated more than 125°F (52°C). Never expose R-12 directly to open flame.
USING INDIVIDUAL R-12 CANS
Disposable refrigerant cans (referred to as one pound cans) have a flat type seal or a screw type seal, and proper can tap must be used for each
type. Be sure sealing gasket on can tap is in good condition. A proper safety can tap will prevent refrigerant from flowing back into open can,
as tap has a one-way flow control.
MULTI-CAN DISPENSING VALVES
A multi-can dispensing valve allows attachment of several cans of refrigerant, and is a good substitute when a bulk container is not available.
Cans are installed onto each leg of multi-can dispensing valve in the same manner as the individual cans, and each leg has its own can tap.
CAN TAP INSTALLATION FLAT TYPE SEAL CANS
On cam-lock or one-piece can taps, first turn the handle outward to the fully open position. Securely engage locking lugs over the can flange,
and lock them in place by turning cam lock or locking nut. Screw tap assembly into adapter so sealing gasket is fully seated against the can
top. Turn tap inward to pierce the can and close the tap. DO NOT open tap until ready to purge the service hose or dispense refrigerant into
the system.
On 2-piece can taps, be certain tap handle is turned fully inward to the closed position. Check that locking base is turned to its outer limit.
Securely engage locking lugs over the can flange. Turn entire tap assembly (without disturbing the closed setting) downward into the locking
base to pierce the can. DO NOT open tap until ready to dispense into system. CAUT ION: When discharging air conditioning system , use only approved refrigerant recovery/recycling
equipm ent. Make every attem pt to avoid discharging refrigerant into the atm osphere.
NOTE:Recent findings by the EPA indicate that R-11, R-12 and R-113 are harm ful to the Earths' protective
Ozone layer. Make every attem pt possible, to avoid discharging R-11, R-12 or R-113 into the
atm osphere.
CAUT ION: When R-12 is exposed to an open flam e, drawn into a running engine, or detected with a Halide
(propane) leak tester, poisonous phosgene gas is form ed. Keep work areas ventilated and avoid
running engines near work area.
NOTE:Recent findings by the EPA indicate that refrigerant is harm ful to the Earth's protective Ozone layer.
When discharging refrigerant avoid allowing refrigerant to enter the atm osphere. Refrigerant recovery
system should be used when discharging the system .
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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
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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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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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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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