ECU FORD FESTIVA 1991 Owner's Manual

Fig. 2: Bosch 6
-Cylinder Compressor Clutch
Courtesy of BMW OF NORTH AMERICA, INC.
CALSONIC V5 CLUTCH R & I
Removal
1. Remove shaft nut while holding armature plate with clutch disk wrench. Install clutch disk puller and remove clutch plate. Remo ve sn ap
ring from center of clutch pulley.
2. Use a universal gear puller to remove clutch pulley. See Fig. 3
.Remove screw securing clutch coil ground lead. Use puller to remove
clutch coil.
Installation
1. To install clutch coil, reverse removal procedure. Carefully press clutch coil into place. Ensure that coil lead and connector are
positioned on same side as removed coil.
2. Install a NEW clutch pulley snap ring, being careful not to damage shaft seal. Press clutch plate into place. Install shaft nut and torque
to 0.9-1.4 INCH lbs. (0.10-.12 N.m).
3. Use a feeler gauge to check clutch plate-to-pulley clearance. Clearance should be .012-.024" (0.3-0.6 mm). If clearance is too large,
remove shaft nut and again press in clutch plate. If clearance is too small, increase gap by pulling up clutch plate. Do not remo ve sh aft
nut.
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Fig. 6: Exploded View of Compressor Clutch (Ford FX
-15)
Courtesy of MAZDA MOTORS CORP.
HARRISON R4 4-CYL CLUTCH R & I
Removal
1. Clamp Holding Fixture (J-25008-A) in a vise and attach compressor to holding fixture with thumb screws. Use Clutch Hub Holder (J-
33027) to hold clutch. Remove shaft nut using Shaft Nut Socket (J-9399).
2. Thread Clutch Plate and Hub Assembly Remover (J-33013-B) into hub. Hold body of remover with a wrench and turn center screw into
remover body to remove clutch plate and hub assembly. Remove shaft key and retain for assembly. See Fig. 5
.
Installation
1. Install shaft key into hub key groove. Allow key to project approximately 1/8" out of key way. Shaft key is curved slightly to provide an
interference fit in hub key groove.
2. Ensure frictional surface of clutch plate and clutch rotor are clean before installing clutch plate and hub assembly. Align shaft key with
shaft key way and place clutch plate and hub assembly onto compressor shaft.
3. Hold hex portion of Installer (J-9480-B) with a wrench. Tighten center screw to press hub into shaft until there is .020-.040" (.5-1.0
mm) air gap between frictional plate and clutch rotor.
4. Install new shaft nut with small diameter boss of nut against crankshaft shoulder. Use Thin Wall Socket (J-9399) and Clutch Hub
Holder (J-25030). Tighten shaft nut to 10 ft. lbs. (14 N.m). Spin pulley rotor by hand to ensure rotor is not rubbing on clutch drive
plate.
HARRISON R4 4-CYL SHAFT SEAL R & I
Removal
1. Clamp Holding Fixture (J-25008-A) in a vise and attach compressor to holding fixture with thumb screws. Use Clutch Hub Holder (J-
33027) to hold clutch. Remove shaft nut using Shaft Nut Socket (J-9399).
2. Thread Clutch Plate and Hub Assembly Remover (J-33013-B) into hub. Hold body of remover with a wrench and turn center screw into
remover body to remove clutch plate and hub assembly. Remove clutch plate and shaft key. Pry out dust seal (if equipped). Remove seal
seat snap ring. Thoroughly clean compressor neck area and "O" ring groove surrounding shaft. Any dirt or foreign material may cause
compressor damage.
3. Use Seal Remover/Installer (J23128-A), remove seal with a twisting motion. Use "O" Ring Remover (J-9553-01) to remove "O" ring.
Installation
1. Coat new shaft seal with refrigerant oil and install shaft seal on remover/installer. Align compressor shaft machined surface with shaft
seal and install. Turn remover/installer slightly counterclockwise to secure shaft seal tangs.
2. Using Seal Installer (J-33011), install "O" ring and coat with refrigerant oil. Coat seal seat with refrigerant oil and install using seal seat
remover/installer. Install snap ring. Install dust seal (if supplied in seal kit). See Fig. 7
.
NOTE:DO NOT drive or pound on clutch hub or shaft.
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Fig. 8: Exploded View of Harrison V5 5
-Cylinder Compressor
Courtesy of GENERAL MOTORS CO.
HITACHI 5 & 6-CYL CLUTCH R & I
Removal
1. Using Clutch Holder (KV99412302), hold clutch hub. Remove shaft nut from shaft. Using Clutch Hub Remover (KV994C5780),
remove clutch hub.
2. Pry inner snap ring off. Remove pulley and bearing assembly. If assembly cannot be removed by hand, use Pulley and Bearing Remo vers
(KV994C5781 and KV994C5782).
3. Remove clamping screws that secure coil assembly leads. Remove inner snap ring from coil assembly. Remove coil assembly from fro n t
cover. See Fig. 9
.
Inspection
Check friction surfaces of clutch for damage due to excessive heat, or excessive grooving due to slippage. Replace compressor components as
necessary. Oil or dirt on friction surfaces should be cleaned with a solvent and a dry rag. Check coil for binding, shorted or open leads.
Installation
1. Install coil assembly on compressor. Properly position terminals. Using snap ring pliers, install snap ring. Using a plastic mallet, drive
pulley and bearing assembly onto neck of front cover. Turn pulley, making sure that there is no noise and that rotation is free. Ensure
there is no pulley play.
2. Using snap ring pliers, install inner snap ring. Remove all oil from clutch pulley. Fit key and clutch hub to shaft. Select adjusting spacer
which gives the correct clearance between pulley and clutch hub.
3. Coat shaft nut with Loctite and install. Using a feeler gauge, measure clutch hub-to-pulley clearance. Clearance should be .020-
.031" (.5-.8 mm). If specified clearance is not obtained, replace adjusting spacer and readjust.
4. When replacing compressor clutch assembly, DO NOT forget break-in operation. This is accomplished by engaging and disengaging
clutch 30 times.
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Fig. 16: Removing Rotary Vane Compressor Shaft Seal (Panasonic)

Courtesy of CHRYSLER MOTORS.
SANDEN SCROLL CLUTCH & SHAFT SEAL R & I
Removal
1. Secure 2 box-end wrenches, to hold armature plate, using two 6 mm bolts 1 in. (25 mm) or longer. Holding box-end wrenches, use a
socket and ratchet to remove clutch hub nut.
2. Remove armature plate. See Fig. 17
. Remove snap ring with internal snap ring pliers. Remove clutch hub. Remove snap ring and clutch
coil.
3. Remove bolts retaining front housing. Remove front housing and "O" ring from compressor. Remove shaft seal from shaft. Remove snap
ring from back side of front housing. Remove seal plate.
4. Use brass drift and hammer to lightly tap shaft bearing from front housing. Remove felt seal.
Installation
1. Lubricate shaft seal with compressor oil. Align notches on shaft seal with notches on crank shaft. Install shaft seal plate on the front
housing. Install front seal housing to compressor.
2. Use Press Tool (MB991301) to install felt into front housing. Make sure felt metal section faces up. Use Press Tool (MB991301) to
press bearing into front housing.
3. Align and install clutch coil. Install snap ring so that the tapered surface is facing outward. Install clutch hub. Install snap ring. Install
armature plate, aligning raised area to notch.
4. Secure 2 box-end wrenches, to hold armature plate, using two 6 mm bolts 1 in. (25 mm) or longer. Holding box-end wrenches, use a
socket and ratchet to tighten clutch hub nut to 12 ft. lbs. (16 N.m).
5. Use feeler gauge to measure distance between armature and clutch hub. If gap is not .01-.02" (.25-.51 mm), remove clutch assemb l y an d
add or remove shims accordingly.
NOTE:Check com pressor refrigerant oil level when replacing seals.
NOTE:Do not touch the sealing surfaces of the shaft seal carbon ring and shaft seal plate.
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Back To Article
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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SCREW TYPE SEAL CANS
Ensure can tap is fully closed. Screw refrigerant can into can tap fitting until tight. This will pierce the can. Connect tap to center hose on
manifold gauge set. DO NOT open tap until ready to dispense R-12 into system.
CONNECTING LINES & FITTINGS
1. A new "O" ring should be used in all instances when connecting lines and fittings (dip "O" ring in clean refrigeration oil and make
certain it is not twisted during installation). Always use two wrenches to avoid twisting or distorting lines and fittings, tighten coupling
nuts securely.
2. Ford spring-coupling fittings require a special coupling tool (Motorcraft YT-1056) to open or close. Use the following procedure to
connect or disconnect the spring-coupling fitting.
Ford Spring-Coupling Fitting
1. Discharge system using approved refrigerant recovery/recycling equipment. Place proper end of tool over refrigerant line. Tool fits both
3/8" and 1/2" fittings. Push tool into fitting cage to release spring inside. Pull lines apart and remove tool.
2. Before connecting, check internal spring for damage. If necessary, pry spring out and replace it. Clean fittings and install new "O" rings.

Fig. 1: Assembling Ford Spring
-Coupling Fitting
PLACING SYSTEM IN OPERATION
After component replacement and/or system servicing has been completed and all connections have been made, proceed as follows:
1. Evacuate the system using a vacuum pump.
2. Charge the system with new R-12 (refrigerant) according to each individual vehicle as outlined in the GENERAL SERVICING article.
Also see Refrigerant Capacity in this Section.
3. Leak test the system, with particular attention to all new connections and components.
4. Make a performance test of the system. Never assume that a recharging has automatically corrected a problem.
COMPRESSOR REMOVAL INFORMATION - ISOLATION METHOD
On systems which have compressors equipped with stem-type service valves (Tecumseh), it is possible to isolate the compressor for removal.
Isolating
Turn both high and low pressure manual valves to extreme clockwise (front seat) position. Loosen cap on high pressure manual valve
connection to compressor and allow gas to escape until compressor is relieved of pressure.
COMPRESSOR REMOVAL INFORMATION-DISCHARGE METHOD
This procedure is to be used on vehicles which have compressor equipped with Schrader service valves. In these cases, the compressor cannot
be isolated and the system must be discharged, using approved refrigerant recovery/recycling equipment, prior to compressor removal. WARNING:DO NOT open high side hand valve while air conditioning system is in operation. T his high pressure
could rupture can or fitting at safety can valve, resulting in dam age and personal injury.
CAUT ION: Use ONLY "O" rings designed for these Ford fittings (Motorcraft YF-982). Norm al refrigerant "O" rings
will NOT seal.
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00039191
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5. Check blower motor fan switch continuity. Resistance should not exceed 4 ohms. See BLOWER MOTOR FAN SWITCH
CONTINUITY table. If continuity is not present, replace fan switch. If continuity is okay, repair open in Black wire from blower motor
switch to ground.
BLOWER MOTOR FAN SWITCH CONTINUITY
REMOVAL & INSTALLATION
CONTROL PANEL
1. Remove bezel screws and accessory bezel. Remove radio. Remove 4 screws securing control panel to instrument panel. Remove glove
box attaching screws and glove box. Remove the retaining clip and disconnect fresh/recirculation air door cable from mode door lever.
2. Disconnect mode select cable at mode control door lever. Disconnect temperature control cable at temperature control mode door lever.
Pull control panel away from instrument panel. Disconnect blower motor switch connector. Disconnect illumination electrical
connector. Remove control panel. To install, reverse removal procedure. Adjust control cables. See ADJUSTMENTS in this article.
BLOWER MOTOR FAN SWITCH
Remove control panel. See CONTROL PANEL R & I
. Remove blower motor fan switch knob. Remove attaching nut. To install, reverse
removal procedure.
HEATER CORE
1. Disconnect negative battery cable. Remove steering wheel by prying out center trim insert and removing steering wheel retaining nut.
Remove 2 steering wheel cover retaining screws and remove cover. Using a steering wheel puller, remove steering wheel.
2. Remove 5 screws and remove lower and upper steering column covers. Disconnect electrical connections and remove multifunction
switch. Remove 5 screws and pull instrument cluster hood rearward. Disconnect electrical connections and remove instrument cluster
hood.
3. Disconnect speedometer cable at transaxle. Remove 4 instrument cluster screws. Pull instrument cluster rearward and disconnect
speedometer cable and electrical connections. Remove instrument cluster.
4. Remove 2 center bracket mounting bolts under steering column and remove bracket. Remove glove box attaching screws and remove
glove box. Remove left and right heater ducts. Remove fuse panel cover. Remove 2 screws securing fuse panel and push fuse panel
inward. DO NOT remove fuse panel.
5. Slide both seats to most forward position. Remove 2 console attaching screws, located in front of seat belt anchors. Slide both seats to
rearmost position. Remove parking brake console insert. Using a Phillips screwdriver, remove push retainer insert, located at front lower
edge of parking brake console. Pull back on parking brake lever and remove parking brake console.
6. Remove gearshift knob. Remove screws and remove shift console. Remove radio/heater control panel bezel screws and remove bezel.
Remove 4 radio attaching screws. Pull radio out and disconnect antenna lead and electrical connections. Disconnect radio ground lead
and remove radio.
7. Remove 4 screws attaching heater control panel. Disconnect control cables and electrical connections. Remove control panel, while
pulling cables through opening.
8. Pry out bolt cover trim inserts in top corners of dash. Remove bolts located under trim panels. Remove 7 instrument panel attaching
bolts and 2 nuts. Pull instrument panel rearward. Disconnect any harness connectors and clips. Remove instrument panel.
9. Disconnect electrical connections at blower and resistor. Remove harness from routing brackets on heater box. Loosen clamp screw
securing air inlet housing. Remove attaching nuts at top and bottom of heater box. Disconnect defroster ducts and remove heater
assembly.
10. Disconnect link connecting 2 defroster doors. Remove attaching screw just above and to right of blower resistor. Turn heater assembly
around and remove screw just to left of blower motor opening. Remove clips securing 2 halves of heater assembly. Separate halves. Lift
out heater core.
11. To install, reverse removal procedure. Ensure all heater control cables are routed and adjusted properly. See ADJUSTMENTS in this
article. Fill cooling system. Check for leaks.
BLOWER MOTOR & RESISTOR
Disconnect negative battery cable. Remove instrument panel spacer brace located below steering column. Remove airflow duct below steering
column. Disconnect blower motor or resistor wiring. Remove 3 blower motor attaching screws or 2 resistor attaching screws and remove
component. To install, reverse removal procedure.
Switch PositionContinuity Between Wire Colors
1Black-to-Blue/White
2Black-to-Blue/Yellow & Blue/Yellow-to-Blue/Red
3Black-to-Blue/Black & Blue/Black-to-Blue/Red
Page 2 of 4 MITCHELL 1 ARTICLE - HEATER SYSTEM 1990-92 HEATER SYSTEMS Ford Motor Co.
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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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