refrigerant type FORD FESTIVA 1991 Service Manual

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1991 GENERAL SERVICING
A/C Com pressor Refrigerant Oil Checking
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.
SERVICING PRECAUTIONS
DISCHARGING SYSTEM PRECAUTIONS
If compressor has stem-type service valves, it can be isolated and removed without discharging entire system. See ISOLATING
COMPRESSOR at the beginning of this article. Otherwise, discharge system completely 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 DRAIN & REFILL
1. Before checking and adjusting oil level, operate compressor at engine idling speed, with controls set for maximum cooling and high
blower speed, for 20 to 30 minutes to return oil to compressor.
2. Stop engine, discharge refrigerant and remove compressor from vehicle. See SERVICING PRECAUTIONS at beginning of article. Drain
compressor oil from compressor discharge port and measure the amount. Oil is sometimes hard to drain when compressor is cool.
Remove oil while compressor is warm.
3. If the amount drained is less than 3 ounces, conduct leak tests at system connections, and if necessary, repair or replace faulty parts.
Check purity of oil and adjust oil level as follows.
4. If amount drained was above 3 ounces, oil level is right. Pour in same amount as was drained. If amount drained was below 3 ounces,
pour in 3 ounces of new refrigerant oil.
BOSCH 6-CYL DRAIN & REFILL
1. Before checking and adjusting oil level, operate compressor at engine idling speed, with controls set for maximum cooling and high
blower speed, for 20 to 30 minutes to return oil to compressor.
2. Stop engine and discharge refrigerant. Remove refrigerant oil level inspection plug on side of compressor. Oil should be at lower lip of
threaded hole. Add necessary new refrigerant oil (if low). Replace inspection plug and tighten to 10-12 ft. lbs. (14-16 N.m). NOTE:Only com pressors with stem -type service valves can be isolated.
NOTE:Recent findings by the EPA indicate that refrigerant is harm ful to the earth's protective Ozone layer.
When discharging refrigerant, DO NOT allow refrigerant to enter the atm osphere. If available, use
refrigerant recovery/recycle system s when discharging system . Always follow m anufacturer's
instructions.
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 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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compressor label before adding refrigerant oil to A/C compressor/system. See Fig. 2 . The following R-134a refrigerant oils are currently
available.
Lexus
PAG Refrigerant Oil (ND-OIL 8) with 10P/10PA swashplate (piston) compressor. Synthetic Refrigerant Oil (ND-OIL 9) with through-va n e
(rotary vane) compressor.
Mercedes-Benz
PAG Refrigerant Oil (001 989 08 03).
Nissan
PAG Refrigerant Oil (KLH00-PAGR0) with rotary vane compressor. PAG Refrigerant Oil (KLH00-PAGS0) with piston (swashplate)
compressor.
Saab
PAG Refrigerant Oil (40 74 787).
SERVICE EQUIPMENT
Because R-134a is not interchangeable with R-12, separate sets of hoses, manifold gauge set and recovery/recycling equipment are required to
service vehicles. This is necessary to avoid cross-contaminating and damaging system.
All equipment used to service systems using R-134a must meet SAE standard J1991. The service hoses on the manifold gauge set must have
manual (turn wheel) or automatic back-flow valves at the service port connector ends. This will prevent refrigerant from being released into
the atmosphere.
For identification purposes, R-134a service hoses must have a Black stripe along its length and be clearly labeled SAE J2196/R-134a. The low
pressure test hose is Blue with a Black stripe. The high pressure test hose is Red with a Black stripe, and the center test hose is Yellow with a
Black stripe.
R-134a manifold gauge sets can be identified by one or all of the following.
Labeled FOR USE WITH R-134a on set
Labeled HFC-134 or R-134a on gauge face
Light Blue color on gauge face
In addition, pressure/temperature scales on R-134a gauge sets are different from R-12 manifold gauge sets.
SYSTEM SERVICE VALVES
SCHRADER-TYPE VALVES
Schrader valve is similar in construction and operation to a tire valve. When a test gauge hose with built-in valve core depressor is attached,
Schrader stem is pushed inward to the open position and allows system pressure to reach gauge.
If test hose does not have a built-in core depressor, an adapter must be used. Never attach hose or adapter to Schrader valve unless it is first
connected to manifold gauge set.
Refrigerant R-12 Schrader-type valve cores have TV5 thread size. Refrigerant R-134a Schrader-type valve cores use M6 (Metric) threads. R-
134a valve cores can be easily identified by use of "O" rings and external spring. See Fig. 1
.
SERVICE VALVE LOCATIONS
SERVICE VALVE LOCATIONS NOTE:Synthetic/PAG oils absorb m oisture very rapidly, 2.3-5.6% by weight, as com pared to a m ineral oil
absorption rate of .005% by weight.
NOTE:Refrigerant R-12 service hoses will ONLY be labeled SAE J2196.
NOTE:Although sim ilar in construction and operation to a tire valve, NEVER replace a Schrader-type valve
with a tire valve.
VehicleHighLow
Audi(14) (15)
Acura(2) (3)
BMW(4) (5)
Chrysler, Eagle & Mitsubishi
Colt, Mirage & Summit(10) (11)
Colt Vista & Summit Wagon(10) (11)
Diamante(1) (1)
Eclipse & Expo(10) (11)
Galant(10) (11)
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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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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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1991 AIR CONDIT IONING & HEAT
MANUAL A/C
A/C SYSTEM SPECIFICATIONS
SPECIFICATIONS
DESCRIPTION
This A/C-heater system is fully integrated to provide cooling, heating and ventilation with either fresh or recirculated air. A/C system is
expansion valve type. Interior air temperature is controlled by cycling the compressor on and off at different rates. A/C compressor is protected
by a low pressure switch, which stops compressor operation when refrigerant pressure is too low. Compressor operation is cut when throttle is
wide open to improve driveability.
The primary system components are compressor, receiver-drier, evaporator, low pressure switch, thermostatic switch, thermostatic expansion
valve, A/C control module, refrigerant lines and air ducts. See Fig. 1
and Fig. 2 . The heater core is continuously supplied with coolant. To
control temperature, air goes through and/or around heater core by way of temperature blend door.

Fig. 1: Identifying A/C System Components

Courtesy of FORD MOTOR CO. 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.
ApplicationSpecification
Compressor TypeNippondenso 10-Cylinder
Refrigerant (R-12) Capacity25 ozs.
System Oil Capacity10 ozs.
Compressor Belt Deflection
New9/32-11/32" (8-9 mm)
Used11/32-7/16" (9-11 mm)
System Operating Pressure (1)
Low Side19-25 psi (1.3-1.7 kg/cm2 )
High Side199-220 psi (13.9-15.4
kg/cm
2 )
(1)When measured at 79°F (26°C).
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