FORD FESTIVA 1991 Service Manual

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.
Page 11 of 19 MITCHELL 1 ARTICLE - ENGINE OVERHAUL 1991-92 FORD MOTOR CO. ENGINES 1.3L & 1.6L 4-Cylinder
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Fig. 8: Identifying Oil Pan Sealing Points

Courtesy of FORD MOTOR CO.
OVERHAUL
VALVE SPRINGS
Measure valve springs squareness and free length. Replace spring if either measurement is out of specification. See, at end of article, VALVES
& VALVE SPRINGS table in ENGINE SPECIFICATIONS.
VALVE STEM INSTALLED HEIGHT
Measure protruding length of each valve stem. See VALVE STEM INSTALLED HEIGHT table. If length is at service limit, use valve spring
shims to bring measurement within range of acceptable limit. If length is greater than service limit, replace valve seat or cylinder head.
VALVE STEM INSTALLED HEIGHT
VALVE GUIDES
Remove cylinder head, camshaft(s) and valves. Check valve stem-to-guide oil clearance. If clearance exceeds specification, replace valve
guides and/or valves. See CYLINDER HEAD
table under ENGINE SPECIFICATIONS at end of this article.
ROCKER ARM SHAFT ASSEMBLY (1.3L)
Remove valve cover. Keep components in order of removal to ensure reassembly to original position. Remove rocker arm shaft retaining bolts
and rocker arm shaft assembly. To install, reverse removal procedure.
VALVE LASH ADJUSTERS (1.3L)
Warm engine to normal operating temperature. Remove valve cover. Inspect hydraulic lash adjuster operation by pushing each rocker arm
down by hand. If rocker arm moves downward, replace hydraulic lash adjuster. Adjustment on valve lash adjusters is NOT possible or
necessary.
CAM SHAFT(S) (1.6L)
Remove cam cover. Remove camshaft(s). Keep components in order of removal to ensure reassembly to original position. To install, reverse
removal procedure.
VALVE LASH ADJUSTERS (1.6L)
Inspect friction surfaces for wear and damage. Hold bucket body (each adjuster) and press between thumb and forefinger. If plunge r mo ve s,
ApplicationIn. (mm)
1.3L
New1.520-1.539 (38.6-39.1)
Acceptable Limit1.539-1.579 (39.2-40.1)
Service Limit1.579 (40.1)
1.6L
New1.713-1.732
Acceptable Limit1.7732-1.772 (44-45)
Service Limit1.772 (45)
NOTE:For additional valve specifications, see, at end of this article, VALVES & VALVE SPRINGS
table under
ENGINE SPECIFICAT IONS.
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replace hydraulic lash adjuster. Adjustment on valve lash adjusters is NOT possible or necessary.
PISTON & ROD ASSEMBLY
1. Remove cylinder head assembly. Remove oil pan. Mark connecting rod caps for reassembly reference. Remove rod nuts. Remove lower
rod cap and bearing. Tap piston out top of cylinder block. DO NOT scratch crank journal or cylinder walls during removal.
2. Repeat procedure for remaining pistons. Keep removed parts in order to ensure installation to original position. Position piston assembly
in correct cylinder bore. Align piston mark "F" (1.3L), or notch (1.6L) located at piston pin bore area, and connecting rod oil gr o o ve
toward engine front. To complete installation, reverse removal procedure. Tighten all bolts and nuts to specification. See TORQUE
SPECIFICATIONS table at end of article.
FITTING PISTONS
1. With piston assembly removed, remove piston rings and clean piston. Measure piston outer diameter in thrust direction, below oil ring
groove. Diameter is 2.793-2.794" (70.954-70.974 mm) for 1.3L engines and 3.0690-3.0698 (77.954-77.974) for 1.6L engines.
2. Place piston upside down in cylinder from which it was removed. Using a feeler gauge, measure clearance between piston and cylinder
bore. If clearance is not within specification, bore cylinder and replace piston as necessary. See CYLINDER BLOCK
table in ENGINE
SPECIFICATIONS at end of article.
PISTON RINGS
Install rings on piston. Ensure marked side of rings are in proper position. Set ends of rings to proper position. See Fig. 9
.

Fig. 9: Positioning Piston Rings

Courtesy of FORD MOTOR CO.
PISTON PIN REPLACEMENT
1. With piston removed and cleaned, mark piston-to-rod to ensure proper reassembly. Using Piston Pin Remover/Installer Set (D81L-6135-
A for 1.3L or D90P-6135-AH for 1.6L), place piston and rod assembly in press.
2. Apply pressure and press piston pin from piston assembly. Keep all removed components together for reassembly. Remove piston and
rod from press and inspect.
3. Using a micrometer, measure piston pin O.D. in several areas. Measure piston pin I.D. Measure I.D. of piston pin bore and rod pin bore.
Replace components if not within specifications. See, at end of article, PISTONS PINS & RINGS
table in ENGINE
SPECIFICATIONS
4. If measurements of rod, piston and pin are within specification, reassemble using piston pin assembly set. Ensure piston-to-rod position
is proper, with connecting rod oil groove on side of piston marked "F" or by a notch. Lubricate pin with engine oil before reassembly.
With piston assembly reassembled, rod should fall by its own weight with piston held horizontally. Repeat procedure for remaining
pistons.
Rod Bearings Check rod bearing for abnormal wear. Check crankshaft journal. Check rod bearing-to-crankshaft clearance with Plastigage.
Machine or replace as necessary. See, at end of article, CRANKSHAFT MAIN & CONNECTING ROD BEARINGS
table under ENGINE
SPECIFICATIONS.
CRANKSHAFT & MAIN BEARINGS
1. Drain oil and remove oil pan. Ensure main bearing caps are marked for installation to original location and position.
NOTE:Installation press pressure for piston pins is 1100-3300 lbs. (500-1500 Kg)
NOTE:If replacing bearing inserts with engine in vehicle, rem ove one bearing at a tim e for m easurem ent
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2. Remove main bearing cap bolts. Remove cap and lower bearing insert. Use bearing remover or fabricated cotter key to remove upper
bearing insert. Insert bearing remover in journal lubrication hole. Rotate crankshaft in normal direction of operation only. Repeat
procedure for remaining main bearings.
3. Check bearings for abnormal wear. Check crankshaft for grooves, scratches and pitting. Using Plastigage method, check clearance of
main bearing-to-crankshaft. Always keep at least 2 bearings and caps tight during clearance check. See, at end of article,
CRANKSHAFT MAIN & CONNECTING ROD BEARINGS
table under ENGINE SPECIFICATIONS.
4. Lubricate and install new bearings in cap and block. Match bearing tangs with notch in cap and block. Position cap in its proper
location and position. Install cap bolts and tighten to specification. See TORQUE SPECIFICATIONS
table at end of article. Repeat
procedure for remaining main bearings.
CRANKSHAFT END PLAY
Check crankshaft end play with dial indicator. End play should be .0031-.0111" (.08-.282 mm). Service limit is .012" (.30 mm). If end play is
not within specification, replace thrust bearings as necessary.
CYLINDER BLOCK
1. Using straightedge and feeler gauge, check entire cylinder head surface of cylinder block. Ensure warpage does not exceed .006" (.15
mm). If warpage exceeds specification, cylinder block surface can be machined a maximum of .008" (.20 mm).
2. Replace cylinder block if it needs to be machined more than .008" (.20 mm). Check cylinder bore for wear, out-of-round, taper and
piston fit. See CYLINDER BORE SPECIFICATIONS
table. Oversize pistons are available in .010" and .020" (.25 mm and .50 mm).
CYLINDER BORE SPECIFICATIONS
LUBRICATION
ENGINE OILING SYSTEM
Oiling system is force-feed type and uses a full-flow oil filter. Oil is retrieved from oil pan by oil pump pick-up tube and distributed to oil
filter. Oil is then filtered and routed throughout engine.
Crankcase Capacity
1.3 L crankcase capacity is 3.2 qts. (3.0 L) without filter change and 3.6 qts. (3.4 L) with filter change. For 1.6 L vehicles, capacity is 3.2 qts
(3.2 L) without filter and 3.72 qts. (3.5 L) with filter.
Normal Oil Pressure (Hot)
Normal oil pressure is 50-64 psi (3.5-4.5 kg/cm2 ) at 3000 RPM.
Pressure Regulator Valve
Pressure regulator valve is located in oil pump body and is nonadjustable.
OIL PUMP
Removal
Remove oil pan, pick-up tube and screen, timing belt and crankshaft sprocket. Remove front engine cover bolts and remove front cover.
R e mo ve b o l t s r e t a in in g p u mp c o ve r t o b a c k sid e o f fr o n t c o ve r h o u sin g.
2) Remove pump cover and inner and outer gears. Pry out front seal from front cover. Remove cotter pin. Remove pressure regulator retainer,
spring and valve.
OIL PUMP SPECIFICATIONS or replacem ent.
ApplicationIn. (mm)
Cylinder Diameter
Standard Bore
1.3L2.7953-2.7960 (71.000-71.019)
1.6L3.0709-3.0716 (78.000-78.019)
Maximu m Bo re
1.3L2.8020 (71.17)
1.6L3.0905-3.0913 (78.500-78.519)
Maximu m Ou t -Of-Ro u n d & Tap er.0007 (.019)
Piston-To-Bore Clearance.006 (.15)
ApplicationIn. (mm)
Inner Gear-To-Outer Gear
1.3L.008 (.20)
1.6L.0008-.0063 (.02-.16)
Outer Gear-To-Housing
1.3L.009 (.22)
1.6L.0035-.0071 (.09-.18)
End Play
1.3L.006 (.14)
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Installation
1. Install pressure regulator valve, spring, retainer and new cotter pin. Press a new seal in front cover housing. Install outer and inner gears
in housing. Install pump cover. Coat bolts with Loctite and tighten to specification. See TORQUE SPECIFICATIONS
table at end of
article.
2. Install new gasket and install front cover housing. Install new gasket and install pick-up tube and screen. Tighten all bolts/nuts to
specification. To complete installation, reverse removal procedure.
ENGINE COOLING
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
1.6L.0012-.0043 (.03-.11)
NOTE:Refer to WAT ER PUMP
under REMOVAL & INSTALLATION in this article.
ApplicationFt. Lbs. (N.m)
"A" Arm Front Bolt72-86 (97-117)
A/C Compressor Bolt29-40 (39-54)
Camshaft Sprocket Bolt36-45 (49-61)
Connecting Rod Nut
Step 111-13 (15-18)
Step 2
1.3L22-25 (30-34)
1.6L35-38 (47-52)
Crankshaft Pulley Bolts9-13 (12-17)
Crankshaft Sprocket Bolt80-87 (108-118)
Crossmember-To-Body Bolt
1.3L47-66 (64-89)
1.6L27-37 (35-50)
Cylinder Head Bolt
Step 135-40 (48-54)
Step 256-60 (76-81)
Exhaust Manifold-To-Cylinder Head
1.3L12-17 (16-23)
1.6L29-42 (39-57)
Exhaust Pipe-To-Manifold29-42 (39-57)
Exhaust Pipe-To-Support Bracket32-45 (43-61)
Flywheel Bolt71-76 (96-103)
Front Cover Housing Bolt (1.3L)14-19 (19-26)
Front Engine Mount Nut32-38 (43-52)
Heater Tube32-45 (43-61)
Intake Manifold-To-Cylinder Head
1.3L14-20 (19-27)
1.6L47-66 (64-89)
Main Bearing Cap Bolts40-44 (54-59)
O2 Sensor27-33 (37-45)
Oil Pump Cover Bolt (1.6L)14-18 (19-25)
P/S Pump Bracket (Nut & Bolt)35-49 (47-66)
P/S Adjusting Nut27-38 (37-52)
P/S Pivot Bolt23-34 (31-46)
Pulse Air Tube Nut23-34 (31-46)
Rear Engine Mount Nut
1.3L21-34 (28-46)
1.6L47-66 (64-89)
Rocker Arm Shaft Bolts16-21 (22-28)
Side Engine Mount Nuts
1.3L29-40 (39-54)
1.6L
RH49-67 (67-91)
LH33-48 (45-65)
Spark Plug11-17 (15-23)
Thermostat Housing Bolt14-22 (19-30)
Timing Belt Tensioner Adjusting Bolt14-19 (19-26)
Turbo Oil Supply Tube
Engine Block Side12-18 (16-24)
Banjo Side(1) 106-159 (12-18)
Turbo-To-Manifold29-42 (39-57)
Water Outlet Bolt14-22 (19-30)
Water Pump Pulley Bolts (1.3L)36-45 (49-61)
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ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
CRANKSHAFT MAIN & CONNECTING ROD BEARINGS
Water Pump-To-Block14-19 (19-26)
Wheels66-89 (90-120)
INCH Lbs. (N.m)
Camshaft Bearing Cap Bolt97-124 (11-14)
Camshaft Cover71-97 (8-11)
Camshaft Thrust Plate Bolt71-106 (8-12)
Front Cover Housing Bolt (1.6L)71-97 (8-11)
Oil Pan Bolt
1.3L71-80 (8-9)
1.6L71-97 (8-11)
Oil Pressure Sender106-159 (12-18)
Oil Pump Cover Bolt (1.3L)89-133 (10-15)
Pickup Tube-To-Oil Pump Bolt71-97 (8-11)
Radiator Fan Bracket71-97 (8-11)
Rear Engine Plate Bolt71-97 (8-11)
Temperature Sender44-89 (5-10)
Timing Belt Cover Bolt71-97 (8-11)
Valve Cover Bolt44-79 (5-9)
Water Pump Pulley Bolts (1.6L)71-97 (8-11)
(1)This specification is INCH Lbs.
ApplicationSpecification
Displacement
1.3L80.8 Cu. In. (1.3L)
1.6L97.4 Cu. In. (1.6L)
Bore
1.3L2.80" (71.0 mm)
1.6L3.07" (78 mm)
Stroke (1.3L & 1.6L)3.29" (83.6 mm)
Compression Ratio
1.3L9.7:1
1.6LN/A
Fuel SystemPFI
HP@RPM
1.3L58 @ 5000
1.6L
(Non-Turbo)100 @ 5750
(Turbo)132 @ 6000
Torque Ft. Lbs.@RPM
1.3L73 @ 3000
1.6L
(Non-Turbo)95 @ 5500
(Turbo)136 @ 3000
ApplicationIn. (mm)
Crankshaft
End Play.0031-.0111 (.080-.282)
Runout (Maximum).002 (.05)
Main Bearings
Journal Diameter1.9661-1.9668 (49.938-
49.956)
Journal Out-Of-Round.002 (.05)
Journal Taper.002 (.05)
Oil Clearance.0009-.0017 (.024-.042)
Connecting Rod Bearings
Journal Diameter
1.3L1.5724-1.5731 (39.939-
39.957)
1.6L1.7693-1.7699 (44.940-
44.956)
Journal Out-Of-Round.002 (.05)
Journal Taper.002 (.05)
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CONNECTING RODS
CONNECTING RODS
PISTONS, PINS & RINGS
PISTONS PINS & RINGS
CYLINDER BLOCK
CYLINDER BLOCK
VALVES & VALVE SPRINGS
VALVES & VALVE SPRINGS
Oil Clearance.0011-.0027 (.028-.068)
ApplicationIn. (mm)
Bore Diameter
Pin Bore
1.3L.7854-.7859 (19.948-19.961)
1.6L.7875-.7880 (20.003-20.014)
Crankpin Bore1.8897-1.8904 (48.000-48.016)
Center-To-Center Length5.230-5.234 (132.85-132.95)
Maximu m Ben d & Twist (1)
1.3L.0016 (.04)
1.6L.0078 (.198)
Side Play.012 (.30)
(1)Per 3.94" (100 mm) of length.
ApplicationIn. (mm)
Piston
Clearance (Max.).006 (.15)
Diameter
1.3L2.793-2.794 (70.954-70.974)
1.6L3.0690-3.0698 (77.954-77.974)
Pins
Outside Diameter
1.3L.7864-.7866 (19.974-19.980)
1.6L.7869-.7871 (19.987-19.993)
Inside Diameter.524 (13.309)
Pin-To-Piston Fit
1.3L.0003-.0005 (.0076-.0127)
1.6L.0004-.0012 (.0100-.0260)
Rod Fit(1) 0-.0012 (0-.030)
Rings
No. 1
End Gap.006-.012 (.15-.30)
Side Clearance.001-.003 (.03-.07)
No. 2
End Gap.006-.012 (.15-.30)
Side Clearance.001-.003 (.03-.07)
No. 3 (Oil)
End Gap.008-.028 (.20-.70)
Side Clearance
1.3L.039 (1.0)
1.6L.001-.003 (.03-.07)
(1)This is a negative clearance (interference fit).
ApplicationIn. (mm)
Cylinder Bore
Standard Diameter
1.3L2.7953-2.7961 (71.00-
71.02)
1.6L3.0709-3.0716
(78.000-78.019)
Maximu m Tap er.0007 (.018)
Maximu m Ou t -Of-Ro u n d.0007 (.018)
Maximu m Deck Warp age.006 (.15)
ApplicationIn. (mm)
In t ake Val ves
Face Angle45°
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CYLINDER HEAD
CYLINDER HEAD
CAMSHAFT SPECIFICATIONS
CAMSHAFT SPECIFICATIONS
Head Diameter
1.3LN/A
1.6L1.217-1.224 (30.90-31.10)
Min imu m Margin.020 (.50)
Stem Diameter
1.3L.2744-.2750 (6.970-6.985)
1.6L.2350-.2356 (5.970-5.985)
Exhaust Valves
Face Angle45°
Head Diameter
1.3LN/A
1.6L1.028-1.035 (26.1-26.3)
Min imu m Margin
1.3L.039 (1.0)
1.6L.020 (.5)
Stem Diameter
1.3L.2742-.2748 (6.965-6.980)
1.6L.2348-.2354 (5.965-5.980)
Valve Springs
Free Length
1.3L1.717 (43.6)
1.6L1.858 (47.2)
Out-Of-Square
1.3L.059 (1.50)
1.6L.063 (1.60)
ApplicationIn. (mm)
Maximu m Warp age.006 (.15)
Valve Seats
Intake Valve
Seat Angle45°
Seat Width
1.3L.043-.067 (1.10-1.70)
1.6L.030-.055 (.80-1.40)
Maximu m Seat Ru n o u t.0016 (.04)
Exhaust Valve
Seat Angle45°
Seat Width
1.3L.043-.067 (1.10-1.70)
1.6L.030-.055 (.80-1.40)
Maximu m Seat Ru n o u t.0016 (.04)
Valve Guides
Intake Valve
Valve Guide I.D.
1.3L.276-.277 (7.01-7.03)
1.6L.2366-.2374 (6.01-6.03)
Valve Stem-To-Guide
Oil Clearance
1.3LMaximu m Service Limit .0 0 8
(.20)
1.6L.0010-.0024 (.025-.060)
Exhaust Valve
Valve Guide I.D.
1.3L.276-.277 (7.01-7.03)
1.6L.2366-.2374 (6.01-6.03)
Valve Stem-To-Guide
Oil Clearance
1.3LMaximu m Service Limit .0 0 8
(.20)
1.6L.0012-.0026 (.300-.650)
ApplicationIn. (mm)
End Play(1) .002-.007 (.05-.18)
Journal Diameter
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1.3L
No. 1 & 31.7102-1.7109 (43.440-
43.456)
No. 21.7091-1.7100 (43.410-
43.435)
1.6L (All Journals)1.0213-1.0222 (25.940-
25.965)
Journal Runout.002 (.05)
Lobe Height
1.3L(2) 1.4332-1.4371 (36.403-
36.503)
1.6L(3) 1.6098 (40.888)
Oil Clearance
1.3L
No. 1 & 3 Journals(4) .0014-.0033 (.035-.085)
No. 2 Journal(4) .0026-.0045 (.065-.115)
1.6L (All Journals)(4) .0014-.0033 (.035-.085)
(1)End play limit is .008" (.20 mm).
(2)Wear limit is 1.4272" (36.253 mm)
(3)Wear limit is 1.5940" (40.489)
(4)Maximum clearance is .0059" (.150 mm)
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00048707
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Back To Article
ST ART ER
1991 ELECT RICAL Starters
DESCRIPTION
The Nippondenso direct drive starter is a conventional 12-volt, 4-pole, brush-type starter. The integral solenoid is attached to the drive
housing. When starter is energized, starter solenoid causes the starter pinion to engage with the flywheel ring gear. The overrunning clutch
pinion drive is mounted directly on armature shaft drive end.

Fig. 1: Starter System Schematic

Courtesy of FORD MOTOR CO.
TROUBLE SHOOTING
ENGINE CRANKS SLOWLY
Undercharged battery. Loose or corroded cable connections. Bad starter.
ENGINE WILL NOT CRANK
Undercharged battery. Bad ignition switch. Bad clutch engage switch (M/T) or neutral safety switch (A/T). Loose or corroded cable
connections. Bad starter. Faulty circuit grounds.
STARTER SPINS & ENGINE DOES NOT CRANK
Bad starter. Bad flywheel ring gear and/or starter drive pinion.
ENGINE STARTS WITH CLUTCH ENGAGED (M/T)
Bad clutch engage switch. Adjust or replace.
ENGINE STARTS IN GEAR (A/T)
Bad neutral safety switch. Adjust or replace.
ON-VEHICLE TESTING
PRELIMINARY TEST
Ensure battery is fully charged and has load tested okay. If starter will not crank engine with fully charged battery, proceed with the following
test.
1. Using a digital voltmeter, connect positive voltmeter lead to starter solenoid terminal "S", and negative lead to starter housing. See Fig.
1 .
2. Turn ignition switch to START position, and observe voltmeter reading. If voltage at terminal "S" is greater than 8 volts, starter or circuit
malfunction is indicated. See VOLTAGE DROP TEST
and STARTER GROUND CIRCUIT TEST under ON-VEHICLE TESTING.
Page 1 of 6 MITCHELL 1 ARTICLE - STARTER 1991 ELECTRICAL Starters
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