%27 FORD FESTIVA 1991 User Guide

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)
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Article GUID: A00048707
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Crankshaft Pulley Bolts10-13 (12-17)
Crankshaft Sprocket Bolt80-87 (108-118)
Power Steering Adjuster Nut27-38 (37-52)
Timing Belt Tensioner Adjuster Bolt14-19 (19-26)
Water Pump Pulley Bolts36-45 (49-61)
INCH Lbs. (N.m)
Camshaft Cover71-97 (8-11)
Timing Belt Cover Bolt71-97 (8-11)
Valve Cover Bolt44-79 (5-9)
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Article GUID: A00155957
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Article GUID: A00022701
Page 3 of 3 MITCHELL 1 ARTICLE - J - PIN VOLTAGE CHARTS 1991 ENGINE PERFORMANCE Ford/Mercury Pin Voltage Charts
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VANE AIRFLOW (VAF) METER
Removal
1. Disconnect negative battery cable. On Capri, disconnect primary and secondary wires from coil. On Festiva, disconnect VAF wire
harness connector. Remove air duct.
2. On Capri, remove retaining bolt and ground wire from air cleaner cover. Remove air cleaner cover bolts and air cleaner cover. From
inside of air cleaner cover, remove VAF meter retaining nuts. On Festiva, remove attaching bolt and 4 nuts. Remove vane airflow met er.
Installation
To install, reverse removal procedure. Position new gasket over VAF mounting studs. Tighten bolts and nuts to specification, see TORQUE
SPECIFICATIONS at end of article.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS NOTE:For all on-vehicle adjustm ents not covered in this article, see ADJUST MENT S article in the ENGINE
PERFORMANCE Section.
ApplicationFt. Lbs. (N.m)
Coolant By-Pass Tube Outlet-To-Water Pump Bolts14-19 (19-26)
Distributor Mounting Bolts14-19 (19-26)
Exhaust Manifold Retaining Nuts29-42 (39-57)
Exhaust Pipe Nuts18-25 (24-34)
Fuel Line-To-Fuel Filter Bolt18-25 (24-34)
Fuel Pressure Regulator Nut(1)
Fuel Rail Retaining Bolt14-19 (19-26)
Heat Shield Bolts14-19 (19-26)
Intake Plenum Bolts/Nuts11-16 (15-22)
Oil Supply Line-To-Turbocharger Bolt12-17 (16-23)
Oxygen Sensor(1)
Power Steering Pump Bracket-To-Engine Bolts/Nut35-48 (47-65)
Throttle Body Bolt/Nuts12-17 (16-23)
Turbocharger Support Bracket Bolts32-45 (43-61)
Turbocharger-To-Exhaust Manifold Nuts20-25 (27-34)
INCH Lbs. (N.m)
Barometric Pressure (BP) Sensor Nut54-84 (6-9)
MAP Sensor Nuts54-84 (6-9)
Oil Supply Line-To-Engine Block Bolt104-156 (12-18)
Vane Airflow Meter Nuts110-152 (12-18)
(1)Information not available from manufacturer.
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Article GUID: A00022705
Page 5 of 5 MITCHELL 1 ARTICLE - N - REMOVE/INSTALL/OVERHAUL 1991 ENGINE PERFORMANCE Ford/Mercury Removal, O
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K - SENSOR RANGE CHART S
1991 ENGINE PERFORMANCE Ford Motor Co. Sensor Operating Range Charts
INTRODUCTION
Sensor operating range information can help determine if a sensor is out of calibration. An out-of-calibration sensor may not set a trouble
code, but it may cause driveability problems.
BAROMETRIC PRESSURE SENSOR OUTPUT VOLTAGE
ENGINE COOLANT TEMPERATURE SENSOR RESISTANCE
IGNITION DIAGNOSTIC MONITOR VOLTAGE
THROTTLE POSITION SENSOR RESISTANCE
(1)
VANE AIRFLOW METER VOLTAGE NOTE:Unless stated otherwise in test procedure, perform all voltage tests using a Digital Volt-Ohm m eter
(DVOM) with a m inim um 10-m egohm input im pedance.
Vacuum In. Hg.(1) Volts
03.84
53.36
102.66
151.93
201.26
25.58
(1)Voltage may vary by plus or minus 15 percent.
Temperature °F (°C)Ohms
-4 (-20)14,600-17,800
68 (20)2200-2700
104 (40)1000-1300
140 (60)500-650
176 (80)290-350
RPM (1) Volts
5001.103
10001.257
15001.542
20001.768
25002.06
30002.15
35002.26
40002.50
45002.47
50002.40
(1)Revolutions per minute.
Throttle Opening(2) Ohms
1/8989
1/41104
3/81278
1/21462
5/81480
3/41459
7/81144
Fully Open1072
(1)Capri only. Festiva uses throttle position switch.
(2)Resistance may vary by plus or minus 15 percent.
Door Opening(1) Volts (Capri)(1) Volts (Festiva)
Fully Closed(2) .5-1.5
1/83.24.59
1/45.601.19
3/85.621.78
1/25.832.38
5/86.022.97
3/46.573.56
7/87.464.16
Fully Open7.874.5-5.0
Page 1 of 2 MITCHELL 1 ARTICLE - K - SENSOR RANGE CHARTS 1991 ENGINE PERFORMANCE Ford Motor Co. Sensor Operatin
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VANE AIR TEMPERATURE RESISTANCE (1)
(1)Voltage may vary by plus or minus 15 percent.
(2)Voltage specification is not available.
Temperature °F (°C)Ohms
-4 (-20)15,000
32 (0)5200
68 (20)2500
104 (40)1100
140 (60)600
176 (80)300
(1)Resistance may vary by plus or minus 15 percent.
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1991 ENGINE PERFORMANCE
Fuel Pressure Specifications
FUEL SYSTEMS
FUEL PRESSURE
1991 FUEL PRESSURE SPECIFICATIONS (EEC-IV - CARS)
1991 FUEL PRESSURE SPECIFICATIONS (EEC-IV - TRUCKS)
1991 FUEL PRESSURE SPECIFICATIONS (EEC - CARS)
EngineKOER psi (kg/cm2 )KOEO psi (kg/cm2 )
2.3L HSC EFI SEFI45-60 (3.2-4.2)50-60 (3.5-4.2)
3.0L SHO SEFI28-33 (2.0-2.3)30-45 (2.1-3.2)
3.8L SC SEFI30-40 (2.1-2.8)35-40 (2.5-2.8)
All Others30-45 (2.1-3.2)35-40 (2.5-2.8)
EngineKOER psi (kg/cm2 )KOEO psi (kg/cm2 )
4.9L EFI45-60 (3.2-4.2)50-60 (3.5-4.2)
All Others30-45 (2.1-3.2)35-45 (2.5-3.2)
EngineKOER psi (kg/cm2 )KOEO psi (kg/cm2 )
1.3L25-31 (1.8-2.2)64-85 (4.5-6.0)
1.6L28-31 (2.0-2.2)64-85 (4.5-6.0)
1.8L(1) 64-85 (4.5-6.0)
2.2L27-33 (1.9-2.3)64-85 (4.5-6.0)
2.2L Turbo27-33 (1.9-2.3)64-85 (4.5-6.0)
(1)Fuel pressure should be 30-37 psi (2.1-2.6 kg/cm2 ) with engine running and vacuum hose connected to fuel pressure regulator.
Fuel pressure should be 38-45 psi (2.7-3.2 kg/cm
2 ) with engine running and vacuum hose disconnected to fuel pressure regulator.
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Connect BOB. Remove dust cover from BP sensor, located on passenger side cowl. Turn ignition on. Connect vacuum pump to BP sensor.
Measure voltage between pins BP and SIGRTN on BOB while applying vacuum to BP sensor. See BAROMETRIC PRESSURE SENSOR
OUTPUT VOLTAGE . Replace BP sensor if voltage is not as specified.
BAROMETRIC PRESSURE SENSOR OUTPUT VOLTAGE
BRAKE ON-OFF (BOO) SWITCH
Unplug connector from BOO switch at brake pedal. Connect ohmmeter to switch terminals. With pedal released, ohmmeter should indicate no
continuity. Ohmmeter should indicate continuity with pedal depressed.
CLUTCH ENGAGE SWITCH (CES)
Unplug connector from CES switch at clutch pedal. Connect ohmmeter to switch terminals. With pedal released, ohmmeter should indicate
continuity. Ohmmeter should indicate no continuity with pedal depressed.
CRANKSHAFT POSITION SENSOR (CPS) (1.3L)
Unplug 3-wire connector from distributor. Measure resistance between CPS terminal on distributor (Yellow/Blue wire) and ground. Replace
CPS if resistance is not 210-250 ohms.
CYLINDER IDENTIFICATION (CID) SENSOR (1.6L)
Turn ignition off. Connect BOB, leaving ECA connected. Turn ignition on, but DO NOT start engine. Measure voltage at BOB pin No. 34
(Yellow wire). Volt- meter should indicate less than one volt or more than 10 volts. Start engine and run at idle. Voltmeter should indicate 3-
5 volts. Replace CID sensor if voltage is not as specified.
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
1. Remove ECT sensor. ECT sensor is threaded into top of lower intake manifold on 1.3L, and on underside of intake manifold on 1.6L.
Place ECT sensor and thermometer into container of coolant.
2. Connect ohmmeter to coolant temperature sensor terminals. Cool or heat container. Note resistance at specified temperatures. See
ENGINE COOLANT TEMPERATURE SENSOR RESISTANCE
. Replace ECT sensor if resistance is not within specification.
ENGINE COOLANT TEMPERATURE SENSOR RESISTANCE
EXHAUST GAS OXYGEN (EGO) SENSOR
With engine at normal operating temperature, unplug connector from EGO in exhaust manifold. Measure voltage between EGO sensor
terminal and ground. Voltage should increase with increasing engine speed and decrease with decreasing engine speed. Voltage at idle should
fluctuate within a range of .2-.8 volt.
IDLE SW ITCH (1.6L)
Unplug connector from throttle position sensor on throttle body. Connect ohmmeter to switch terminals IDL and ground (Green/Orange and
Blue/Yellow wires on mating connector). Resistance must be less than 5 ohms with throttle in idle position, and more than 10,000 ohms with
throttle pedal depressed.
KNOCK SENSOR (1.6L TURBO)
Disconnect vacuum hose at distributor. Connect timing light. Start engine and record ignition timing. Tap intake plenum with a plastic mallet.
Knock sensor is okay if timing retards. If timing does not retard, check associated circuitry and components. See TIMING CONTROL
SYSTEMS under IGNITION SYSTEM.
NEUTRAL GEAR SWITCH (M/T)
1. Unplug connector near transmission. Place transmission in Neutral. Resistance across switch should be infinite.
2. Place transmission in any other gear. Resistance across switch should be zero ohms. If necessary, replace switch.
Vacuum In. Hg.(1) Voltage
03.84
53.36
102.66
151.93
201.26
25.58
(1)Voltage may vary by plus or minus 15 percent.
Temperature °F (°C)Ohms
-4 (-20)14,600-17,800
68 (20)2200-2700
104 (40)1000-1300
140 (60)500-650
176 (80)290-350
NOTE:A steady voltage higher than .55 volt indicates a continuously rich condition. A steady voltage lower
than .55 volt indicates a continuously lean condition.
Page 2 of 7 MITCHELL 1 ARTICLE - I - SYSTEM/COMPONENT TESTS 1991 ENGINE PERFORMANCE Ford Motor Co. - Ford/Merc
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