Ignition lock FORD FESTIVA 1991 User Guide
[x] Cancel search | Manufacturer: FORD, Model Year: 1991, Model line: FESTIVA, Model: FORD FESTIVA 1991Pages: 454, PDF Size: 9.53 MB
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SOLENOIDS & SOLENOID VALVES
SOLENOIDS & SOLENOID VALVES LOCATION
SWITCHES
SWITCHES LOCATION
MISCELLANEOUS
MISCELLANEOUS LOCATION
COMPONENT LOCATION GRAPHICS
Fig. 1: Component Locations (1 Of 3)
FrontOn left rear corner of engine
bay, on firewall. See Fig. 1
.
RearIn liftgate, behind trim panel.
ComponentLocation
Canister Purge SolenoidOn center of firewall, to right of wiper motor. See Fig. 1 .
Idle-Up Speed Control (ISC) SolenoidOn left rear of engine, left of injector No. 4.
Kickdown Solenoid Valve (A/T)On lower right front corner of transaxle. See Fig. 1 .
ComponentLocation
A/C Pressure SwitchOn A/C line, near right front strut tower. See Fig. 1 .
A/C Thermostatic Switch (1992)On bottom of evaporator housing, below glove box.
Back-Up Light SwitchMounted on transaxle. See Fig. 1 .
Brake Fluid Level SwitchOn brake fluid reservoir.
Brake On-Off Switch (1992)On bracket, above brake pedal.
Clutch Interlock SwitchOn bracket, above clutch pedal.
Cooling Fan SwitchIn thermostat housing. See Fig. 1 .
Inertia SwitchIn left rear quarter panel.
Kickdown Switch (A/T)Mounted on accelerator pedal.
Neutral Safety SwitchOn right rear side of transaxle.
Oil Pressure SwitchOn rear center of engine block.
Parking Brake SwitchOn base of parking brake lever.
Passive Restraint Limit SwitchAt top of left & right "A" pillar.
Power Steering Pressure SwitchMounted on power steering pump assembly.
Seat Belt Switch (1991)On driver's seat belt buckle.
Stoplight SwitchOn brake pedal lever.
Wide Open Throttle A/C Cut-Off (WAC) Switch (1991)On left corner of engine bay, left of cooling fan.
ComponentLocation
Blower ResistorNear blower motor.
RPM Test ConnectorOn left rear of engine bay, next to ignition module. See Fig. 1 .
NOTE:Figures m ay show m ultiple com ponent locations. Refer to appropriate table for proper figure
references.
Page 2 of 3 MITCHELL 1 ARTICLE - ELECTRICAL COMPONENT LOCATOR 1991-92 ELECTRICAL COMPONENT LOCATION For...
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FUSES & CIRCUIT BREAKERS
Fuses & Circuit Breakers 1988-93 Festiva
FUSES & FUSIBLE LINKS
FUSE PANEL & FUSIBLE LINK BLOCK LOCATIONS
The vehicle has a fuse block with fusible links and a fuse panel with circuit fuses. The fuse panel is located behind the instrument panel, left o
f
the steering column. The fuse block is located under the hood.
FUSE PANEL IDENTIFICATION
Fig. 1: Fuse Panel Identification
Courtesy of FORD MOTOR CO.
Fuse & Circuit Breaker Identification
1 - 15 Amp License Plate Light, Rear Side Marker Ligh t , Fr o n t P a r kin g Ligh t s, C l u st e r a n d Ta il Ligh t s
2 - 15 Amp Horn, Brakelights, High-Mount Brakelight
3 - 15 Amp (1988-89) Safety Belt Warning, Turn & Hazard Warning Flasher Lights, Radio, Trunk Light, Ignition Key Reminder Buzzer
3 - 15 Amp (1990-93) Safety Belt Warning, Turn & Hazard Warning Flasher Lights, Ignition Key Reminder Buzzer
4 - 15 Amp Audio System, Cigarette Lighter, Remote Control Mirror
5 - 15 Amp Rear Wiper/Washer, Daytime Running Light System (Canada)
6 - 15 Amp Heater & Air Conditioner
7 - 20 Amp Heater & Air Conditioner, Cooling Fan System
8 - 10 Amp (1988-89) Interior Courtesy Lights 10 Amp (1990-93) Radio, Interior Courtesy Lights, Luggage Compartment Light
9 - 15 Amp (1988-89) Front Wiper/Washer
9 - 15 Amp (1990-93) Front Wiper/Washer, Shift-Lock System (ATX), Engine Control System
10 - 10 Amp Charging System, Emission Control System
11 - 10 Amp (1988-90) Safety Belt Warning, Turn & Hazard Warning Flasher Lights, Back-Up Lights, Instrument Cluster, Warning
Lights,
11 - 10 Amp (1991-93) Safety Belt Warning, Turn & Hazard Warning Flasher Lights, Back-Up Lights, Instrument Cluster, Warning
Lights, Shift-Lock System
12 - 15 Amp Rear Window Defroster
13 - Not Used (1988-89) Spare
13 - 30 Amp (1990-93) Passive Restraint System (Automatic Seat Belt)
In-Line Fuse Identification
15 Amp (1990-93) Condenser Fan Motor (A/T Models Only)
10 Amp (1990-93) A/C System (located on left side of heater case)
FUSIBLE LINK BLOCK IDENTIFICATION
Page 1 of 3 MITCHELL 1 ARTICLE - FUSES & CIRCUIT BREAKERS Fuses & Circuit Breakers 1988-93 Festiva
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Fig. 2: Underhood Fusible Link Block Identification
Courtesy of FORD MOTOR CO.
Fusible Link Identification
A - Brown (PTC) (1988-89 Carburetor) EFE Carburetor Heater
A - Brown (EGI) (1989-93 EFI) EFI System (1989-92), EGI-EFI System (1993)
B - Red (Main) Back-Up, Interior & Parking Lights, Brakelights, Taillights, Horn, Luggage Compartment Light, Turn Signal & Hazard
F l a sh e r Ligh t s, C l u st e r & Wa r n in g Ligh t s, R a d io , C iga r e t t e Ligh t e r , C h a r gin g & E missio n C o n t r o l S yst e ms, Wip e r / Wa sh e r S yst e ms,
A/C-Heater System, Cooling Fan System, Rear Window Defroster, Ignition & Starting Systems, Shift Lock System, Remote Control
Mirror, Ignition Key Reminder, Passive Restraint System (1990-93)
C - Brown (Head) Headlights, Daytime Running Lights, Starting & Charging System
BATTERY SPECIFICATIONS
All 1988-92 models use a BX-35 battery. The 1993 Festiva uses a 50D 20L standard battery.
CAUTIONS & WARNINGS
BATTERY WARNING
REPLACING BLOWN FUSES
Before replacing a blown fuse, remove ignition key, turn off all lights and accessories to avoid damaging the electrical system. Be sure to use
fuse with the correct indicated amperage rating. The use of an incorrect amperage rating fuse may result in a dangerous electrical system
overload.
BRAKE PAD WEAR INDICATOR
Indicator will cause a squealing or scraping noise, warning that brake pads need replacement.
CAUT ION: When battery is disconnected, vehicles equipped with com puters m ay lose m em ory data. When battery
power is restored, driveability problem s m ay exist on som e vehicles. T hese vehicles m ay require a
relearn procedure. See COMPUTER RELEARN PROCEDURES
article in the GENERAL INFORMAT ION
section.
WARNING:When battery is disconnected, vehicles equipped with com puters m ay lose m em ory data. When battery
power is restored, driveability problem s m ay exist on som e vehicles. T hese vehicles m ay require a
relearn procedure. See COMPUTER RELEARN PROCEDURES
article in GENERAL INFORMAT ION
section.
Page 2 of 3 MITCHELL 1 ARTICLE - FUSES & CIRCUIT BREAKERS Fuses & Circuit Breakers 1988-93 Festiva
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Fig. 2: Ground Numbers & Locations (2001 & Prior Model Years)
WIRING DIAGRAM COMPONENT LOCATIONS
When trying to locate a component in a wiring diagram and you don't know the specific system where it is located, use this handy component
locator to find the system wiring diagram in which the component is located. Then, go to that system and locate the component within the
wiring diagram.
For example, if you don't know the specific system in which the ignition switch is located, look up ignition switch in the wiring diagram
component location tables and go to the appropriate wiring diagram(s) which contain either full or partial views of the ignition switch. The full
view of the ignition switch is located in Power Distribution.
The first listing for the component will be the full or most complete view of the component. Additional listings will be partial views of the
component. Not all components are used on all models.
All components will have a partial view in Ground Distribution and Power Distribution. Data Link Connectors show connecting circuits
between modules. Alternate names for components may be listed in wiring diagram component locations tables.
WIRING DIAGRAM COMPONENT LOCATIONS
ComponentWiring Diagram
ABS Electronic Control UnitAnti-Lock Brakes; Data Link Connectors
ABS Hydraulic UnitAnti-Lock Brakes
Acceleration SensorAnti-Lock Brakes
Accessory Delay RelayPower Windows
A/C Compressor Clutch RelayEngine Performance
A/C SensorEngine Performance
A/C Pressure SwitchEngine Performance
Adaptive Lamp Control ModuleExterior Lights
Air Bag(s)Air Bag Restraint System
Air Bag ModuleAir Bag Restraint System
Air Bag Sensor(s)Air Bag Restraint System
Air Injection Pump RelayEngine Performance
Air Temperature SensorOverhead Console
Alternator (Generator)Generators & Regulators
Anti-Theft Control ModuleAnti-Theft System; Starters
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Height SensorElectronic Suspension
HornsSteering Column Switches
Horn RelaySteering Column Switches
Idle Air Control (IAC) Motor/ValveEngine Performance
Ignition Coil(s)Engine Performance
Ignition Key Lock CylinderAnti-Theft System
Ignition ModuleEngine Performance
Ignition SwitchPower Distribution; Engine Performance; Generators &
Regulators; Starters
Illuminated Entry ModuleIllumination/Interior Lights
Illumination LightsIllumination/Interior Lights
Impact SensorAir Bag Restraint System
Inertia Fuel Shutoff SwitchEngine Performance
In h ib it Rel ayStarters
Instrument ClusterAnalog Instrument Panels
Intake Air Temperature (IAT) SensorEngine Performance
Interior LightsIllumination/Interior Lights
In t erl o ck Swit chStarters
Junction BlockPower Distribution
Keyless Entry ReceiverRemote Keyless Entry
Key Reminder SwitchStarters
Knock SensorEngine Performance
Lamp Control ModuleExterior Lights
License Plate LampExterior Lights
Lighting Control ModuleLighting Control Modules; Anti-Theft System; Daytime Running
Lights; Headlight Systems
Lower RelayPower Convertible Top
Malfunction Indicator Light (MIL)Engine Performance; Instrument Panels
Manifold Absolute Pressure (MAP) SensorEngine Performance
Mass Airflow (MAF) SensorEngine Performance
Mega FuseGenerators & Regulators
Memory Seat/Mirror ModuleMemory Systems
M ir r o r De fo gge rRear Window Defogger
Moon Roof MotorPower Moon Roof
Moon Roof RelayPower Moon Roof
Multi-Function Control ModuleWarning Systems
Neutral Safety SwitchStarters
Oil Level SwitchEngine Performance
Oil Pressure Switch/Sending UnitAnalog Instrument Panels; Engine Performance
Overhead ConsoleOverhead Console
Oxygen Sensor(s) (O2S)Engine Performance
Parking Brake SwitchAnalog Instrument Panels
Park LightsExterior Lights
Park/Neutral Position SwitchStarters; Engine Performance; Anti-Theft System; Body Control
Module
Perimeter Lighting Control RelayExterior Lights
Power AmplifierPower Antennas
Power Antenna ModulePower Antennas
Power Antenna MotorPower Antennas
Power Distribution CenterPower Distribution; Generators & Regulators; Starters
Power Door Lock MotorsPower Door Locks
Power Mirror MotorsPower Mirrors; Memory Systems
Power Sliding Door ControllerPower Sliding Side Door
Power Seat MotorsPower Seats; Memory Systems
Power Steering Pressure SwitchEngine Performance
Power Top MotorPower Convertible Top
Power Top Relay(s)Power Convertible Top
Powertrain Control ModuleEngine Performance; Analog Instrument Panels; Cruise Control
Systems; Data Link Connectors; Generators & Regulators; Starters
Power Window MotorsPower Windows
Power Window Relay(s)Power Windows
Radiator Fan Motor(s)Electric Cooling Fans
Radiator Fan Relay(s)Engine Performance; Electric Cooling Fans;
Rainsense ModuleWiper/Washer Systems
Raise RelayPower Convertible Top
Remote Anti-Theft Personality (RAP) ModuleAnti-Theft System; Starters; Warning Systems
Seat Belt PretensionersAir Bag Restraint System
Seat Belt Retractor SolenoidPassive Restraints
Seat Belt SwitchAir Bag Restraint System; Passive Restraints
Shift Interlock SolenoidShift Interlock Systems
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WIRING DIAGRAMS
1991 WIRING DIAGRAMS Ford Motor Co.
IDENTIFICATION
COMPONENT LOCATION MENU
COMPONENT LOCATIONS
WIRING DIAGRAMS
ComponentFigure No. (Location)
A/C RELAY3 (B 8)
A/T SELECT LIGHT3 (E 8)
ALTERNATOR1 (C 3)
BACK-UP LIGHT SWITCH5 (D 19)
BATTERY1 (A 2)
BLOWER SWITCH3 (C 9)
BRAKE WARNING SWITCH1 (C 2)
CIG LTR4 (E 14)
CLUTCH INTERLOCK SWITCH (M/T)1 (B 2)
CONDENSER FAN (A/T)3 (C 8)
COOLANT FAN MOTOR1 (D 3)
COOLANT FAN RELAY1 (D 3)
DEFOG SWITCH5 (C 16)
DIR/HAZARD SWITCH4 (B-C 12)
ELECT CONTROL ASSY (ECA)2 (A 4-7)
FRONT WASHER MOTOR1 (E 3)
FRONT WIPER MOTOR1 (E 3)
FRONT WIPER/WASHER SWITCH5 (A 16)
FUEL PUMP INERTIA SWITCH2 (D 4)
FUEL PUMP RELAY2 (C 4)
FUSE BLOCK3 (D-E 9-10)
HEADLIGHT RELAY4 (D 14)
HORN RELAY3 (E 11)
HORN SWITCH4 (E 15)
IGNITION COIL2 (E 5)
IGNITION KEY REMINDER SWITCH4 (E 13)
IGNITION SWITCH3 (C-D 11)
INSTRUMENT CLUSTER4 (A-E 15)
INSTRUMENT PANEL LIGHT CONTROL4 (D-E 12)
INTERIOR LIGHT SWITCH4 (E 14)
LIGHT SWITCH4 (C-D 12)
MAIN FUSE PANEL1 (A 3)
MAIN RELAY2 (D 5)
NEUTRAL SAFETY SWITCH (A/T)1 (B 2)
PARKING LIGHT RELAY4 (C 14)
PASSIVE RESTRAINT CONTROL MODULE3 (A 11)
REAR WASHER MOTOR5 (D 17)
REAR WIPER/WASHER SWITCH5 (E 16)
SHIFT LOCK SERVO ASSY4 (A 12)
STARTER1 (B 3)
STOP LIGHT SWITCH5 (D 19)
TIMER/BUZZER UNIT4 (E 12)
TRUNK LIGHT5 (B 16)
WAC RELAY3 (B 8)
Page 1 of 6 MITCHELL 1 ARTICLE - WIRING DIAGRAMS 1991 WIRING DIAGRAMS Ford Motor Co.
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levels to proper level.
Removal (1.6L & 1.6L Turbo)
1. Relieve fuel pressure and discharge air conditioning system (if equipped). See FUEL PRESSURE RELEASE under REMOVAL &
INSTALLATION. Disconnect and remove battery, battery tray and battery tray support bracket.
2. Release wiring harness retaining straps from battery support tray. Disconnect windshield washer supply hose between fluid reservoir and
hood. Mark hinge locations and remove hood.
3. Disconnect intake air tube and wiring to ignition coil and vane airflow meter. Remove air cleaner/vane airflow meter assembly. Remove
air cleaner assembly support brackets. Disconnect intercooler hoses from turbocharger (if equipped).
4. Drain engine coolant and remove radiator. Disconnect accelerator cable, and remove retaining bracket from cam cover. Position cable to
one side.
5. Disconnect and plug fuel lines at fuel filter and pressure regulator. Disconnect power brake booster manifold vacuum hose from
manifold. Disconnect heater hoses at heater core tubes. Label and remove vacuum hoses located at throttle body.
6. For manual transaxle turbocharged vehicles, disconnect clutch cable and remove support bracket and cable from transmission. On non-
turbo vehicles, disconnect clutch slave hydraulic line. For automatic transaxle, remove transaxle cooler lines.
7. Disconnect starter wiring at starter. Remove harness from locating strap on bracket. Disconnect alternator wiring. Disconnect wiring
from engine coolant sensors located on rear of engine block. Remove ground connection at bracket on thermostat cover. Disconnect O2
sensor wire, main wiring harness connector, TPS connector (turbocharged only), knock sensor connector, distributor wiring and
transaxle wiring. Disconnect ground wire and strap at front of engine, and reinstall lifting eye.
8. Remove engine oil dipstick and retaining clip. Remove power steering pump from mounting bracket. Remove power steering pump
mounting bracket. With hoses attached, position pump aside. Remove upper air conditioning compressor retaining bolts (if equipped).
9. Raise vehicle on hoist. Drain engine oil and cooling system. On vehicles with air conditioning, remove lower air conditioning
compressor mounting bolts, and position compressor out of way.
10. Remove front wheels and tires. Remove front ball joints-to-ste e r in g kn u c kl e s r e t a in in g b o l t s. R e mo ve sp l a sh gu a r d s. Dr a in t ransmission
oil and remove half shafts from differential. Remove front exhaust pipe bracket located on lower side of engine. Disconnect front
exhaust pipe from exhaust manifold, or turbocharger (if equipped).
11. Remove frame support bar-to-engine support bolt. Loosen right control arm bolt and, pivot support bar downward. Disengage rubber
exhaust hangers located directly behind catalytic converter. Allow exhaust system to hang down 6 inches, and support system with
mechanic's wire. Unbolt shift linkage and stabilizer bar at transaxle. Remove nuts from front and rear engine mounts, and lower vehicle.
12. Attach chains onto lift eyes at ends of cylinder head, and support engine with hoist. Remove RH engine mount through bolt. Raise
engine off mounts and slightly pivot engine/transaxle assembly. Disconnect oil pressure sensor and route starter/alternator wiring
harness from engine. Carefully lift engine/transaxle assembly, turn assembly while raising to clear brake master cylinder, shift linkage
universal joint, radiator support and air conditioning lines (if equipped).
13. Remove intake manifold support bracket. Remove gusset plate(s) (if equipped). Remove starter. Remove transaxle-to-engine retaining
bolts. Identify bolts to ensure correct installation. Separate transaxle from engine. On manual transaxle, remove pressure plate, clutch
disc and flywheel. On automatic transaxle, remove flexplate.
Installation (1.6L & 1.6L Turbo)
1. Install transaxle to engine in reverse order of removal. Attach hoist to engine/transaxle assembly and position assembly in vehicle.
Before engine contacts mounts, route starter, alternator and oil pressure sensor wiring, and connect oil pressure sensor. Lower engine
until front mount seats on crossmember. Install through bolt on RH engine mount. DO NOT tighten bolt.
2. Remove hoist. Raise vehicle and support with jackstands. Align rear engine mount to crossmember, and install retaining nuts to front
and rear engine mounts. Tighten nuts to specification. See TORQUE SPECIFICATIONS
table at end of article.
3. On manual transaxles, connect shift coupling and stabilizer. Tighten to specification. On automatic transaxles, connect shift linkage and
oil cooler lines. Tighten linkage retaining bolt, shift cable pivot and oil cooler hose clamps to specification. Connect front exhaust pipe
to manifold (or turbocharger). Install exhaust pipe to support bracket. Tighten bolts to specification. Tighten manifold (or turbocharger)
to specification. Attach rubber exhaust hangers. Position cross brace. Tighten retaining nut and bolt and right control arm front bolt.
4. Install drive axles. Install ball joint retaining bolts and tighten to specification. Mount A/C Compressor to engine (if equipped). Tighten
lower retaining bolts to specification. Install splash guards. Install tire and wheel assemblies. Tighten retaining nuts to specification.
5. Lower vehicle. Install upper A/C compressor retaining bolts (if equipped). Tighten bolts to specification. Tighten RH engine mo u n t
through bolt to specification. Connect alternator wiring.
6. Position power steering pump bracket on stud. Lower pump into engine compartment. Install power steering pump bracket retaining
bolts and nut. Tighten to specification. Install power steering pump and belt. Tighten adjustment nut and pivot bolt to specification.
7. Install engine oil dipstick and retaining clip. Install ground strap and ground wire to cylinder head. Install clutch cable (if equipped).
Connect clutch hydraulic line if equipped with manual transaxle or naturally aspirated. Connect transmission electrical connectors.
Connect fuel lines to fuel filter and pressure regulator. Install intake air tube to throttle body.
8. Install intercooler hoses on turbocharged models. Install air cleaner assembly brackets. Install air cleaner assembly with airflow meter
attached. Install intake air tube. Install coil and airflow meter connectors. Connect coolant crankcase and air bypass hoses. Install
vacuum hoses as noted in disassembly.
9. Connect accelerator cable. Install retaining bracket. Install power brake booster hose. Remove speedometer cable from transaxle. Fill
transaxle to specification. See CAPACITIES in SERVICE & ADJUSTMENT SPECIFICATIONS article. Install speedometer cable.
Connect speedometer cable connector. Fill engine oil to capacity.
10. Install radiator/fan assembly. Tighten bracket retaining bolts to specification. Connect coolant hoses and fan electrical connector. Fill
coolant to specification.
11. Install hood and connect washer hose. Install battery tray support, battery tray, battery and battery hold-down. Connect battery
terminal. Evacuate and charge air conditioning system (if equipped). Road test vehicle and inspect for leaks.
INTAKE MANIFOLD
Removal (1.3L)
CAUT ION: DO NOT allow com pressor to hang by hoses. T ie up com pressor with m echanic's wire.
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1. Position new gasket on exhaust manifold, and install turbocharger onto studs. Install 4 retaining nuts and tighten to specification. See
TORQUE SPECIFICATIONS
table at end of article.
2. Remove oil supply line from turbocharger. Position new (2-piece) exhaust gasket on cylinder head with heavy gasket installed first .
Carefully position turbocharger assembly in engine compartment and slide exhaust manifold on studs. Position heater tube bracket onto
exhaust stud. Install 11 retaining nuts onto exhaust manifold and tighten to specification. See TORQUE SPECIFICATIONS
table at
end of article. Tighten heater tube clamp bolt securely.
3. Raise vehicle. Position new gasket and install 2 retaining bolts on heater tube outlet. Install 2 retaining bolts into turbocharger support
bracket and tighten bolts to specification.
4. Connect coolant return hose. Connect oil return hose and secure with clamp. Position exhaust pipe onto turbocharger, and start nuts
and washers. Install 2 retaining bolts on exhaust hanger at engine. Slide on 2 rubber exhaust hangers at catalytic converter. Tighten
exhaust pipe retaining nuts to specification. Lower vehicle.
5. Install retaining bolt and brass washers on oil supply line, carefully position oil line into vehicle and hand-start bolt into engine block.
Connect and finger tighten oil line to turbocharger. Tighten oil line bolt and oil supply line on turbocharger to specification.
6. Connect coolant supply hose. Position air cleaner duct tube on turbocharger and tighten clamp. Install 2 screws retaining air cleaner
duct tube. Position power steering pump bracket on engine, and install 2 retaining bolts and one retaining nut. Tighten to specification.
Position power steering pump on mounting bracket, and install though bolt and adjuster. Connect lower radiator hose. Install power
steering belt. Position upper heat shield and install 2 retaining bolts finger tight.
7. Position lower heat shield and install three retaining bolts finger tight. Tighten all heat shield bolts to specification. Connect O2 sensor
and install connector into its retaining clip. See TORQUE SPECIFICATIONS
table at end of article. Position intercooler hose on
turbocharger and secure with clamp. Install throttle body air intake tube. Connect negative battery cable. Refill cooling system.
CYLINDER HEAD
Removal (1.3L)
1. Disconnect battery ground cable. Mark and disconnect fuel lines at fuel pump. Remove accessory belts, water pump pulley, crankshaft
pulley, timing belt covers, timing belt tensioner, timing belt, valve cover and exhaust and intake manifolds. Drain cooling system.
2. Mark and remove electrical connectors and vacuum hoses. Remove spark plug wires from spark plugs, and remove spark plugs. Remove
distributor cap. Disconnect vacuum hoses and distributor wiring.
3. Index distributor-to-mount position and remove hold-down bolt. Remove distributor assembly. Remove engine ground strap. Remove
front and rear engine lifting hooks. Remove upper radiator hose, by-pass hose and bracket.
4. Remove bolts retaining rocker arm shaft. Remove rocker arm assemblies. Remove cylinder head bolts. Remove head and gasket.
Inspection (1.3L)
1. Thoroughly clean and check gasket mating surface of cylinder head and block. Check cylinder for cracks, nicks, burrs or damage. Using
a straightedge and feeler gauge, check warpage over entire gasket area. Ensure cylinder head and/or block warpage does not
exceed .006" (.15 mm).
2. If warpage exceeds .006" (.15 mm), machine cylinder head and/or block gasket surface. Maximum machining allowed is .008" (.20 mm).
If more machining is required, replace block and/or cylinder head.
Installation (1.3L)
1. Place new head gasket properly on block. Carefully place cylinder head in position on block. Install head bolts. Tighten bolts in
sequence and in 2 steps. See Fig. 1
.
2. While tightening rocker arm shaft, slide shaft springs away from retaining bolt to prevent pinching springs. Tighten rocker arm shaft bolts
in sequence and to specification. See Fig. 5
. To complete installation, reverse removal procedure. Tighten all bolts/nuts to
specification. Fill all fluids to proper levels. NOTE:T urbocharger-to-exhaust m anifold m ounting nuts are of special quality. Ensure correct nuts are
used.
NOTE:Ensure one brass washer is positioned on each side of oil line fitting.
NOTE:Feed O2 sensor wire through upper heat shield. Install wire retainer under LH bolt.
NOTE:If turbocharger was replaced: Disconnect ignition coil, crank engine for 20 seconds, connect ignition
coil, start engine and run at idle for 30 seconds and check for leaks.
NOTE:If original tim ing belt is being reused, m ark direction of rotation for installation reference.
Page 4 of 19 MITCHELL 1 ARTICLE - ENGINE OVERHAUL 1991-92 FORD MOTOR CO. ENGINES 1.3L & 1.6L 4-Cylinder
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connector to corresponding terminals on TP sensor connector. Turn ignition on. Measure voltage between TP and SIGRTN terminals on
TP sensor while opening throttle. Compare voltage to specification in TP SENSOR OUTPUT VOLTAGE
table. If voltage is within
specification, repair TP wire to ECA. Go to next step if voltage is not within specification.
3. Turn ignition off. Unplug TP harness connector. Turn ignition on. Measure voltage between VREF and SIGRTN wires on TP harness
connect-or. If voltage is 4-5 volts, replace TP sensor. If voltage is not 4.5-5.5 volts, go to next step.
4. Measure voltage between VREF wire on TP harness connector and ground. If voltage is 4-5 volts, adjust or replace throttle position
sensor. If voltage is not 4-5 volts, go to PINPOINT TEST VREF
.
PINPOINT TEST BP - BAROMETRIC PRESSURE SENSOR
Fig. 12: Identifying BP Sensor Circuits
1.3L
BP sensor is incorporated into ECA; it cannot be checked or serviced separately. If Code 14 is set and cannot be cleared, replace ECA.
1.6L
Turn ignition off. 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 table. Replace BP sensor if voltage is not as specified.
BAROMETRIC PRESSURE SENSOR OUTPUT VOLTAGE
PINPOINT TEST EGO - EXHAUST GAS OXYGEN SENSOR
EGO CIRCUIT PIN IDENTIFICATION
1. Warm engine to operating temperature, and let idle. Unplug EGO sensor. Measure voltage between EGO sensor connector (sensor side) NOTE:Enter this procedure only when a Code 14 is displayed during QUICK T EST S procedure or when
directed here from another PINPOINT T EST . T o prevent unnecessary replacem ent of com ponents, note
following non-EEC item s m ay be at fault: unusually high or low atm ospheric pressure, blocked vacuum
lines, or basic m echanical engine com ponents.
Vacuum (In. Hg.)(1) Voltage
03.84
53.36
102.66
151.93
201.26
25.58
(1)Voltage may vary by 15 percent.
NOTE:Enter this test only when a Code 15 (lean) or Code 17 (rich) is displayed during QUICK TESTS
procedure.
CircuitECA PinBOB PinWire Color
EGO
1.3L2N29BLU
1.6L2D29BLK
Page 13 of 20 MITCHELL 1 ARTICLE - G - TESTS W/CODES 1991-92 ENGINE PERFORMANCE Ford Motor Co. Self-Diagnostics
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Page 195 of 454
IDLE SPEED
While the engine is cold, the Idle Speed Control By-Pass Air (ISC-BPA) Valve increases idle speed to warm the engine quickly. At engine
temperatures less than 140°F (60°C), the valve is open. As the engine warms, the valve begins to close. The valve is fully closed at engine
temperatures higher than 140°F (60°C). Idle speed is also affected by various switches, sensors and load on the engine.
ELECTRONIC IGNITION SYSTEM
CAPRI
A pick-up coil within the distributor sends a signal to a Distributor-Mounted Ignition Module With Vacuum Advance (DMIVA) within the
distributor. The DMIVA then sends a signal which fires the coil. When the coil fires, the distributor directs high voltage current to the spark
plugs. The DMIVA system operates independently of the ECA.
FESTIVA
A pick-up coil within the distributor sends a signal to a transistorized ignition module on the coil bracket. A timing signal also goes from the
ECA to the ignition module. The ignition module then sends a signal which fires the coil. When the coil fires, the distributor directs high
voltage current to the spark plugs.
IGNITION TIMING CONTROL SYSTEM
CAPRI
Spark timing is controlled by vacuum and centrifugal advance mechanisms and by a signal from the ECA. The ECA does not affect ignition
timing on turbo models. On turbo models, a knock sensor and control unit retard ignition timing when knock occurs.
FESTIVA
The ECA generates a spark timing signal from data received from the BP, CPS and VAF. This signal goes to the ignition module. The ignition
module then sends a signal to fire the coil.
HIGH ALTITUDE SPARK ADVANCE CORRECTION
A barometric pressure sensor is incorporated into the ECA on Festiva and is a separate component on Capri. At high altitudes, the ECA sends
a signal to the ignition module to advance ignition timing. This feature is not used on turbo models.
KNOCK SENSOR (CAPRI)
A Knock Sensor (KS) generates a signal when knock occurs. A control unit processes this signal and then sends it to the ignition module to
retard spark timing. The KS is located in the engine block, near the oil pressure switch. This device is only used on 1.6L turbo engines.
KNOCK CONTROL UNIT (CAPRI)
The Knock Control Unit filters normal engine vibration signals from the KS, then sends a signal to the ignition module to retard spark timing.
This unit, used only on 1.6L turbo engines, is located on right side of engine compartment.
EMISSION SYSTEMS
DECELERATION SYSTEM (DASHPOT)
The deceleration control system closes the throttle plate gradually during deceleration. The dashpot prevents engine stalling on deceleration
and provides a smooth transition from deceleration to sudden acceleration.
EVAPORATIVE SYSTEM
CARBON CANISTER
The carbon canister stores vapors from the fuel tank until they are purged and burned in the engine. On Festiva, carbon canister is
located under the brake booster. On Capri, carbon canister is located on the right side of the engine compartment near the cowl panel.
CANISTER PURGE SOLENOID
This component is connected between the carbon canister and intake manifold. When the ECA sends a signal to the solenoid to open,
fuel vapors in the carbon canister are drawn into the engine.
CANISTER PURGE VALVE
This valve opens to purge vapors from the carbon canister into the engine intake system. The valve is part of the canister purge solenoid.
ROLLOVER VENT VALVE
This valve, located in front of the fuel tank, blocks the vapor line in case of vehicle rollover.
This valve, located in front of the fuel tank, blocks the vapor line in case of vehicle rollover.
CATALYTIC CONVERTER
The catalytic converter is in the exhaust system, between the exhaust manifold and the muffler. It converts certain pollutants in the exhaust
Page 5 of 6 MITCHELL 1 ARTICLE - E - THEORY/OPERATION 1991 ENGINE PERFORMANCE Ford/Mercury Theory & Operation
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