battery FORD FESTIVA 1991 User Guide

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WIPER/WASHER SYST EM
1991 ACCESSORIES & SAFET Y EQUIPMENT Ford Motor Co. Wiper/Washer System s
DESCRIPTION & OPERATION
Capri and Festiva vehicles are equipped with a 2-speed wiper motor with an optional intermittent system. The Festiva rear wiper uses a single
speed wiper motor. Washer systems for both front and rear washers use pumps mounted near fluid reservoirs.
ADJUSTMENTS
W IPER ARM ADJUSTMENT
Remove wiper arm and blade assemblies from pivot shafts. Turn wiper switch on and allow wiper motor to cycle 2 to 3 times. Turn wiper
switch off to place pivot shafts in park position. Reinstall wiper arm and blade assemblies with tips of wiper blades at specified distance from
lower edge of windshield. See WIPER BLADE ADJUSTMENT SPECIFICATIONS
table. Tighten wiper arm retaining nut to 89-124
INCH Lbs. (10-14 N.m).
WIPER BLADE ADJUSTMENT SPECIFICATIONS
TESTING
FRONT WIPER MOTOR TEST
Capri
1. Check WIPER fuse in interior fuse block and replace if necessary. Perform FRONT INTERVAL WIPE MODULE TEST . If
wiper/washer switch and interval module are operating properly, disconnect wiper motor connector. Turn ignition on and place
wiper/washer switch in HIGH position. Measure voltage at Blue/Red and Blue wires at wiper motor vehicle harness connector.
2. If battery voltage is not present, check Blue/Red or Blue wire for open circuit. If battery voltage is present at Blue/Red and Blue wires,
check Black ground wire at wiper motor vehicle harness connector for an open circuit and repair as necessary. If Black ground wire is
okay, replace wiper motor.
Festiva
1. Place wiper in any position other than park. Remove WIPER fuse. Disconnect wiper motor electrical connector. Using an ohmmeter,
check for continuity to ground at motor case. Continuity should exist. If continuity does not exist, replace or repair wiper motor ground
strap or wire.
2. Check for continuity to ground at Blue/Black terminal of wiper motor. Continuity should exist. If continuity does not exist, replace
wiper motor.
FRONT INTERVAL WIPE MODULE TEST
Capri
1. Check WIPER fuse in interior fuse block and replace if necessary. Perform FRONT WIPER/WASHER SWITCH TEST . Access
interval wipe module connector. Interval wipe module is located below instrument panel near console. Ensure wiper switch is in OFF
position. Turn ignition on and measure voltage at Blue/White and Blue/Black wires of module connector. Battery voltage should not be
present. Turn wiper switch to LOW position. Measure voltage at Blue/White and Blue/Black wires of module connector. Battery voltage
should be present.
2. Turn wiper switch to HIGH position. Measure voltage at Blue/White, Blue/Black and Blue/Red wires of module connector. Battery
voltage should be present. Turn wiper switch to INT position. Measure voltage at Blue/White and Blue/Black wires of module
connector. Battery voltage should be present during each cycle. If module does not perform as specified, replace module.
Festiva
Information is not available from manufacturer.
FRONT WIPER/WASHER SWITCH TEST
Capri
Remove lower steering column cover to gain access to wiper switch electrical connector. Using an ohmmeter, ensure continuity exists between
terminals listed in table at specified switch positions. If switch does not test as specified, replace wiper/washer switch. See FRONT
WIPER/WASHER SWITCH CONTINUITY (CAPRI) table. See Fig. 1 .
FRONT WIPER/WASHER SWITCH CONTINUITY (CAPRI)
ApplicationIn. (mm)
Capri
Driver Side1.0 (25)
Passenger Side1.26 (32)
Festiva
Both Sides1.0 (25)
Rear(1) 3.15 (80)
(1)From left edge of liftgate window.
TerminalPositionContinuity
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Fig. 2: Identifying Front Wiper/Washer Switch Terminals (Festiva)

Courtesy of FORD MOTOR CO.
FRONT WASHER MOTOR TEST
Remove washer fluid reservoir. Remove washer motor from reservoir. Connect fused jumper wire between washer motor terminal that
corresponds with Blue/Orange wire (Capri) or Blue wire (Festiva) and battery positive terminal. Connect other washer motor terminal to
ground. Washer motor should run smoothly. If washer motor does not run smoothly or does not run, replace motor.
REAR WIPER MOTOR TEST
Festiva
1. Place wiper in any position other than park. Disconnect wiper motor electrical connector. Using an ohmmeter, check for continuity to
ground at motor case. Continuity should exist. If continuity does not exist, repair wiper motor housing ground wire.
2. Check for continuity to ground at Blue terminal of wiper motor. Continuity should exist. If continuity does not exist, replace wiper
mo t o r.
REAR WIPER/WASHER SWITCH TEST
Festiva
Remove rear wiper/wash switch. Using a self-powered test light or an ohmmeter, ensure continuity exists between terminals listed in table at
specified switch positions. If switch does not test as specified, replace wiper/washer switch. See Fig. 3
. Also, refer to the REAR
WIPER/WASHER SWITCH CONTINUITY (FESTIVA) table.
REAR WIPER/WASHER SWITCH CONTINUITY (FESTIVA)
TerminalPositionContinuity
BLU - BLKOffNo
"OnYes
GRN/BLK - BLKOffNo
"OnYes
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Fig. 3: Identifying Rear Wiper/Washer Switch Terminals (Festiva)

Courtesy of FORD MOTOR CO.
REAR WASHER MOTOR TEST
See FRONT WASHER MOTOR TEST under TESTING.
REMOVAL & INSTALLATION
FRONT WIPER MOTOR
Removal
Disconnect negative battery cable. On Capri, gently pry linkage off ball socket at wiper motor arm. On Festiva, remove access plate then gently
pry linkage off ball socket at wiper motor arm. On all models, disconnect wiper motor electrical connector. Remove 4 mounting bolts and
rubber insulators and remove wiper motor.
Installation
Position wiper motor on firewall. Install 4 rubber insulators and mounting screws and tighten to 62-89 INCH lbs. (7-10 N.m). Reverse removal
procedure to complete installation. Check wipers for proper operation.
FRONT WIPER/WASHER SWITCH
Removal & Installation (Capri)
Remove center trim panel and access cover under steering column. Remove 2 screws and remove lower steering column shroud. Disconnect
wiper/washer switch electrical connector and pull wiring from routing clip. Firmly grasp switch and lever and remove from mounting. To
install, reverse removal procedure.
Removal & Installation (Festiva)
1. Disconnect negative battery cable. From back of steering wheel, remove 2 screws securing horn pad. Disconnect horn wire from horn
pad and remove pad. Remove steering wheel nut. Scribe reference mark on steering shaft and steering wheel hub for reassembly. Using
Steering Wheel Puller (T67L-3600-A), remove steering wheel.
2. Remove 4 screws from upper half of lower steering column cover. Remove cover. Remove upper steering column cover. Remove 5 clips
from lower half of lower steering column cover. Remove cover.
3. Release wiring harness clip and unplug 4 harness connectors from back of combination switch. From below steering column, loosen
band clamp securing switch hub to steering column jacket. Pull switch assembly from steering column.
4. To install, slide combination switch assembly onto steering column. Make sure switch assembly is seated and level against end of
column jacket. To complete installation, reverse removal procedure.
FRONT WASHER MOTOR & RESERVOIR
Removal & Installation (Capri)
Drain reservoir if necessary. Remove 2 bolts securing reservoir to inner finder. Disconnect electrical connector from washer pump mo t o r.
NOTE:Disconnect linkage from wiper m otor arm ball socket NOT by rem oving nut and wiper m otor arm . This
will elim inate the need to retim e wiper m otor and linkage. Replacem ent m otors are supplied with arm
attached. Manufacturer does not give procedure for tim ing m otor arm to wiper park position.
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Disconnect fluid lines and remove reservoir. To install, reverse removal procedure.
Removal & Installation (Festiva)
1. Disconnect negative battery cable. Remove washer reservoir filler neck attaching bolt. Remove coolant expansion reservoir. Disconnect
washer pump electrical connector. Remove left front splash shield.
2. Disconnect washer pump fluid lines and detach lines from reservoir clips. Remove reservoir attaching nuts and bolt. Detach washer
reservoir from filler neck and remove reservoir. To install, reverse removal procedure.
REAR WIPER MOTOR
Removal & Installation (Festiva)
Remove rear wiper arm and blade assembly. Remove boot from outer bushing attaching nut. Remove outer bushing attaching nut and remove
outer bushing. Remove liftgate trim panel. Disconnect wiper motor electrical connector. Remove 4 wiper motor mounting bolts and remove
motor. To install, reverse removal procedure.
REAR WIPER/WASHER SWITCH
Removal & Installation (Festiva)
Disconnect negative battery cable. Remove steering column covers. Remove screws securing instrument panel bezel to instrument panel. Pull
instrument bezel away from instrument panel. Disconnect electrical connectors from switches in bezel. Compress wiper/washer switch lock
tabs and remove switch from bezel. To install, reverse removal procedure.
REAR WASHER MOTOR & RESERVOIR
Removal & Installation (Festiva)
Open liftgate and detach reservoir cap. Remove rear quarter trim panel. Remove reservoir mounting bolts. Disconnect electrical connector
from washer pump. Disconnect fluid lines. Remove reservoir. To install, reverse removal procedure.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
WIRING DIAGRAMS
See appropriate chassis wiring diagram in the WIRING DIAGRAMS Section.
ApplicationINCH Lbs. (N.m)
Front Wiper Arm Retaining Nut89-124 (10-14)
Front Wiper Motor Mounting Bolts62-89 (7-10)
Rear Outer Bushing Retaining Nut27-44 (3-5)
Rear Wiper Arm Nut53-62 (6-7)
Rear Wiper Motor Mounting Bolts71-97 (8-11)
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00028304
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ALTERNATOR & REGULATOR
1991 ELECT RICAL Alternators & Regulators
DESCRIPTION
Mitsubishi alternator is a 50-amp, conventional 3-phase, self-rectifying type unit, containing 6 diodes (3 main diodes and a smaller diode trio)
and a case-mounted Integrated Circuit (IC) regulator. A charge indicator light in the instrument panel indicates charging system mal fu n ct io n s.
See Fig. 1
.

Fig. 1: Charging System Wiring Schematic

Courtesy of FORD MOTOR CO.
ADJUSTMENTS
BELT TENSION
BELT ADJUSTMENTS
(1)
ON-VEHICLE TESTING
ALTERNATOR OUTPUT
ApplicationNew BeltUsed Belt
A/C & P/S Belts110-125 (50-57)92-110 (42-50)
Alt. Belt110-130 (50-60)95-110 (43-50)
(1)Tension in Lbs. (Kg) Using Strand Tension Gauge
NOTE:Before testing, check alternator wiring harness connections, drive belt tension and battery voltage.
Ensure battery cables and engine ground cable are clean and tight. Wait at least 30 seconds after
starting engine before m easuring voltage.
CAUT ION: DO NOT start engine with "L" and "S" term inal connectors disconnected from alternator. DO NOT allow
"L" term inal to contact ground while engine is running. See Fig. 2
.
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Fig. 2: Identifying Alternator Test Terminals

Courtesy of FORD MOTOR CO.
1. Turn ignition switch to OFF position. Connect positive voltmeter lead wire to alternator "B" terminal and negative wire to ground. See
Fig. 2
. Ensure voltmeter indicates battery voltage. If voltmeter indicates zero volts, an open circuit exists in wire between "B" terminal
and battery positive terminal.
2. Remove voltmeter. Disconnect negative battery cable. Remove output lead from alternator terminal "B". Connect a 100-amp ammeter in
series between "B" terminal and disconnected output lead. Connect positive lead of ammeter to "B" terminal and negative lead to
disconnected output wire.
3. Connect voltmeter in parallel between alternator "B" terminal and battery positive terminal. Connect positive lead wire of voltmeter to
"B" terminal and negative lead wire to positive terminal of battery. Reconnect negative battery cable.
4. Install tachometer (if necessary) to monitor engine RPM. Start engine. Turn all lights and accessories on and depress brake pedal to load
system. Increase engine speed to 2500-3000 RPM. Ensure alternator output is at least 35 amps.
5. Observe voltmeter reading. If voltmeter indicates .2 volt and amperage output is at least 35 amps, system is okay. If voltage drop is
greater than .2 volt, wiring is defective between alternator "B" terminal and battery positive terminal.
6. Allow engine to idle. Turn off all accessories to remove load from system. Disconnect voltmeter. Connect negative lead of voltmeter to
ground. Using positive lead of voltmeter, backprobe "S" terminal connector at rear of alternator. See Fig. 2
.
7. Increase engine speed to 2500-3000 RPM. With no load on system, ammeter should read 5 amps or more. Battery voltage with no load
at indicated speed should be 14.1-14.7 volts. If amperage output is less than indicated with or without load and no external faults exist
in alternator circuit, overhaul or replace alternator.
BENCH TESTING
Rotor
Check continuity across rotor slip rings. If no continuity exists, replace rotor. Check continuity between individual slip rings and rotor
core/shaft. If continuity exists, rotor coil or slip ring is grounded. Replace rotor.
Stator
Ensure no continuity exists between stator coil leads and stator core. Check continuity between leads of stator coil. If continuity does not
exist, replace stator.
Brushes
Inspect brushes. Replace brushes if worn to wear line (leading edge of small square cast into brush). Use a spring pressure gauge to push each
NEW brush into its holder until .079" (2 mm) projects from holder. Spring force should be 10.6-15.6 oz. (.3-.4 kg). If spring force is not
within specification, replace brush spring.
Rectifier
1. Using an ohmmeter, check for continuity between positive side of diode leads and heat sink. If no continuity exists from any positive
diode lead to heat sink, replace rectifier assembly.
2. Reverse ohmmeter leads, and check for continuity between negative side of diodes and heat sink. If continuity exists from any n e ga t ive
diode lead to heat sink, replace rectifier assembly.
3. Check diode trio (smaller diodes between main diode leads) for continuity in both directions. Continuity should exist in one direction
only. If any diode shows continuity in both directions or does not show continuity in either direction, replace diode trio.
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ELECT RICAL COMPONENT LOCAT OR
1991-92 ELECT RICAL COMPONENT LOCAT ION Ford Motor Co. Electrical Com ponents
BUZZERS, RELAYS & TIMERS
BUZZERS, RELAYS & TIMERS LOCATION
CIRCUIT PROTECTION DEVICES
CIRCUIT PROTECTION DEVICES LOCATION
CONTROL UNITS
CONTROL UNITS LOCATION
SENDING UNITS & SENSORS
SENDING UNITS & SENSORS LOCATION
MOTORS
MOTORS LOCATION
ComponentLocation
A/C Clutch Relay (1991)On right front of engine bay, near power
steering pump.
A/C RelayOn left front corner of engine bay, left of
cooling fan. See Fig. 1
& Fig. 2
A/C Wide Open Throttle (WAC) RelayOn left front corner of engine bay, left of
cooling fan. See Fig. 1
& Fig. 2 .
Cooling Fan RelayOn left front fender panel, near
headlight. See Fig. 1
& Fig. 2 .
Condenser Fan RelayOn left front of engine bay, left of
cooling fan. See Fig. 1
& Fig. 2 .
Daytime Running Light (DRL) Relay (Canada) (1992)On left front corner of engine bay, near
headlight. See Fig. 1
.
Fuel Pump RelayBehind left side of dash, near ECA.
Headlight RelayBehind left headlight. See Fig. 1 .
Horn RelayUnder left side of dash. See Fig. 3 .
Main RelayIn left front corner of engine bay, near
battery.
P a r kin g Ligh t R e l a yOn right front corner of engine bay. See
Fig. 1
.
Turn Signal/Flasher RelayUnder left side of dash, behind ECA.
See Fig. 3
.
ComponentLocation
A/C In-Line FuseOn left side of heater case.
Condenser Fan In-Line FuseOn right side of steering column.
Fuse PanelBehind access panel, to left of steering column.
Fusible LinksOn left front strut tower. See Fig. 1 .
ComponentLocation
Electronic Control Assembly (ECA)Behind left side of dash, left of steering column.
Passive Restraint ModuleUnder driver's seat.
ComponentLocation
Airflow MeterOn right front corner of engine bay. See Fig. 1 .
Coolant Temperature Sending UnitBelow thermostat housing.
Crankshaft Position SensorInside distributor. See Fig. 1 .
EGR Temperature Sensor (1991)In exhaust manifold, near EGR valve.
Engine Coolant Temperature (ECT) SensorOn top of engine, near injector No. 1.
Fuel Gauge Sending Unit (1992)In fu el t an k.
Throttle Position Sensor (TPS)On left side of throttle body. See Fig. 1 .
ComponentLocation
Blower MotorUnder center of dash, behind
radio.
Windshield Washer Motors:
Front (1991)On right front fender panel,
bottom of washer reservoir.
Front (1992)On left front corner of engine
bay, in front of battery.
RearOn body panel, behind right
rear quarter panel.
Windshield Wiper Motor
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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.
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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.
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3. If voltage is not present or is less than 8 volts at starter solenoid terminal "S", malfunction in circuit to terminal "S" is indicated. Proceed
to the following tests.
IGNITION SWITCH TEST
1. Locate ignition switch connector under dash. Using a 12-volt test light or voltmeter, ensure voltage is present on Black/Yellow wire
when ignition switch is turned to RUN or ON position. This will verify proper operation of ignition switch.
2. If there is no voltage on Black/Yellow wire, the problem is either ignition switch or circuit between battery and ignition switch.
CLUTCH ENGAGE SWITCH (M/T) TEST
Unplug clutch engage switch from main wiring harness. Using an ohmmeter, check for continuity across switch terminals. Continuity should
exist when switch plunger is pushed in and should not exist when switch plunger is released. If clutch engage switch does not operate as
specified, replace switch.
NEUTRAL SAFETY SWITCH (A/T) TEST
Unplug neutral safety switch from main wiring harness. Using an ohmmeter, check for continuity across switch terminals "A" and "B". See Fig.
2 . Place transmission shift selector in Park or Neutral position. Continuity should exist between terminals "A" and "B". Continuity should not
exist in any other transmission shift selector positions. If switch does nor operate as specified, replace switch.

Fig. 2: Identifying Neutral Safety Switch Terminals

Courtesy of FORD MOTOR CO.
VOLTAGE DROP TEST
1. Disconnect and ground coil wire from distributor cap to prevent engine from starting. Connect remote starter switch between starter
solenoid terminal "S" and battery positive terminal. See Fig. 3
.
2. Using a digital voltmeter set on low scale, connect positive voltmeter lead to battery positive terminal. Connect negative lead to starter
solenoid terminal "M". See Fig. 3
.
3. Engage remote starter switch. Observe and record voltmeter reading. Voltmeter reading should be less than .5 volt. If voltage at terminal
"M" is greater than .5 volt, move negative voltmeter lead to solenoid terminal "B", and repeat test.
4. If voltage at terminal "B" is less than .5 volt, inspect solenoid cable connections and solenoid contacts for problem.
5 . Cl ean so l en o id t ermin al s "B", "M" an d "S", an d rep eat st ep s 1 ) through 4). If voltmeter still reads greater than .5 volt at termin al "M"
and less than .5 volt at terminal "B", solenoid contacts are bad.
6. If voltmeter reads greater than .5 volt at terminal "B", clean cables and connections at solenoid. If voltmeter still reads greater than .5
volt, check for poor positive battery cable connection or bad cable. Repair or replace as necessary.
7. To locate excessive voltage drop, move negative voltmeter lead toward battery, and check each connection point. When high voltmeter
reading is no longer present, last connection point is bad.
NOTE:Make all voltm eter connections at com ponent term inal rather than at cable or wire end.
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