brake light FORD FESTIVA 1991 User Guide

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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Shift Lock ActuatorShift Interlock Systems
Side Marker LightsExterior Lights
SIR Coil Assembly (Clockspring)Air Bag Restraint System
Slip Ring (Clockspring)Air Bag Restraint System; Steering Column Switches
SRS Control ModuleAir Bag Restraint System
Starter MotorStarters
Starter Interrupt RelayStarters
Starter SolenoidStarters
Starter RelayStarters
Steering Wheel Position SensorAnti-Lock Brakes
StoplightsExterior Lights
Stoplight SwitchEngine Performance; Cruise Control Systems; Anti-Lock Brakes
Sun Roof ECUPower Sun Roof
Sun Roof MotorPower Sun Roof
Sun Roof Position SensorPower Sun Roof
TaillightsExterior Lights
Throttle Position (TP) SensorEngine Performance
Torque Converter Clutch Solenoid/SwitchEngine Performance
Traction Control SwitchAnti-Lock Brakes
Trailer Tow ConnectorExterior Lights
Trailer Tow RelayExterior Lights
Transmission/TransaxleEngine Performance
Transmission Control Module (TCM)Engine Performance; Starters
Transmission Range SensorStarters; Back-Up Lights; Engine Performance
Transmission Range SwitchBack-Up Lights; Engine Performance; Anti-Theft System
Turn Signal FlasherExterior Lights
Tu r n S ign a l Ligh t sExterior Lights
Twilight Sentinel SwitchHeadlight Systems; Daytime Running Lights
Vapor Canister Leak Detection PumpEngine Performance
Vehicle Control Module (VCM)Engine Performance
Vehicle Dynamic ModuleElectronic Suspension
Vehicle Speed Control ServoCruise Control Systems
Vehicle Speed SensorData Link Connectors; Analog Instrument Panels; Cruise Control
Systems; Electronic Suspension
Voltage RegulatorGenerators & Regulators
Water-In-Fuel SensorEngine Performance; Analog Instrument Panels
Wheel Speed SensorsAnti-Lock Brakes
Window Timer ModulePower Convertible Top
Windshield Intermittent Wiper RelayWiper/Washer Systems
Windshield Washer MotorWiper/Washer Systems
Wiper MotorWiper/Washer Systems
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00130983
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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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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.
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Fig. 1: Testing Canister Purge Solenoid

Courtesy of FORD MOTOR CO.
Carbon Canister
1. Start and run engine until it is at operating temperature. Stop engine. Remove carbon canister. Carbon canister on 1.3L is located under
brake booster. Carbon canister is located in right side of engine compartment near cowl panel on 1.6L.
2. Inspect carbon canister for presence of liquid fuel, as evidenced by odor or weight. Blow into air vent and ensure air exits fro m fu el
vapor inlet. Replace carbon canister if it contains fuel, or if air does not pass freely through it.
POSITIVE CRANKCASE VENTILATION (PCV)
1. Remove PCV valve from valve cover and disconnect it from PCV h o se . S h a ke va l ve vigo r o u sl y t o e n su r e p l u n ge r is fr e e t o mo ve .
Replace PCV valve if plunger is not free.
2. Idle engine until it is warm. Remove fresh air hose at inlet end. Plug nipple immediately to prevent stalling. Verify presence of vacuum at
inlet end of hose. If vacuum is not present, replace PCV valve or service hoses or loose oil dipstick.
THROTTLE CONTROLS
Dashpot
Disconnect PCV valve. Remove resonance chamber. Push dashpot rod in and then release it. Replace dashpot if rod does not go in slowly and
return quickly.
MISCELLANEOUS CONTROLS
A/C CLUTCH
A/C Clutch Relay
Remove relay from its socket near left headlight, in front of battery. Connect ohmmeter to contact terminals (Blue/Red and Black/White wires
on mating connector). Ohmmeter should indicate continuity. Supply 12 volts to remaining terminals (Green/Yellow and Yellow wires on
mating connector). Ohmmeter should indicate no continuity.
COOLING FAN
Cooling Fan
Unplug connector from cooling fan. Apply 12 volts to one terminal of fan connector. Ground remaining fan connector terminal. Replace fan if
it does not run.
Cooling Fan Control Relay
Remove relay from its socket near left headlight. Connect ohmmeter to contact terminals. Wire colors are Yellow/Red and Black on mating
connector on Festiva; Yellow/Green and Black on Capri. Ohmmeter should indicate continuity. Supply 12 volts to remaining 2 relay
terminals. Ohmmeter should indicate no continuity.
NOTE:Although som e of the controlled devices listed here are not technically engine perform ance
com ponents, they can affect driveability if they m alfunction.
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memory. Intermittent failures may be caused by a sensor, connector, or wiring. See INTERMITTENTS in TESTS W/O CODES article in the
ENGINE PERFORMANCE Section.
VISUAL CHECK & VEHICLE PREPARATION
Before connecting any equipment to diagnose EEC system, perform following preparatory procedures:
Verify condition of air cleaner and air ducts.
Check all vacuum hoses for leaks, restrictions, or improper routing.
Check EEC system wiring harness electrical connections for corrosion, bent or broken pins, loose wires or terminals, or improper
routing.
Check ECA, sensors, and actuators for physical damage.
Check engine oil and coolant level.
Perform all necessary safety precautions to prevent personal injury or vehicle damage.
Set parking brake. Place shift lever in Park for automatic transmissions, or Neutral for manual transmissions. DO NOT move shift lever
during test unless specifically directed.
Turn off all lights and accessories. Ensure vehicle doors are closed when measuring voltage or resistance.
Start engine. Run at idle until upper radiator hose is hot and pressurized and engine is off fast idle. Check for leaks around exhaust
manifold, exhaust gas oxygen sensor, and vacuum hose connections.
Turn ignition off. Service items as required. Go to EQUIPMENT HOOK-UP .
EQUIPMENT HOOK-UP
VOM
1. Turn ignition off. Connect a jumper wire from STI connector to ground. Refer to SELF-TEST CONNECTOR LOCATION and
SELF
-TEST CONNECTOR WIRE COLORS tables. See Fig. 1 .
2. Connect VOM between STO terminal and engine ground. Set VOM to measure 0-20 volts DC.
CHECK ENGINE Light (MIL)
Connect a jumper wire between STI connector and ground.
SUPER STAR II Tester
Turn ignition off. Connect adapter cable leads to diagnostic tester. Connect service adapter cables to vehicle self-test connectors. Ground
adapter cable.
SELF-TEST CONNECTOR LOCATION
SELF-TEST CONNECTOR WIRE COLORS

Fig. 1: Self
-Test Connector Terminal ID
Courtesy of FORD MOTOR CO.
RETRIEVING CODES
Reading Service Codes
ApplicationLocation
1.3LLeft Rear Corner Of Engine Compartment
1.6LRight Rear Corner Of Engine Compartment
CircuitWire Color
1.3L
SMLBlue/Green
STIYellow/Green
STOYellow/White
1.6L
SMLBlack/Blue
STIYellow
STOGreen/Black
Page 2 of 20 MITCHELL 1 ARTICLE - G - TESTS W/CODES 1991-92 ENGINE PERFORMANCE Ford Motor Co. Self-Diagnostics
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CLEARING CODES
Clearing Codes Procedure
Disconnect negative battery cable. Press brake pedal for 5-10 seconds. Turn off VOM or Super Star II tester. Reconnect battery.
ECA LOCATION
ECA is located on center console behind kick panel on Capri, and under instrument panel on driver side of Festiva.
QUICK TESTS
KEY ON, ENGINE OFF (KOEO) SELF-TEST
KOEO
1. This is a test of electronic engine control system, conducted with power (voltage) applied and engine not running. Activate self-test, and
record all codes displayed.
2. Erase codes, and repeat self-test. Diagnose only codes occurring during repeat self-test. See TROUBLE CODE DEFINITION
table. If
no codes are present, proceed to KEY ON, ENGINE RUNNING (KOER) SELF
-TEST .
KEY ON, ENGINE RUNNING (KOER) SELF-TEST
KOER
1. Deactivate self-test. Start and run engine at 2000 RPM for 2 minutes to warm up EGO sensor. Turn off engine and wait 10 seconds.
2. Restart engine, and activate self-test. Record all service codes displayed. See TROUBLE CODE DEFINITION
table. If no codes are
present, proceed to SWITCH MONITOR TEST
.
SWITCH MONITOR TEST
This test procedure checks input signals received by ECA from individual switches. Use following procedure to perform switch monitor test:
Turn engine off and allow it to cool.
Ensure all accessories are turned off.
Deactivate self-test.
Ensure transmission is in Neutral or Park.
Turn ignition on.
SUPER STAR II Tester
Connect Super Star II tester adapter cable. Turn on tester. Latch center button. Operate each switch listed in SWITCH MONITOR TEST
table. Note output of LED on adapter cable as each switch operates. Record test results.
VOM
1. Ground STI connector. Connect VOM positive lead to SML terminal on self-test connector. Connect negative lead to ground. See Fig.
1 .
2. Operate each switch listed in SWITCH MONITOR TEST
table. Note output on VOM as each switch is operated. Go to specified
PINPOINT TEST if any switch does not meet specification.
SWITCH MONITOR TEST
(1)Festiva only.
(2)Capri only.
NOTE:DO NOT m ove throttle during KOEO self-test.
NOTE:It is necessary to clear codes in m em ory before perform ing this test. DO NOT m ove throttle during test.
NOTE:All switches m ust be tested individually. Allowing a switch to rem ain on while testing another will lead
to false test results.
NOTE:DO NOT m ove throttle, clutch, or transm ission lever unless so directed.
SwitchVOM Indication/Condition(1) Pinpoint Test
A/C SwitchLess Than 1.5 Volts; A/C & Blower Switch OnSTG
Blower Motor SwitchLess Than 1.5 Volts; Switch Set To "2" Or HigherSTG
Brake On/Off SwitchLess Than 1.5 Volts; Brake Pedal Partially
PressedSTP
Clutch Engage/Neutral Gear Switch (2) Less Than 1.5 Volts; In Gear, Clutch ReleasedSTG
Coolant Temperature SwitchLess Than 1.5 Volts; Cooling Fan OnSTP
Defrost SwitchLess Than 1.5 Volts; Defrost Switch OnSTP
Headlight SwitchLess Than 1.5 Volts; Headlight Switch OnSTP
Id l e Swit chLess Than 1.5 Volts; Accelerator Pedal PressedSTG
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GENERAL INFORMATION
Com puter Relearn Procedures
COMPUTER RELEARN PROCEDURES
Vehicles equipped with engine or transmission computers may require a relearn procedure after vehicle battery is disconnected. Many vehicle
computers memorize and store vehicle operation patterns for optimum driveability and performance. When vehicle battery is disconnected,
this memory is lost. The computer will use default data until new data from each key start is stored. As computer memorizes vehicle operation
for each new key start, driveability is restored. Vehicle computers may memorize vehicles operation patterns for 40 of more key starts.
Customers often complain of driveability problems during relearn stage because vehicle acts differently then before being serviced. Depending
on type and make of vehicle and how it is equipped, the following complaints (driveability problems) may exist:
Harsh Or Poor Shift Quality
Rough Or Unstable Idle
Hesitation Or Stumble
Rich Or Lean Running
Poor Fuel Mileage
These symptoms and complaints should disappear after a number of drive cycles have been memorized. To reduce the possibility of
complaints, after any service which requires battery power to be disconnected, vehicle should be road tested.
GENERIC COMPUTER RELEARN PROCEDURES
Some manufacturers identify a specific relearn procedure which will help establish suitable driveability during relearn stage. These procedures
are especially important if vehicle is equipped with and electronically controlled automatic transmission or transaxle. Always complete
procedure before returning vehicle to customer. The following general procedures are to be used if driveability problems are encountered after
power loss or battery has been disconnected. These procedures may provide an aid in eliminating these problems.
Automatic Transmission
Set parking brake, start engine in "P" or "N" position. Warm-up vehicle to normal operating temperature or until cooling fan cycles.
Allow vehicle to idle for one minute in "N" position. Select "D" and allow engine to idle for one minute.
Accelerate at normal throttle position (20-50%) until vehicle shifts into top gear.
Cruise at light to medium throttle.
Decelerate to a stop, allowing vehicle to downshift, and use brakes normally.
Process may be repeated as necessary.
Manual Transmission
Place transmission in Neutral position.
Ensure emergency brake has been set and all accessories are turned off.
Start engine and bring to normal operating temperature.
Allow vehicle to idle in Neutral for one minute.
Initial relearn is complete, and process will be completed during normal driving.
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00012612
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GENERAL INFORMATION
Gear T ooth Contact Patterns
* PLEASE READ THIS FIRST *
INSPECTION
Wipe lubricant from internal parts. Rotate gears and inspect for wear or damage. Mount dial indicator to housing and check backlash at several
points around ring gear. Backlash must be within specification at all points. If no defects are found, check gear tooth pattern contact.
GEAR TOOTH CONTACT PATTERN
1. Paint ring gear teeth with marking compound. Wrap cloth or rope around drive pinion flange to act as brake. Rotate gear until clear
contact pattern is obtained.
2. Contact pattern will indicate whether correct pinion bearing mounting shim has been installed and if drive gear backlash has been set
properly. Backlash between drive gear pinion must be maintained within specified limits until correct tooth pattern is obtained.
ADJUSTMENTS
GEAR BACKLASH & PINION SHIM CHANGES
1. With no change in backlash, moving pinion further from ring gear moves drive pattern toward heel and top of tooth, and moves coast
pattern toward toe and top of tooth.
2. With no change in backlash, moving pinion closer to ring gear moves drive pattern toward toe and bottom of tooth, and moves coast
pattern toward heel and bottom of tooth.
3. With no change in pinion shim thickness, an increase in backlash moves ring gear further from pinion. Both drive and coast patterns
move toward heel and top of tooth.
4. With no change in pinion shim thickness, a decrease in backlash moves ring gear closer to pinion gear. Both drive and coast patterns
move toward toe and bottom of tooth. NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For m odel-specific inform ation see appropriate articles where
available.
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For m odel-specific inform ation see appropriate articles where
available.
NOTE:Drive pattern should be well centered on ring gear teeth. Coast pattern should be centered, but m ay be
slightly toward toe of ring gear teeth.
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For m odel-specific inform ation see appropriate articles where
available.
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For m odel-specific inform ation see appropriate articles where
available.
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. For m odel-specific inform ation see appropriate articles where
available.
Page 1 of 2 MITCHELL 1 ARTICLE - GENERAL INFORMATION Gear Tooth Contact Patterns
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