sensor 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
Page 104 of 454
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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Page 105 of 454
Fig. 1: Installing Cylinder Head Bolts (1.3L)
Courtesy of FORD MOTOR CO.
Removal (1.6L)
1. Release fuel pressure. Drain cooling system. Disconnect negative battery terminal. Remove intake air tube from throttle body.
Disconnect air by-pass hoses. Remove spark plug wires and retainers. Remove intake air tube from air cleaner assembly. Disconnect
coolant hose from thermostat cover. Disconnect vacuum hoses and coolant hoses from throttle body and intake manifold.
2. Disconnect throttle cable and remove retaining brackets and cable. Disconnect fuel lines at fuel filter and pressure regulator. Disconnect
main harness connector. Disconnect O2 sensor connector and remove ground connection retaining screw at bracket. Disconnect
intercooler tubes from turbocharger (if equipped). Remove ground wire and strap retaining bolts at front sides of cylinder head.
3. Remove timing belt covers and timing belt. On turbocharged vehicles, remove exhaust manifold and turbocharger as an assembly. On
non-turbocharged vehicles, disconnect front exhaust pipe from exhaust manifold. Remove intake manifold support upper retaining bolts.
4. Remove cam cover. Remove cylinder head and intake manifold as an assembly. Separate intake manifold from cylinder head (if
required).
Installation (1.6L)
1. Position new (2-piece) exhaust gasket on cylinder head with heavy gasket installed first. Install exhaust manifold to head. Install intake
manifold to head using new gasket. Tighten all manifold nuts to specification. See TORQUE SPECIFICATIONS
table at end of
article.
2. Ensure gasket surfaces of head and block are clean of old gasket and sealant. Place new head gasket on cylinder block. Carefully, place
cylinder head on block. Tighten cylinder head in sequence and in two stages to correct specification. See Fig. 2
.
Fig. 2: Installing Cylinder Head Bolts (1.6L)
Courtesy of FORD MOTOR CO.
3. Install intake manifold support upper retaining bolts and tighten to specification. See TORQUE SPECIFICATIONS
table at end of
NOTE:Ensure coolant passage openings in gasket align with m anifold and cylinder head.
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Page 106 of 454
article. Install timing belt and covers. Install cam cover. On non-turbo engines, connect front exhaust pipe to exhaust manifold. Tighten
nuts to specification.
4. On turbocharged engines, install exhaust manifold and turbocharger assembly. Install ground wire and strap to cylinder head with
retaining bolts. Connect intercooler tubes (if equipped). Connect O2 sensor connector, and install ground wires to bracket on cylinder
head with retaining screw. Connect main engine harness connector. Connect fuel lines to fuel filter and pressure regulator. Install
throttle cable and retaining brackets.
5. Install coolant hoses and vacuum lines to intake manifold and throttle body. Install coolant hose to thermostat cover. Install intake air
tube to air cleaner. Install spark plug wires and retainers. Install intake air tube to throttle body, and connect by-pass hoses. Fill cooling
system. Connect negative battery terminal. Start engine, check for leaks and system operation.
TIMING BELT COVER
Removal & Installation (1.3L)
Remove accessory belts. Remove water pump pulley. Remove crankshaft damper. Remove bolts retaining upper and lower cover halves to
engine front. Remove both covers. To install, reverse removal procedure.
Removal & Installation (1.6L)
Raise vehicle on hoist. Remove RF tire and wheel assembly. Remove RF splash guard. Lower vehicle. Remove spark plugs and set camsh aft
timing to TDC No. 1 cylinder. Remove oil dipstick. Remove water pump pulley. Remove crankshaft pulley, damper and baffle plate. Remove
upper timing belt cover. Remove center and lower timing belt covers. To install, reverse removal procedure.
TIMING BELT
Removal (1.3L)
Remove accessory belts, water pump pulley, crankshaft damper and upper and lower timing belt covers. Mark timing belt direction of rotation
for installation reference. Remove timing belt tensioner pulley bolt. Remove tensioner pulley, spring and spring cover. Remove timing belt.
Installation (1.3L)
1. Ensure timing belt and sprockets are clean and not worn or damaged. Align crankshaft and camshaft timing marks. See Fig. 3 . No. 1
cylinder must be at TDC of compression stroke.
2. Position belt on camshaft sprocket. Install timing belt tensioner spring, spring cover and pulley. Tighten tensioner pulley bolt to
specification. See TORQUE SPECIFICATIONS
table at end of article. To complete installation, reverse removal procedure. Tighten
all bolts and nuts to specification.
Fig. 3: Aligning Camshaft & Crankshaft Timing Marks (1.3L)
Courtesy of FORD MOTOR CO.
Removal (1.6L)
NOTE:Always rotate engine in direction of norm al operation. Rotating crankshaft backwards m ay cause belt to
jump timing.
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Installation
1. Install pressure regulator valve, spring, retainer and new cotter pin. Press a new seal in front cover housing. Install outer and inner gears
in housing. Install pump cover. Coat bolts with Loctite and tighten to specification. See TORQUE SPECIFICATIONS
table at end of
article.
2. Install new gasket and install front cover housing. Install new gasket and install pick-up tube and screen. Tighten all bolts/nuts to
specification. To complete installation, reverse removal procedure.
ENGINE COOLING
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
1.6L.0012-.0043 (.03-.11)
NOTE:Refer to WAT ER PUMP
under REMOVAL & INSTALLATION in this article.
ApplicationFt. Lbs. (N.m)
"A" Arm Front Bolt72-86 (97-117)
A/C Compressor Bolt29-40 (39-54)
Camshaft Sprocket Bolt36-45 (49-61)
Connecting Rod Nut
Step 111-13 (15-18)
Step 2
1.3L22-25 (30-34)
1.6L35-38 (47-52)
Crankshaft Pulley Bolts9-13 (12-17)
Crankshaft Sprocket Bolt80-87 (108-118)
Crossmember-To-Body Bolt
1.3L47-66 (64-89)
1.6L27-37 (35-50)
Cylinder Head Bolt
Step 135-40 (48-54)
Step 256-60 (76-81)
Exhaust Manifold-To-Cylinder Head
1.3L12-17 (16-23)
1.6L29-42 (39-57)
Exhaust Pipe-To-Manifold29-42 (39-57)
Exhaust Pipe-To-Support Bracket32-45 (43-61)
Flywheel Bolt71-76 (96-103)
Front Cover Housing Bolt (1.3L)14-19 (19-26)
Front Engine Mount Nut32-38 (43-52)
Heater Tube32-45 (43-61)
Intake Manifold-To-Cylinder Head
1.3L14-20 (19-27)
1.6L47-66 (64-89)
Main Bearing Cap Bolts40-44 (54-59)
O2 Sensor27-33 (37-45)
Oil Pump Cover Bolt (1.6L)14-18 (19-25)
P/S Pump Bracket (Nut & Bolt)35-49 (47-66)
P/S Adjusting Nut27-38 (37-52)
P/S Pivot Bolt23-34 (31-46)
Pulse Air Tube Nut23-34 (31-46)
Rear Engine Mount Nut
1.3L21-34 (28-46)
1.6L47-66 (64-89)
Rocker Arm Shaft Bolts16-21 (22-28)
Side Engine Mount Nuts
1.3L29-40 (39-54)
1.6L
RH49-67 (67-91)
LH33-48 (45-65)
Spark Plug11-17 (15-23)
Thermostat Housing Bolt14-22 (19-30)
Timing Belt Tensioner Adjusting Bolt14-19 (19-26)
Turbo Oil Supply Tube
Engine Block Side12-18 (16-24)
Banjo Side(1) 106-159 (12-18)
Turbo-To-Manifold29-42 (39-57)
Water Outlet Bolt14-22 (19-30)
Water Pump Pulley Bolts (1.3L)36-45 (49-61)
Page 15 of 19 MITCHELL 1 ARTICLE - ENGINE OVERHAUL 1991-92 FORD MOTOR CO. ENGINES 1.3L & 1.6L 4-Cylinder
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Page 130 of 454
IDLE SPEED & MIXTURE
IDLE MIXTURE
IDLE SPEED
1. Turn off all accessories. Place automatic transmission in Park or manual transmission in Neutral. Set parking brake. Connect tachometer
to engine. Warm engine to normal operating temperature. Connect a jumper wire between single-wire STI test connector (Green on
Capri; Black on Festiva) and ground. See Fig. 1
.
2. Locate idle speed control by-pass air (ISC-BPA) valve on intake manifold. Remove cap, and adjust idle speed to specification by turning
idle air adjust screw on ISC-BPA valve. See Fig. 2
. Remove jumper wire.
IDLE RPM
Fig. 2: Locating Idle Air Adjust Screw
Courtesy of FORD MOTOR CO.
THROTTLE POSITION SWITCH (TP)
CAPRI
Throttle position sensor is preset at factory. No adjustment is required.
FESTIVA
1. Ensure idle speed and ignition timing are adjusted to specification. Stop engine. Disconnect negative battery cable.
2. Unplug TP connector at throttle body. Insert appropriate feeler gauge between throttle stop screw and stop lever. Check for continuity
between specified terminals on TP connector. See TP ADJUSTMENT table.
3. To adjust, loosen TP attaching screws. Connect ohmmeter between terminals IDL and TL. See Fig. 3
. Insert a .020" (.5 mm) feeler
gauge between throttle stop screw and stop lever.
4. Rotate TP until ohmmeter indicates continuity. Insert a .028" (.7 mm) thickness gauge between stop screw and stop lever. Ohmmeter
should indicate no continuity. If ohmmeter indicates continuity, repeat adjustment procedure.
ApplicationAuto. Trans.Man. Trans.
1.3L9-11 @ 8509-11 @ 700
1.6L Non-Turbo1-3 @ 8500-4 @ 850
1.6L Turbo10-14 @ 8500-4 @ 850
NOTE:Idle m ixture is controlled by ECA and is not adjustable.
ApplicationAuto. Trans.Man. Trans.
1.3L830-870680-720
1.6L800-900800-900
CAUT ION: DO NOT tam per with throttle stop screw at throttle lever. Doing so m ay result in dam age to throttle
body.
Page 2 of 3 MITCHELL 1 ARTICLE - D - ADJUSTMENTS 1991 ENGINE PERFORMANCE Ford/Mercury - On-Vehicle Adjustments
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Page 137 of 454
AIS-VCV
AIS Vacuum Control Valve
AIS-VSV
AIS Vacuum Switching Valve
AIS-VT
AIS Vacuum Tank
AIS-VCV
AIS Vacuum Control Valve
AIS-VSV
AIS Vacuum Switching Valve
AP
Air Pump Injection System
AP-ACV
AP Air Control Valve
AP-AMV
AP Air Management Valve
AP-BPV
AP By-Pass Valve
AP-CKV
AP Check Valve
AP-CS
AP Control Solenoid
BP/EGR
Backpressure EGR System
BP/EGR-BPS
BP/EGR Backpressure Sensor
BP/EGR-BPT
BP/EGR Backpressure Transducer
BP/EGR-BPV
BP/EGR Backpressure Valve
BP/EGR-BS
BP/EGR Bleed Solenoid
BP/EGR-BVSV
BP/EGR Bimetallic Vacuum Switching Valve
BP/EGR-C
BP/EGR Controller
BP/EGR-CLR
BP/EGR Cooler
BP/EGR-CS
BP/EGR Control Solenoid
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Page 139 of 454
EVAP-CPCV
EVAP Canister Purge Control Valve
EVAP-CPRV
EVAP Canister Purge Regulator Valve
EVAP-CPSV
EVAP Canister Vent Shut Valve
EVAP-CPT
EVAP Canister Purge Timer
EVAP-CPTVS
EVAP Canister Purge Thermal Vacuum Switch
EVAP-CPV
EVAP Canister Vent Valve
EVAP-CPVCSV
EVAP Canister Purge Volume Control
EVAP-CPVDV
EVAP Canister Purge Vacuum Delay Valve
EVAP-CS
EVAP Control Solenoid
EVAP-CSPS
EVAP Control System Pressure Sensor
EVAP-ORVR
Evaporative On-Board Refueling Vapor Recovery System
EVAP-ORVRFTVRV
EVAP-ORVR Fuel Tank Vapor Recirculation
EVAP-OVCV
EVAP Outer Vent Control Valve
EVAP-OW V
EVAP One-Way Valve
EVAP-PCSV
EVAP Purge Cut-Off Solenoid Valve
EVAP-PFS
EVAP Purge Flow Sensor
EVAP-PFSVVSV
EVAP Purge Flow Switching Valve Vacuum Switching Valve
EVAP-PRRV
EVAP Pressure Relief Rollover Valve
EVAP-VC
EVAP Vapor Canister
FF
Flexible Fuel
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Page 140 of 454
FLV
Fill Limit Valve
FR
Fill Pipe Restrictor
FVV
Fuel Vapor Valve
HO2S
Heated Oxygen Sensor
MFI
Multiport Fuel Injection
MFI-MAF
MFI Mass Airflow Sensor
MIL
Malfunction Indicator Light
OC
Oxidation Catalytic Converter
OHC
Overhead Cam
ORVR
On-Board Refueling Vapor Recovery
ORVR-COV
ORVR Cut-Off Valve
ORVR-CV
ORVR Control Valve
ORVR-FMV
ORVR Flow Management Valve
ORVR-FTVCV
ORVR Fuel Tank Vapor Control Valve
ORVR-FTVRV
ORVR Fuel Tank Vapor Recirculation Valve
ORVR-LV
ORVR Leveling Valve
ORVR-OCKV
ORVR Overfill Check Valve
ORVR-RCV
ORVR Refueling Control Valve
ORVR-VCV
ORVR Vapor Cut Valve
ORVR-VRV
ORVR Vapor Recirculating Valve
Page 8 of 9 MITCHELL 1 ARTICLE - EMISSION CONTROL APPLICATIONS Emission Applications - Ford Motor Co. - Imports (1968-
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Page 141 of 454
ORVR-VSV
ORVR Vent Shut Valve
ORVR-VV
ORVR Vent Valve
OVCV
Outer Vent Control Valve
O2S
Oxygen Sensor
PAIR
Pulsed Secondary Air Injection
PCV
Positive Crankcase Ventilation
SFI
Sequential Multiport Fuel Injection
SFI-MAF
SFI Mass Airflow Sensor
SPK
Spark Controls
SPK-AVM
SPK Advance Vacuum Modulator
SPK-BVSV
SPK Bimetal Vacuum Switching Valve
SPK-CC
SPK Computer Controlled
SPK-CKV
SPK Check Valve
TWC
Three-Way Catalytic Converter
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00157498
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Page 148 of 454
Removal
Drain radiator and remove negative battery cable. Disconnect throttle cable. Remove air duct from throttle body. Disconnect throttle position
sensor/switch connector. Mark all coolant and vacuum hoses for reassembly reference and remove from throttle body. See Fig. 4
. Remove
intake plenum bolts and remove intake plenum and gasket.
Installation
To install, reverse removal procedure. Use NEW intake plenum-to-intake manifold gasket. Tighten bolts to specification, see TORQUE
SPECIFICATIONS at end of article.
OXYGEN (O2) SENSOR
Removal & Installation
Disconnect negative battery cable. Disconnect wire harness connector, and remove oxygen sensor. If exhaust sensor is difficult to remove, use
rust penetrant to avoid possible damage to exhaust threads. If new sensor is not pre-coated with anti-seize, apply anti-seize compound to
sensor threads. DO NOT remove anti-seize from sensor. To install, tighten sensor and attach wire harness connector.
THROTTLE BODY
Removal & Installation
Drain radiator and remove negative battery cable. Remove resonance chamber. Disconnect throttle cable. Remove air duct. Mark all coolant
and vacuum hoses for reassembly reference and remove from throttle body. Disconnect throttle position sensor/switch connector. Remove
throttle body nuts and bolts. Remove throttle body and gasket. To install, reverse removal procedure using NEW throttle body-to-intake
plenum gasket.
THROTTLE POSITION SENSOR/SWITCH
Removal & Installation
Disconnect negative battery cable. Disconnect throttle position sensor/switch connector. Remove attaching bolts. Remove sensor/switch from
throttle body. To install, reverse removal procedure.
TURBOCHARGER
Removal
1. Drain radiator and remove negative battery cable. Remove throttle body air intake tube. Disconnect intercooler hose from turbocharger
assembly. Disconnect O2 sensor. Remove lower heat shield retaining bolts and lower heat shield from turbocharger. Remove upper heat
shield retaining bolts and upper heat shield from exhaust manifold.
2. Slide O2 sensor wire and guide through upper heat shield. Remove side heat shield retaining bolts from turbocharger, and remove sid e
heat shield. Remove power steering belt. Remove power steering pump through bolt and adjuster nuts and bolts. Disconnect lower
radiator hose from water pump.
3. Pull pump from bracket, and position pump to access mounting bracket retaining nut and bolts. Remove mounting bracket-to-engine nut
and bolts and remove bracket. Remove air cleaner duct retaining screws. Loosen clamp at turbocharger and move duct tube out of way.
Disconnect coolant supply hose at turbocharger.
4. Remove bolt and sealing washers attaching oil supply line at engine block. Raise vehicle on hoist. Remove nuts and washers from
exhaust pipe flange. Remove bolts attaching exhaust hanger to engine block. Slide rubber exhaust hangers from catalytic converter. Pull
exhaust pipe downward and to left side of vehicle. Disconnect oil return hose from turbocharger. Disconnect coolant return hose fro m
turbocharger.
5. Remove turbocharger support bracket retaining bolts. Remove coolant by-pass tube outlet-to-water pump bolts. Lower vehicle. Loosen
retaining clamp bolt on coolant by-pass tube at rear of cylinder head. Remove 11 retaining nuts from exhaust manifold. Position coolant
by-pass tube out of way after pulling bracket from exhaust stud.
6. Remove exhaust manifold by pulling off studs and moving assembly towards right side of engine compartment, clearing cooling fan.
With assembly removed from vehicle, remove turbocharger-to-exhaust manifold nuts. Separate assembly and discard gasket.
Installation
1. Install NEW gasket on exhaust manifold and install turbocharger onto studs. Install turbocharger-to-exhaust manifold nuts. Remo ve o il
supply line from turbocharger. Install NEW exhaust gasket on cylinder head. Install turbocharger and exhaust manifold assembly onto
studs. Install coolant by-pass tube bracket onto exhaust stud. Install 11 retaining nuts onto exhaust manifold.
2. Securely tighten heater tube clamp bolt. Raise vehicle. Install coolant by-pass tube outlet-to-water pump bolts. Install turbocharger
support bracket retaining bolts. Connect coolant return hose to turbocharger. Connect oil return hose to turbocharger. Install exhaust
pipe onto turbocharger, and hand tighten nuts and washers. Install bolts attaching exhaust hanger to engine block.
3. Slide rubber exhaust hangers onto catalytic converter. Tighten exhaust pipe nuts and washers. Lower vehicle. Install bolt and sealing
washers attaching oil supply line at engine block. Install oil supply line onto turbocharger. To complete installation, reverse removal
procedure. Tighten bolts and nuts to specification, see TORQUE SPECIFICATIONS
at end of article. NOTE:T o prevent dust and dirt from entering intake m anifold ports, cover ports with clean cloth after
rem oving intake plenum .
WARNING:DO NOT rem ove oxygen sensor when engine is hot.
NOTE:Clean throttle body exterior before rem oval.
CAUT ION: Before installing turbocharger, put .8 oz. (25 m l) engine oil into turbocharger oil inlet.
Page 4 of 5 MITCHELL 1 ARTICLE - N - REMOVE/INSTALL/OVERHAUL 1991 ENGINE PERFORMANCE Ford/Mercury Removal, O
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