torque FORD FESTIVA 1991 Owner's Manual

bearing oil seal. To complete installation, reverse removal procedure.
WATER PUMP
Removal & Installation (1.3L)
Remove timing belt. Drain cooling system. Remove lower radiator hose and heater return hose from water pump. Remove water pump
retaining bolts and water pump. Clean gasket mounting surface and replace gasket. To install, reverse removal procedure.
Removal (1.6L)
1. Remove timing belt. See TIMING BELT . Drain cooling system. Remove timing belt tensioner and idler pulleys. Remove oil dipstick
bracket retaining bolt.
2. Remove power steering pump from retaining bracket, leaving hoses attached. Remove power steering bracket and position power
steering pump to one side. Remove water pump outlet. Remove water pump retaining bolts and water pump.
Installation (1.6L)
1. Clean all gasket surfaces. Transfer rubber belt cover seal to new water pump (if required). Position water pump with new gasket and
install retaining bolts. Install pump outlet with new gasket and "O" ring. See TORQUE SPECIFICATIONS
table at end of article.
2. Install oil dipstick retaining bolt. Install timing belt tensioner and idler pulleys. Install power steering pump bracket. Install power
steering pump. Tighten all bolts and nuts to specification. See TORQUE SPECIFICATIONS
table at end of article.
3. Install timing belt. Fill cooling system. Start engine and check for leaks and proper system function.
OIL PAN
Removal (1.3L)
Disconnect battery ground cable. Raise vehicle and drain engine oil. Remove flywheel housing dust cover. Remove oil pan retaining bolts,
nuts and stiffeners. Rotate crankshaft while removing oil pan. Remove baffle plate from oil pan. Clean gasket mating surfaces thoroughly.
Installation (1.3L)
Ensure gasket surfaces are clean. Apply oil resistant sealer to front and rear engine covers and across joint line of cylinder block.
Removal (1.6L)
1. Raise vehicle and drain engine oil. Remove frame brace retaining bolt. Loosen RH "A" arm front bolt, and pivot brace downward.
Disconnect front exhaust pipe from exhaust manifold (or turbocharger). Remove exhaust pipe bracket retaining bolts. Loosen rubber
exhaust hangers at catalytic converter.
2. Allow exhaust to hang supported by mechanic's wire. Disconnect turbocharger oil return hose (if equipped). Remove oil pan retaining
bolts. Carefully pry oil pan loose from cylinder block.
Installation (1.6L)
1. Clean pan and block gasket surfaces. Apply Gasket Sealant (E3AZ-19562-A) to new front and rear pan seals. Install seals to cylinder
block. Apply Gasket Sealant (E3AZ-19562-A) to oil pan gasket surface. See Fig. 8
. Install oil pan and tighten pan retaining bolts to
specification. See TORQUE SPECIFICATIONS
table at end of article.
2. Connect turbocharger oil return hose (if equipped). Install rubber exhaust hanger to brackets. Install new gasket and connect fro n t
exhaust pipe to exhaust manifold (or turbocharger). Install front exhaust pipe bracket. Tighten nuts and bolts to specification.
3. Pivot frame brace into position. Tighten retaining bolt to crossmember and RH "A" arm front retaining bolt to specification. Lower
vehicle, fill with oil and start engine. Check for oil leaks and system operation. NOTE:Raise engine slightly with floor jack, if required, to gain clearance for water pum p rem oval.
CAUT ION: DO NOT force a pry tool between cylinder block and oil pan.
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replace hydraulic lash adjuster. Adjustment on valve lash adjusters is NOT possible or necessary.
PISTON & ROD ASSEMBLY
1. Remove cylinder head assembly. Remove oil pan. Mark connecting rod caps for reassembly reference. Remove rod nuts. Remove lower
rod cap and bearing. Tap piston out top of cylinder block. DO NOT scratch crank journal or cylinder walls during removal.
2. Repeat procedure for remaining pistons. Keep removed parts in order to ensure installation to original position. Position piston assembly
in correct cylinder bore. Align piston mark "F" (1.3L), or notch (1.6L) located at piston pin bore area, and connecting rod oil gr o o ve
toward engine front. To complete installation, reverse removal procedure. Tighten all bolts and nuts to specification. See TORQUE
SPECIFICATIONS table at end of article.
FITTING PISTONS
1. With piston assembly removed, remove piston rings and clean piston. Measure piston outer diameter in thrust direction, below oil ring
groove. Diameter is 2.793-2.794" (70.954-70.974 mm) for 1.3L engines and 3.0690-3.0698 (77.954-77.974) for 1.6L engines.
2. Place piston upside down in cylinder from which it was removed. Using a feeler gauge, measure clearance between piston and cylinder
bore. If clearance is not within specification, bore cylinder and replace piston as necessary. See CYLINDER BLOCK
table in ENGINE
SPECIFICATIONS at end of article.
PISTON RINGS
Install rings on piston. Ensure marked side of rings are in proper position. Set ends of rings to proper position. See Fig. 9
.

Fig. 9: Positioning Piston Rings

Courtesy of FORD MOTOR CO.
PISTON PIN REPLACEMENT
1. With piston removed and cleaned, mark piston-to-rod to ensure proper reassembly. Using Piston Pin Remover/Installer Set (D81L-6135-
A for 1.3L or D90P-6135-AH for 1.6L), place piston and rod assembly in press.
2. Apply pressure and press piston pin from piston assembly. Keep all removed components together for reassembly. Remove piston and
rod from press and inspect.
3. Using a micrometer, measure piston pin O.D. in several areas. Measure piston pin I.D. Measure I.D. of piston pin bore and rod pin bore.
Replace components if not within specifications. See, at end of article, PISTONS PINS & RINGS
table in ENGINE
SPECIFICATIONS
4. If measurements of rod, piston and pin are within specification, reassemble using piston pin assembly set. Ensure piston-to-rod position
is proper, with connecting rod oil groove on side of piston marked "F" or by a notch. Lubricate pin with engine oil before reassembly.
With piston assembly reassembled, rod should fall by its own weight with piston held horizontally. Repeat procedure for remaining
pistons.
Rod Bearings Check rod bearing for abnormal wear. Check crankshaft journal. Check rod bearing-to-crankshaft clearance with Plastigage.
Machine or replace as necessary. See, at end of article, CRANKSHAFT MAIN & CONNECTING ROD BEARINGS
table under ENGINE
SPECIFICATIONS.
CRANKSHAFT & MAIN BEARINGS
1. Drain oil and remove oil pan. Ensure main bearing caps are marked for installation to original location and position.
NOTE:Installation press pressure for piston pins is 1100-3300 lbs. (500-1500 Kg)
NOTE:If replacing bearing inserts with engine in vehicle, rem ove one bearing at a tim e for m easurem ent
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2. Remove main bearing cap bolts. Remove cap and lower bearing insert. Use bearing remover or fabricated cotter key to remove upper
bearing insert. Insert bearing remover in journal lubrication hole. Rotate crankshaft in normal direction of operation only. Repeat
procedure for remaining main bearings.
3. Check bearings for abnormal wear. Check crankshaft for grooves, scratches and pitting. Using Plastigage method, check clearance of
main bearing-to-crankshaft. Always keep at least 2 bearings and caps tight during clearance check. See, at end of article,
CRANKSHAFT MAIN & CONNECTING ROD BEARINGS
table under ENGINE SPECIFICATIONS.
4. Lubricate and install new bearings in cap and block. Match bearing tangs with notch in cap and block. Position cap in its proper
location and position. Install cap bolts and tighten to specification. See TORQUE SPECIFICATIONS
table at end of article. Repeat
procedure for remaining main bearings.
CRANKSHAFT END PLAY
Check crankshaft end play with dial indicator. End play should be .0031-.0111" (.08-.282 mm). Service limit is .012" (.30 mm). If end play is
not within specification, replace thrust bearings as necessary.
CYLINDER BLOCK
1. Using straightedge and feeler gauge, check entire cylinder head surface of cylinder block. Ensure warpage does not exceed .006" (.15
mm). If warpage exceeds specification, cylinder block surface can be machined a maximum of .008" (.20 mm).
2. Replace cylinder block if it needs to be machined more than .008" (.20 mm). Check cylinder bore for wear, out-of-round, taper and
piston fit. See CYLINDER BORE SPECIFICATIONS
table. Oversize pistons are available in .010" and .020" (.25 mm and .50 mm).
CYLINDER BORE SPECIFICATIONS
LUBRICATION
ENGINE OILING SYSTEM
Oiling system is force-feed type and uses a full-flow oil filter. Oil is retrieved from oil pan by oil pump pick-up tube and distributed to oil
filter. Oil is then filtered and routed throughout engine.
Crankcase Capacity
1.3 L crankcase capacity is 3.2 qts. (3.0 L) without filter change and 3.6 qts. (3.4 L) with filter change. For 1.6 L vehicles, capacity is 3.2 qts
(3.2 L) without filter and 3.72 qts. (3.5 L) with filter.
Normal Oil Pressure (Hot)
Normal oil pressure is 50-64 psi (3.5-4.5 kg/cm2 ) at 3000 RPM.
Pressure Regulator Valve
Pressure regulator valve is located in oil pump body and is nonadjustable.
OIL PUMP
Removal
Remove oil pan, pick-up tube and screen, timing belt and crankshaft sprocket. Remove front engine cover bolts and remove front cover.
R e mo ve b o l t s r e t a in in g p u mp c o ve r t o b a c k sid e o f fr o n t c o ve r h o u sin g.
2) Remove pump cover and inner and outer gears. Pry out front seal from front cover. Remove cotter pin. Remove pressure regulator retainer,
spring and valve.
OIL PUMP SPECIFICATIONS or replacem ent.
ApplicationIn. (mm)
Cylinder Diameter
Standard Bore
1.3L2.7953-2.7960 (71.000-71.019)
1.6L3.0709-3.0716 (78.000-78.019)
Maximu m Bo re
1.3L2.8020 (71.17)
1.6L3.0905-3.0913 (78.500-78.519)
Maximu m Ou t -Of-Ro u n d & Tap er.0007 (.019)
Piston-To-Bore Clearance.006 (.15)
ApplicationIn. (mm)
Inner Gear-To-Outer Gear
1.3L.008 (.20)
1.6L.0008-.0063 (.02-.16)
Outer Gear-To-Housing
1.3L.009 (.22)
1.6L.0035-.0071 (.09-.18)
End Play
1.3L.006 (.14)
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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)
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ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
CRANKSHAFT MAIN & CONNECTING ROD BEARINGS
Water Pump-To-Block14-19 (19-26)
Wheels66-89 (90-120)
INCH Lbs. (N.m)
Camshaft Bearing Cap Bolt97-124 (11-14)
Camshaft Cover71-97 (8-11)
Camshaft Thrust Plate Bolt71-106 (8-12)
Front Cover Housing Bolt (1.6L)71-97 (8-11)
Oil Pan Bolt
1.3L71-80 (8-9)
1.6L71-97 (8-11)
Oil Pressure Sender106-159 (12-18)
Oil Pump Cover Bolt (1.3L)89-133 (10-15)
Pickup Tube-To-Oil Pump Bolt71-97 (8-11)
Radiator Fan Bracket71-97 (8-11)
Rear Engine Plate Bolt71-97 (8-11)
Temperature Sender44-89 (5-10)
Timing Belt Cover Bolt71-97 (8-11)
Valve Cover Bolt44-79 (5-9)
Water Pump Pulley Bolts (1.6L)71-97 (8-11)
(1)This specification is INCH Lbs.
ApplicationSpecification
Displacement
1.3L80.8 Cu. In. (1.3L)
1.6L97.4 Cu. In. (1.6L)
Bore
1.3L2.80" (71.0 mm)
1.6L3.07" (78 mm)
Stroke (1.3L & 1.6L)3.29" (83.6 mm)
Compression Ratio
1.3L9.7:1
1.6LN/A
Fuel SystemPFI
HP@RPM
1.3L58 @ 5000
1.6L
(Non-Turbo)100 @ 5750
(Turbo)132 @ 6000
Torque Ft. Lbs.@RPM
1.3L73 @ 3000
1.6L
(Non-Turbo)95 @ 5500
(Turbo)136 @ 3000
ApplicationIn. (mm)
Crankshaft
End Play.0031-.0111 (.080-.282)
Runout (Maximum).002 (.05)
Main Bearings
Journal Diameter1.9661-1.9668 (49.938-
49.956)
Journal Out-Of-Round.002 (.05)
Journal Taper.002 (.05)
Oil Clearance.0009-.0017 (.024-.042)
Connecting Rod Bearings
Journal Diameter
1.3L1.5724-1.5731 (39.939-
39.957)
1.6L1.7693-1.7699 (44.940-
44.956)
Journal Out-Of-Round.002 (.05)
Journal Taper.002 (.05)
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TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
mm)
ApplicationFt. Lbs. (N.m)
Starter Motor Mounting Bolts23-34 (31-46)
INCH Lbs. (N.m)
Solenoid Retaining Screws36-67 (4.1-7.5)
Through Bolts55-75 (6-8)
Terminal Nuts71-106 (8-12)
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00058016
Page 6 of 6 MITCHELL 1 ARTICLE - STARTER 1991 ELECTRICAL Starters
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Back To Article
FORD
1.3L 4-Cylinder
MANUFACTURER'S SUGGESTED SCHEDULED MAINTENANCE
For Aspire, the manufacturer recommends the belt be replaced every 60,000 miles on Federal vehicles, and 105,000 miles on California
vehicles. For Festiva, the manufacturer recommends the belt be replaced every 60,000 miles.
REMOVAL & INSTALLATION
TIMING BELT
Removal
1. Disconnect negative battery cable. Remove accessory belts. Remove water pump pulley. Remove right inner fender panel to gain access
to crankshaft pulley. See Fig. 1
. Remove outer crankshaft pulley attaching bolts, then outer stiffener and spacer. Remove inner pulley
and baffle plate. Remove bolts retaining upper and lower cover halves to engine front. Remove both covers. See Fig. 2
.
2. 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. Ensure timing belt and sprockets are clean, and not worn or damaged. Align crankshaft and camshaft timing marks. See Fig. 3 . Position
belt onto sprockets in original running direction.
2. Install timing belt tensioner spring, spring cover, and pulley. To complete installation, reverse removal procedure. Tighten all bolts and
nuts to specification. See TORQUE SPECIFICATIONS
. Adjust drive belts to proper tension.

Fig. 1: Removing Right Inner Fender Panel

Courtesy of FORD MOTOR CO. NOTE:Always rotate engine in direction of norm al operation. Rotating crankshaft backwards m ay cause
belt to jum p tim ing.
CAUT ION: Never twist, turn inside out, or bend tim ing belt. Keep belt away from grease and oil.
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Fig. 2: Locating Timing Belt Upper & Lower Covers

Courtesy of FORD MOTOR CO.

Fig. 3: Aligning Timing Marks

Courtesy of FORD MOTOR CO.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
ApplicationFt. Lbs. (N.m)
A/C Compressor Bolt29-40 (39-54)
Camshaft Pulley Bolt9-13 (12-17)
Camshaft Sprocket Bolt36-45 (49-61)
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Back To Article
N - REMOVE/INST ALL/OVERHAUL
1991 ENGINE PERFORMANCE Ford/Mercury Rem oval, Overhaul & Installation
INTRODUCTION
Removal, overhaul and installation procedures are covered in this article. If component removal and installation is primarily an unbolt and
bolt-on procedure, only a torque specification may be furnished.
IGNITION SYSTEM
DISTRIBUTOR
Removal
Disconnect negative battery cable. On Capri, disconnect vacuum hose from vacuum control unit. Disconnect coil wire from distributor cap.
Remove screws and distributor cap. Disconnect electrical connectors. Mark position of distributor housing to cylinder head for reassembly.
Remove distributor mounting bolts and distributor.
Installation
To install, reverse removal procedure. Install new "O" ring if damaged or worn. Insert distributor and rotate until offset drive tangs engage
camshaft slots. See Fig. 1
, Fig. 2 or Fig. 3 . Check and adjust timing as required.

Fig. 1: Exploded View of Distributor Assembly (Festiva)

Courtesy of FORD MOTOR CO. NOTE:On Festiva, DO NOT disassem ble distributor. Entire unit is serviceable only by com plete replacem ent.
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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.
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