check engine FORD FESTIVA 1991 Owner's Guide

CEC
Computerized Engine Controls
DOHC
Dual Overhead Cam
DPFE
Differential Pressure Feedback EGR Valve
EAIR
Electric Air Injection System
EAIR DV
Electric Air Injection System Diverter Valve
ECM
Electronic Control Module
ECU
Electronic Control Unit
EGR
Exhaust Gas Recirculation
EVRS
EGR Vacuum Regulator Solenoid
EVAP
Fuel Evaporative System
EVAP-AAC
EVAP Auxiliary Air Control
EVAP-BPSV
EVAP By-Pass Solenoid Valve
EVAP-BVSV
EVAP Bimetallic Vacuum Switching Valve
EVAP-CAV
EVAP Canister Air Valve
EVAP-CCV
EVAP Control Canister Close Valve
EVAP-CCVSV
EVAP Control Canister Vent Shut Valve
EVAP-CCVVSV
EVAP Closed Canister Valve Vacuum Switching Valve
EVAP-CDCV
EVAP Canister Drain Cut Valve
EVAP-CKV
EVAP Check Valve
EVAP-CPCS
EVAP Canister Purge Control Solenoid
Page 6 of 9 MITCHELL 1 ARTICLE - EMISSION CONTROL APPLICATIONS Emission Applications - Ford Motor Co. - Imports (1968-
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J - PIN VOLT AGE CHART S
1991 ENGINE PERFORMANCE Ford/Mercury Pin Voltage Charts
INTRODUCTION
Pin voltage charts are supplied to reduce diagnostic time. Checking pin voltages at the Electronic Control Assembly (ECA) determin es
whether it is receiving and transmitting proper voltage signals. Charts may also help determine if ECA wiring harness is shorted or opened.

Fig. 1: Identifying ECA Connector Terminals (Festiva)

Courtesy of FORD MOTOR CO.

Fig. 2: Identifying ECA Connector Terminals (Capri)

Courtesy of FORD MOTOR CO.
NOTE:Unless stated otherwise in testing procedures, perform all voltage tests using a Digital Volt-Ohm m eter
(DVOM) with a m inim um 10-m egohm input im pedance. Voltage readings m ay vary slightly due to
battery condition or charging rate.
NOTE:For additional pin voltage inform ation, see appropriate trouble code inform ation in G - T EST S W/
CODES article in the ENGINE PERFORMANCE Section.
Page 1 of 3 MITCHELL 1 ARTICLE - J - PIN VOLTAGE CHARTS 1991 ENGINE PERFORMANCE Ford/Mercury Pin Voltage Charts
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Fig. 3: Checking ECA Pin Voltages (Festiva)

Courtesy of FORD MOTOR CO.

Fig. 4: Checking ECA Pin Voltages (Capri)

Courtesy of FORD MOTOR CO.
Page 2 of 3 MITCHELL 1 ARTICLE - J - PIN VOLTAGE CHARTS 1991 ENGINE PERFORMANCE Ford/Mercury Pin Voltage Charts
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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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ELECTRONIC CONTROL ASSEMBLY (ECA)
REMOVAL & INSTALLATION
Disconnect negative battery cable. On Festiva, from under instrument panel, remove heater duct. On Capri, disengage push-pin retainers by
pulling back on front edges of both center carpet panels. Remove carpet panel retaining screws and panels. Disconnect ECA wire harness
connector. Remove ECA bolts and ECA. To install, reverse removal procedure. On Festiva, ensure mounting clip is inserted into bulkhead
recess.
FUEL SYSTEM
FUEL SYSTEM PRESSURE RELEASE
Remove rear seat assembly. With engine running, disconnect fuel pump connector. Run engine until it stalls to relieve fuel line pressure.
FUEL INJECTORS
Removal
Relieve fuel system pressure. On Capri, remove throttle body. On Festiva, remove intake plenum. See INTAKE PLENUM. Remove fuel inlet
and fuel return line from fuel rail. Remove electrical connectors from injectors. Remove pressure regulator. See Fig. 4
. Remove fuel rail
attaching bolts and fuel rail. Remove fuel injectors.
Installation
Install NEW "O" rings on fuel injectors and lubricate with gasoline. Install fuel injectors into cylinder head. Install fuel rail onto fuel injectors.
Install fuel rail attaching bolts. To complete installation, reverse removal procedure. Check system for leaks.

Fig. 4: Exploded View of Fuel Control System

Courtesy of FORD MOTOR CO.
FUEL PUMP
Removal
Remove fuel tank sending unit. Remove fuel filter from pump. Remove fuel pump wires from sending unit. Remove retaining clamp screw and
clamp. Remove rubber retaining band (if equipped). Remove fuel pump from sending unit.
Installation
To install, reverse removal procedure. Check system for leaks.
INTAKE PLENUM WARNING:ALWAYS relieve fuel pressure before disconnecting any fuel injection-related com ponent. DO NOT
allow fuel to contact engine or electrical com ponents.
WARNING:ALWAYS relieve fuel pressure before disconnecting any fuel-related com ponent. DO NOT allow fuel to
contact engine or electrical com ponents.
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C - SPECIFICATIONS
1991 ENGINE PERFORMANCE Ford/Mercury - Service & Adjustm ent Specifications
INTRODUCTION
Use this article to quickly find specifications related to servicing and on-vehicle adjustments. This is a quick-reference article to use when you
are familiar with an adjustment procedure and only need a specification.
CAPACITIES
BATTERY SPECIFICATIONS
FLUID CAPACITIES
FLUID CAPACITIES
QUICK-SERVICE
SERVICE INTERVALS & SPECIFICATIONS
REPLACEMENT INTERVALS
BELT ADJUSTMENTS
(1)
BELT ADJUSTMENTS
(1)
MECHANICAL CHECKS
ENGINE COMPRESSION
Check engine compression at specified cranking speed with engine at normal operating temperature, all spark plugs removed and throttle wide
open.
COMPRESSION SPECIFICATIONS
ApplicationAmp Hr. Rating
1.3L & 1.6L50
ApplicationQts. (L)
Crankcase (Includes Filter)3.6 (3.4)
Cooling System (Includes Heater)5.3 (5.0)
Manual Transaxle (Mercon)2.6 (2.5)
Automatic Transaxle (Mercon)6.0 (5.7)
ApplicationQts. (L)
Crankcase (Includes Filter)
Non-Turbo3.5 (3.3)
Turbo3.7 (3.5)
Cooling System (Includes Heater)
Non-Turbo5.3 (5.0)
Turbo6.3 (6.0)
Manual Transaxle (Mercon)3.4 (3.2)
Automatic Transaxle (Mercon)6.0 (5.7)
ComponentInterval (Miles)
Air Filter30,000
Camsh aft Timin g Bel t60,000
Coolant30,000
Oil & Filter3000
Spark Plugs30,000
ApplicationNew BeltUsed Belt
A/C Belt110-125 (50-57)92-110 (42-50)
Alternator Belt110-132 (50-60)95-110 (43-50)
(1)Tension in Lbs. (Kg) Using Strand Tension Gauge
ApplicationNew BeltUsed Belt
A/C Belt110-132 (50-60)110-132 (50-60)
Alternator Belt110-132 (50-60)110-132 (50-60)
(1)Tension in Lbs. (Kg) Using Strand Tension Gauge.
ApplicationSpecification
Compression Ratio
1.3L9.7:1
1.6L(1)
Compression Pressure(2)
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F - BASIC TESTING
1991-92 ENGINE PERFORMANCE Ford Motor Co. Basic Diagnostic Procedures
INTRODUCTION
The following diagnostic steps help prevent overlooking simple problems and begin diagnosis for a no-start condition.
The first step in diagnosing any driveability problem is to verify the complaint. Test drive the vehicle under the conditions in which the
problem reportedly occurred.
Before entering self-diagnostics, perform a careful and complete visual inspection. Most engine control problems result from mechanical
breakdowns, poor electrical connections or damaged/misrouted vacuum hoses. Before condemning the computerized system, perform each test
listed in this article.
PRELIMINARY INSPECTION & ADJUSTMENTS
VISUAL INSPECTION
Perform a visual inspection of all electrical wiring. Look for chafed, stretched, cut or pinched wiring. Ensure electrical connections fit tightly
and are not corroded. Ensure vacuum hoses are properly routed and are not cut or pinched. If necessary, see VACUUM DIAGRAMS article in
the ENGINE PERFORMANCE Section to verify routing and connections. Inspect air induction system for possible vacuum leaks.
MECHANICAL INSPECTION
Compression
Engine mechanical condition can be checked using a compression gauge, vacuum gauge or engine analyzer. See engine analyzer instruction
manual for specific instructions. Lowest compression reading must be not less than 75 percent of highest reading.
Exhaust System Backpressure
Exhaust system can be checked with a vacuum gauge or a 0-5 psi pressure gauge. If a pressure gauge is used, remove O2 sensor. Connect gauge
to O2 sensor port. Start engine, and run at 2500 RPM. If exhaust system backpressure is more than 2 psi, exhaust system or catalytic converter
is plugged.
If a vacuum gauge is used, connect it to intake manifold vacuum. Start engine. Observe vacuum gauge. Open throttle part way and hold steady.
If vacuum gauge drops slowly after stabilizing, check exhaust system for a restriction.
FUEL PRESSURE
Fuel Pressure Release
Start engine (if possible), and unplug VAF meter connector. When engine stalls, turn ignition off and reconnect VAF meter wiring. Usin g sh o p
towel, cover fitting to absorb leakage when opening fuel system.
Fuel Pressure Check
1. Connect fuel pressure gauge between fuel filter and fuel rail. Open main valve, and close drain valve. Locate fuel pump check connector
in engine compartment, near left strut. Connect jumper wire between fuel pump test terminals (Black and Green/White wires on Capri
or Black and Green/Red wires on Festiva).
2. Turn ignition on to activate fuel pump. If pump does not run, check fuel pump circuit. If possible, start engine. Measure and record fuel
pressure. For fuel pressure specifications, see FUEL PRESSURE SPECIFICATIONS
article. Disconnect vacuum from pressure
regulator. Turn engine off. Wait 5 minutes and ensure residual pressure is at least 21 psi (1.5 kg/cm
2 ).
3. Operate fuel pump by reconnecting jumper wire at fuel pump check connector. Check fuel pump performance. Pinch hose between
pressure gauge and fuel filter. Do not hold longer than necessary to check pressure.For fuel pressure specifications, see FUEL
PRESSURE SPECIFICATIONS article. If pump does not meet specifications, check fuel pump circuit, fuel pump, fuel tank and fuel
filter or replace fuel pump.
FUEL PUMP PERFORMANCE NOTE:Unless stated otherwise in test procedure, perform all voltage tests with a Digital Volt-Ohm m eter
(DVOM) with a m inim um 10-m egohm input im pedance.
CAUT ION: DO NOT use ignition switch during com pression tests on fuel injected vehicles. Fuel injectors are
triggered by ignition switch during cranking m ode. Use a rem ote starter to crank engine to prevent fire
hazard and catalytic converter and engine oiling system contam ination.
WARNING:ALWAYS relieve fuel pressure before disconnecting any fuel injection system com ponent. DO NOT
allow fuel to contact engine or electrical com ponents.
NOTE:For 1991 fuel pressure specifications, see FUEL PRESSURE SPECIFICAT IONS
article. For 1992 fuel
pressure specifications, see FUEL PRESSURE SPECIFICAT IONS
article.
ApplicationPressure psi (kg/cm2 )Min. Vol. in 10 sec. Ozs. (cc)
Capri(1) 5.5 (167)
Festiva(1) 7.4 (220)
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Fuel Pump Circuit
1. Turn ignition on. Connect jumper wire between fuel pump test connector terminals. See Fig. 1 or Fig. 2 . Turn ignition on to activate
fuel pump.
2. Listen for fuel pump sound. If there is no sound, check main fuse, inertia switch (located at left rear shock tower), fuel pump rel ay, fu el
pump and all electrical connections.

Fig. 1: Festiva Fuel System Electrical Schematic

Courtesy of FORD MOTOR CO.
(1)For 1991 fuel pressure specifications, see FUEL PRESSURE SPECIFICATIONS article. For 1992 fuel pressure specifications,
see FUEL PRESSURE SPECIFICATIONS
article.
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Fig. 2: Capri Fuel System Electrical Schematic
Courtesy of FORD MOTOR CO.
Fuel Pump Relay
Remove fuel pump relay (located near heater duct under carpet). Apply positive 12 volts to relay terminals "A" and "B" together. See Fig. 3 .
Measure voltage between terminal "C" and ground, while individually grounding terminals "D" and "E". Ensure voltage is as specified. See
FUEL PUMP RELAY SPECIFICATIONS
table. If voltage is not as specified, replace relay.
FUEL PUMP RELAY SPECIFICATIONS

Fig. 3: Identifying Fuel Pump Relay Terminals

Courtesy of FORD MOTOR CO.
IGNITION CHECKS
Firing Order
Inspect spark plug wiring routing. Ensure firing order is 1-3-4-2.
Spark
1. Crank engine. Check for a strong Blue spark at each spark plug wire by using a high output spark tester. Ensure resistance of each spark
plug wire is 4000-6000 ohms per foot.
2. Disconnect and inspect all related ignition system connectors and harness. Clean or repair as necessary, and recheck spark. If st il l n o
spark, go to IGNITION COIL POWER SOURCE
.
Ignition Coil Power Source
Disconnect primary wires at ignition coil. Turn ignition on. Measure voltage between Black/White wire on harness connector and ground. If
voltage is not greater than 10 volts, check battery feed, ignition switch and fusible links. If voltage is greater than 10 volts, go to IGNITION
COIL RESISTANCE .
Ignition Coil Resistance
Measure resistance between primary terminals of coil. Measure resistance between positive primary terminal and coil tower. See IGNITION
COIL RESISTANCE table. Verify resistance between coil case and primary positive terminal is infinite. Replace coil if resistance
measurements are not within specifications.
IGNITION COIL RESISTANCE
IDLE SPEED & IGNITION TIMING
Ensure idle speed and ignition timing are set to specification. For adjustment procedures, see ON-VEHICLE ADJUSTMENTS article.
SUMMARY
If no faults were found while performing BASIC TESTING , proceed to TESTS W/CODES article in the ENGINE PERFORMANCE Section.
If no hard codes are found in self-diagnostics, proceed to TESTS W/O CODES article in the ENGINE PERFORMANCE Section for diagnosis
by symptom (i.e., ROUGH IDLE, NO START, etc.) or intermittent diagnostic procedures.
Terminal "D"Terminal "E"Terminal "C" Voltage
OpenOpenLess than one
GroundedOpenLess than 10
OpenGroundedGreater than 10
GroundedGroundedGreater than 10
ApplicationPrimary (Ohms)Secondary (Ohms)
1.3L & 1.6L0.8-1.66000-30,000
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
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P - EGR FUNCT ION T EST ING
1989-95 ENGINE PERFORMANCE Ford Motor Co. EGR Function T esting
TESTING
EGR VALVE
1989 Merkur & 1991-95 Escort/Tracer 1.9L (Ported EGR Valve)
1. Check vacuum lines for correct routing. Ensure no vacuum is available to EGR valve with engine idling. Disconnect idle air by-pass
valve connector.
2. Disconnect vacuum hose at EGR valve and plug hose end. Connect a vacuum pump to EGR valve. Start engine. Apply 5-10 in. Hg to
vacuum hose. If idle becomes unstable or engine stalls, EGR valve is functioning properly.
3. Reconnect idle air by-pass connector. Connect a vacuum pump to EGR vacuum supply hose. Ensure engine is at normal operating
temperature. Increase engine speed 1500-2000 RPM. Vacuum gauge should read more than 5 in. Hg. If system operates as indicated,
system is functioning properly.
1988-89 Festiva & Tracer (Ported EGR Valve)
1. Ensure engine is at normal operating temperature. Check vacuum lines for correct routing. Ensure no vacuum is available to EGR valve
with engine idling. Start engine. Place finger against EGR diaphragm. Increase engine RPM. Diaphragm should move.
2. Remove EGR vacuum supply hose from EGR valve and plug hose end. Connect a vacuum pump to EGR valve. With engine idling,
apply 6 in. Hg to EGR valve. If vacuum holds and idle becomes unstable or engine stalls, EGR valve is functioning properly.
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00022693
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