cool FORD FESTIVA 1991 Repair Manual

Engine control system communicates malfunctions to technician through service codes. These service codes are 2-digit numbers representing a
particular defect. Service codes are transmitted through STO connector.
Service codes are displayed as timed pulses, and may be read with a VOM or Super Star II tester. VOM displays codes by needle sweeps. See
Fig. 2
.
Turn ignition off. Ensure all procedures of EQUIPMENT HOOK
-UP have been followed. Engine should be at normal operating
temperature.

Fig. 2: Reading Service Codes With VOM

Courtesy of FORD MOTOR CO.
VOM
Disconnect and reconnect jumper wire from STI terminal to ground. Turn ignition on. Record displayed codes. Erase codes, and repeat test
procedure to verify all codes are currently valid. See ERASING CODES & RETESTING . Service only those codes which appear during
retest. Refer to TROUBLE CODE DEFINITION
table to find appropriate pinpoint test.
MIL
Turn ignition on. Connect a jumper wire between STI connector and ground. Observe MIL, and record pulses to determine codes stored.
SUPER STAR II Tester
Set center button to TEST position. Turn ignition on. Turn tester on. When activated, tester should display 888 for 2 seconds. Release and
reset center TEST button. After all codes are displayed, release center button. All codes in tester memory may now be reviewed.
ERASING CODES & RETESTING
Erasing codes and retesting will give an indication of whether codes are hard or intermittent defects. Hard codes reset immediately and will be
displayed during retest.
Disconnect negative battery cable. Press brake pedal for 5-10 seconds. Turn off VOM or Super Star II tester. Reconnect battery. Perform tests
under RETRIEVING CODES
to again display and record codes.
TROUBLE CODE DEFINITION
TROUBLE CODE DEFINITION
NOTE:If MIL flashes continuously prior to connecting test equipm ent, go to PINPOINT T EST ST I .
Service CodeFaultCircuit & Pinpoint Test
01Ignition Diagnostic MonitorIDM
02 (1) Crankshaft Position SensorCPS
03 (2) Cylinder Identification SensorCID
06 (2) Vehicle Speed SensorVSS
08Vane Airflow MeterVAF
09Engine Coolant Temperature SensorECT
10Vane Air Temperature SensorVAT
12 (2) Throttle Position SensorTP
14Barometric Pressure SensorBP
15Exhaust Gas Oxygen SensorEGO
17Exhaust Gas Oxygen SensorEGO
25 (2) Fuel Pressure Regulator Control SolenoidPRC
26Canister Purge Control SolenoidCANP
34Idle Speed ControlISC
Codes Not ListedPower & Ground ConnectionsPGC
Page 3 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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connector while moving vane in VAF meter. Voltage should be as specified in VAF METER VOLTAGE table. If voltage is okay,
repair VAF wire to ECA. If voltage is not okay, go to next step.
VAF METER VOLTAGE
4. Unplug connector from VAF. Using jumper wires, connect VPWR and SIGRTN terminals on VAF connector to corresponding terminals
on VAF meter. Leave VAF and VMREF wires disconnected. Measure voltage between VAF terminal at VAF meter, and SIGRTN pin at
harness connector while moving vane in VAF meter. Voltage should be as specified in VAF METER VOLTAGE
table. If voltage is
okay, repair VMREF wire to ECA. If voltage is not okay, go to next step.
5. Unplug connector from VAF meter. Turn ignition on. Measure voltage between SIGRTN and VPWR wire. If voltage is more than 10
volts, replace VAF meter. If voltage is not more than 10 volts, go to next step.
6. Unplug VAF meter connector. Turn ignition on. Measure voltage between VAF meter VPWR wire and ground. If voltage is more than
10 volts, repair VAF wire to ECA. If voltage is not more than 10 volts, go to PINPOINT TEST VPWR.
PINPOINT TEST ECT - ENGINE COOLANT TEMPERATURE SENSOR

Fig. 9: Identifying ECT Sensor Circuits

ECT CIRCUIT PIN IDENTIFICATION
1.3L
1. Turn ignition off. Install BOB. Leave ECA disconnected. Unplug ECT connector. Check for continuity between ECT test pin and ECT
terminal (Red/Blue wire) on ECT harness connector. If continuity does not exist, repair ECT wire between ECA and ECT sensor. If
continuity exists, go to next step.
2. Unplug ECT sensor. Check for continuity between Black wire at ECT sensor and ground. If continuity does not exist, repair Black wire
between ECT sensor and ground. If continuity exists, go to next step.
3. Reconnect ECA. Measure resistance between BOB ECT test pin and ground pin. If resistance is 500-1000 ohms, replace ECA. If
resistance is not 500-1000 ohms, replace ECT sensor.
1.6L
1. Turn ignition off. Install BOB. Leave ECA disconnected. Unplug ECT connector. Check for continuity between ECT test pin and ECT
terminal (Blue/Red wire) on ECT harness connector. If continuity does not exist, repair ECT wire between ECA and ECT sensor. If
Door PositionVolts
1/8 Open3.24
1/4 Open5.60
3/8 Open5.62
1/2 Open5.83
5/8 Open6.02
3/4 Open6.57
7/8 Open7.46
Full Open7.87
NOTE:Enter this test only when a Code 09 is displayed during QUICK T EST S procedure or when directed here
from another PINPOINT T EST . T o prevent unnecessary diagnosis, inspect coolant level, oil level,
cooling fan, therm ostat, and airflow to radiator before testing.
CircuitECA PinBOB PinWire Color
1.3L
ECT2Q7RED/BLU
GND(1) (1) BLK
1.6L
ECT2I7BLU/RED
SIGRTN2C46BLU/YEL
(1)Not specified.
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Check vane airflow meter.
Check idle speed control solenoid.
Check pressure regulator control solenoid.
Check heated exhaust gas oxygen sensor.
Check engine coolant temperature sensor.
Check A/C load control solenoid.
STUMBLE/HESITATION DURING ACCELERATION
Check throttle position switch.
Check vane airflow meter.
Check canister purge solenoid.
Check heated exhaust gas oxygen sensor.
Check wide open throttle A/C (WAC) relay.
Check A/C thermostatic switch.
MISSES/SURGES
Check exhaust gas oxygen sensor.
Check throttle position switch.
Check vane airflow meter.
Check wide open throttle vacuum switch.
Check A/C load control solenoid.
Check engine coolant temperature sensor.
IDLE IS FAST/SLOW RETURN TO IDLE
Check idle speed control solenoid.
Check by-pass air control valve.
Check engine coolant temperature sensor.
Check A/C load control solenoid.
IDLE IS ROUGH
Check idle speed control solenoid.
Check A/C load control solenoid.
Check by-pass air control valve.
Check throttle position switch.
Check vane airflow meter.
Check vane air temperature sensor.
Check canister purge solenoid.
Check engine cooling fan.
Check headlight switch.
Check blower control switch.
Check A/C thermostatic switch.
Check neutral safety switch.
Check neutral gear switch or clutch engage switch.
Check heated exhaust gas oxygen sensor.
ENGINE SPEEDS UP
Check idle speed control solenoid.
Check heated exhaust gas oxygen sensor.
Check by-pass air control valve.
CRANKS NORMALLY/NO START
Verify secondary ignition spark is present.
Verify fuel pressure is within specification.
Check vane airflow meter.
Check engine coolant temperature sensor.
CRANKS NORMALLY/SLOW TO START
Check ignition module.
Check engine coolant temperature sensor.
Check vane airflow meter.
Check evaporative emission control components.
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CLUTCH ENGAGE SWITCH (CES)
This switch is located on the manual transaxle and informs the ECA of transmission operating conditions. The ECA uses this data fo r id l e
speed control and canister purge valve operation.
CRANKSHAFT POSITION SENSOR (CPS) (FESTIVA)
This sensor is located in the distributor and sends engine RPM and crankshaft position data to the ECA. The ECA uses this data in calculating
fuel metering, ignition timing, idle speed control and canister purge valve operation.
CYLINDER IDENTIFICATION SENSOR (CID) (CAPRI)
This sensor is located in the distributor and provides crankshaft position data to the ECA. The ECA uses this data in calculating fuel metering
and ignition timing.
ELECTRICAL LOAD SWITCHES
Blower control, cooling fan, rear window defroster, air conditioning and headlight switches all send signals to the ECA. The ECA uses these
signals for idle speed control.
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
This sensor is located in the intake manifold and sends coolant temperature data to the ECA. The ECA uses this data in calculating fuel
metering, idle speed control and canister purge valve operation.
EXHAUST GAS OXYGEN (EGO) SENSOR
This sensor is located in the exhaust manifold and senses oxygen concentration in the exhaust gas. The ECA uses this data in calculating fuel
metering, idle speed control and canister purge valve operation.
NEUTRAL SAFETY SWITCH (A/T)
This switch is located on the automatic transaxle and sends a signal to the ECA whenever the transaxle is in Neutral or Park ranges. The ECA
uses this signal in calculating fuel metering, idle speed control and canister purge valve operation.
POWER STEERING PRESSURE SWITCH (PSPS)
This switch is located on the power steering pump and sends data about power steering operation to the ECA. The ECA uses this data for idle
speed control.
THROTTLE POSITION SENSOR (TP)
This device is located on the throttle body and contains 2 switches. The Wide Open Throttle (WOT) Switch sends a signal to the ECA when
throttle valve opening is more than 70 degrees. The ECA uses this signal in calculating fuel metering.
The Idle Switch (IDL) sends a signal to the ECA when throttle valve opening is less than 1.5 degrees. The ECA uses this signal for idle speed
control and canister purge valve operation.
VANE AIRFLOW (VAF) METER
This sensor is located in the air cleaner housing and sends intake airflow data to the ECA. The ECA uses this data in calculating fuel metering.
VANE AIR TEMPERATURE (VAT) SENSOR
This sensor is located inside the vane airflow sensor and senses intake air temperature. The ECA uses this data in calculating fu el met erin g,
idle speed control and canister purge valve operation.
CEC OUTPUT SIGNALS
CANISTER PURGE (CANP) SOLENOID
See EMISSION SYSTEMS.
CHECK ENGINE LIGHT
See SELF-DIAGNOSTIC SYSTEM.
FUEL INJECTORS
See FUEL CONTROL.
IDLE SPEED CONTROL BY-PASS AIR (ISC-BPA) VALVE
See IDLE SPEED. NOTE:Vehicles are equipped with different com binations of com puter-controlled com ponents. Not all
com ponents listed below are used on every vehicle. For theory and operation of each output
com ponent, refer to indicated system .
Page 2 of 6 MITCHELL 1 ARTICLE - E - THEORY/OPERATION 1991 ENGINE PERFORMANCE Ford/Mercury Theory & Operation
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CDI
Capacitor Discharge Ignition
CEC
Computerized Engine Control
CID
Cubic Inch Displacement
cm
Centimeter
CMP
Camshaft Position Sensor
CO
Carbon Monoxide
CO
2
Carbon Dioxide
Cont.
Continued
CONV
Convertible
CP
Canister Purge
CKP
Crankshaft Position Sensor
CTS
Coolant Temperature Sensor
Cu. In.
Cubic Inch
CVC
Constant Vacuum Control
CV
Check Valve or Constant Velocity
CW
Clockwise
CYL or Cyl.
Cylinder
C
3 I
Computer Controlled Coil Ignition
C
4
Computer Controlled Catalytic Converter
"D"
"D"
Page 4 of 15 MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations
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EBL
Electronic Back Light
ECM
Engine Control Module
ECT
Engine Coolant Temperature Sensor
EDIS
Electronic Distributorless Ignition System
EEC
Electronic Engine Control
EECS
Evaporative Emission Control System
EEPROM
Electronically Erasable PROM
EFE
Early Fuel Evaporation
EGO
Exhaust Gas Oxygen Sensor
EGR
Exhaust Gas Recirculation
ESA
Electronic Spark Advance
ESC
Electronic Spark Control
EST
Electronic Spark Timing
EVAP
Fuel Evaporative System
EVIC
Electronic Vehicle Information Center
EVP
EGR Valve Position Sensor
Exc.
Except
"F"
° F
Fahrenheit (Degrees)
F/B
Fuse Block
Fed.
Page 6 of 15 MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations
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Broken clutch housingSee STARTER article
Pinion shaft rusted or drySee STARTER article
Engine basic timing incorrectSee Ignition Timing in TUNE-
UP article
Broken teeth on engine flywheelReplace flywheel and check for
starter pinion gear damage
Starter Will Not Crank Engine
Faulty overrunning clutchSee STARTER article
Broken clutch housingSee STARTER article
Broken flywheel teethReplace flywheel and check for
starter pinion gear damage
Armature shaft sheared or reduction gear teeth strippedSee STARTER article
Weak batteryCharge or replace battery as
necessary
Faulty solenoidSee On-Vehicle Tests in
STARTER article
Poor groundsCheck all ground connections
for tight and clean connections
Ignition switch faulty or misadjustedAdjust or replace ignition
switch as necessary
Starter Cranks Engine Slowly
Battery weak or defectiveCharge or replace battery as
necessary
Engine overheatedSee ENGINE COOLING
SYSTEM article
Engine oil too heavyCheck that proper viscosity oil
is used
Poor battery-to-starter connectionsCheck that all between battery
and starter are clean and tight
Current draw too low or too highSee Bench Tests in STARTER
article
Bent armature, loose pole shoes screws or worn bearingSee STARTER article
Burned solenoid contactsReplace solenoid
Faulty starterReplace starter
S t a r t e r E n ga ge s E n gin e On l y M o me n t a r il y
Engine timing too far advancedSee Ignition Timing in TUNE-
UP article
Overrunning clutch not engaging properlyReplace overrunning clutch.
See STARTER article
Broken starter clutchSee STARTER article
Broken teeth on engine flywheelReplace flywheel and check
starter pinion gear for damage
Weak drive assembly thrust springSee STARTER article
Weak hold-in coilSee Bench Tests in STARTER
article
Starter Drive Will Not Engage
Defective point assemblySee Testing in STARTER
article
Poor point assembly groundSee Testing in STARTER
article
Defective pull-in coilReplace starter solenoid
Starter Relay Does Not Close
Dead batteryCharge or replace battery as
necessary
Faulty wiringCheck all wiring and
connections leading to relay
Neutral safety switch faultyReplace neutral safety switch
Starter relay faultyReplace starter relay
Starter Drive Will Not Disengage
Starter motor loose on mountingsTighten starter attach bolts
Worn drive end bushingSee STARTER article
Damaged engine flywheel teethReplace flywheel and starter
pinion gear for damage
Drive yolk return spring broken or missingReplace return spring
Faulty ignition switchReplace ignition switch
Insufficient clearance between winding leads to solenoid terminal and main contact in solenoidReplace starter solenoid
Starter clutch not disengagingReplace starter clutch
Ignition starter switchReplace ignition switch
contacts sticking
Starter Relay Operates but Solenoid Does Not
Faulty solenoid switch, switch connections or relayCheck all wiring between relay
and solenoid or replace relay
or solenoid as necessary
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BRAKES
BRAKE SYSTEM TROUBLE SHOOTING
BRAKE SYSTEM TROUBLE SHOOTING CHART
CONDITIONPOSSIBLE CAUSE
Insufficient, Erratic, or No HeatLow Coolant Level
.....Incorrect thermostat.
.....Restricted coolant flow through core.
.....Heater hoses plugged.
.....Misadjusted control cable.
.....Sticking heater control valve.
.....Vacuum hose leaking.
.....Vacuum hose blocked.
.....Vacuum motors inoperative.
.....Blocked air inlet.
.....Inoperative heater blower motor.
.....Oil residue on heater core fins.
.....Dirt on heater core fins.
Too Much HeatImproperly adjusted cables.
.....Sticking heater control valve.
.....No vacuum to heater control valve.
.....Temperature door stuck open.
Air Flow Changes During AccelerationVacuum system leak.
.....Bad check valve or reservoir.
Air From Defroster At All TimesVacuum system leak.
.....Improperly adjusted control cables.
.....Inoperative vacuum motor.
Blower Does Not Operate CorrectlyBlown fuse.
.....Blower motor windings open.
.....Resistors burned out.
.....Motor ground connection loose.
.....Wiring harness connections loose.
.....Blower motor switch inoperative.
.....Blower relay inoperative.
.....Fan binding or foreign object in housing.
.....Fan blades broken or bent.
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
CONDITION & POSSIBLE CAUSECORRECTION
Brakes Pull Left or Right
Incorrect tire pressureInflate tires to proper pressure
Front end out of alignmentSee WHEEL ALIGNMENT
Mismatched tiresCheck tires sizes
Restricted brake lines or hosesCheck hose routing
Loose or malfunctioning caliperSee DISC BRAKES or
BRAKE SYSTEM
Bent shoe or oily liningsSee DRUM BRAKES or
BRAKE SYSTEM
Malfunctioning rear brakesSee DRUM, DISC BRAKES
or BRAKE SYSTEM
Loose suspension partsSee SUSPENSION
Noises Without Brakes Applied
Front linings worn outReplace linings
Dust or oil on drums or rotorsSee DRUM, DISC BRAKES
or BRAKE SYSTEM
Noises With Brakes Applied
Insulator on outboard shoe damagedSee DISC BRAKES or
BRAKE SYSTEM
Incorrect pads or liningsReplace pads or linings
Brake Rough, Chatters or Pulsates
Excessive lateral runoutCheck rotor runout
Parallelism not to specificationsReface or replace rotor
Wheel bearings not adjustedSee SUSPENSION
Rear drums out-of-roundReface or replace drums
Disc pad reversed, steel against rotorRemove and reinstall pad
Excessive Pedal Effort
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ENGINE MECHANICAL
COOLING SYSTEM TROUBLE SHOOTING
COOLING SYSTEM TROUBLE SHOOTING
Malfunctioning power unitSee POWER BRAKES or
BRAKE SYSTEM
Partial system failureCheck fluid and pipes
Worn disc pad or liningReplace pad or lining
Caliper piston stuck or sluggishSee DISC BRAKES or
BRAKE SYSTEM
Master cylinder piston stuckSee MASTER CYLINDERS
or BRAKE SYSTEM
Brake fade due to incorrect pads for liningsReplace pads or linings
Linings or pads glazedReplace pads or linings
Worn drumsReface or replace drums
Excessive Pedal Travel
Partial brake system failureCheck fluid and pipes
Insufficient fluid in master cylinderSee MASTER CYLINDERS
or BRAKE SYSTEM
Air trapped in systemSee BRAKE BLEEDING or
BRAKE SYSTEM
Rear brakes not adjustedSee Adjustments in DRUM
BRAKES or BRAKE
SYSTEM
Bent shoe or liningSee DRUM BRAKES or
BRAKE SYSTEM
Plugged master cylinder capSee MASTER CYLINDERS
or BRAKE SYSTEM
Improper brake fluidReplace brake fluid
Pedal Travel Decreasing
Compensating port pluggedSee MASTER CYLINDERS
or BRAKE SYSTEM
Swollen cup in master cylinderSee MASTER CYLINDERS
or BRAKE SYSTEM
Master cylinder piston not returningSee MASTER CYLINDERS
or BRAKE SYSTEM
Weak shoe retracting springsSee DRUM BRAKES BRAKE
SYSTEM
Wheel cylinder piston stickingSee DRUM BRAKES or
BRAKE SYSTEM
Dragging Brakes
Master cylinder pistons not returningSee MASTER CYLINDERS
BRAKE SYSTEM
Restricted brake lines or hosesCheck line routing
Incorrect parking brake adjustmentSee DRUM BRAKES BRAKE
SYSTEM
Parking Brake cables frozenSee DRUM BRAKES BRAKE
SYSTEM
Incorrect installation of inboard disc padRemove and replace correctly
Power booster output rod too longSee POWER BRAKE UNITS
BRAKE SYSTEM
Brake pedal not returning freelySee DISC, DRUM BRAKES
BRAKE SYSTEM
Brakes Grab or Uneven Braking Action
Malfunction of combination valveSee CONTROL VALVE or
BRAKE SYSTEM
Malfunction of power brake unitSee POWER BRAKE UNITS
or BRAKE SYSTEM
Binding brake pedalSee DISC, DRUM BRAKES
or BRAKE SYSTEM
Pulsation or Roughness
Uneven pad wear caused by caliperSee DISC BRAKES or
BRAKE SYSTEM
Uneven rotor wearSee DISC BRAKES or
BRAKE SYSTEM
Drums out-of-roundReface or replace drums
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
CONDITION & POSSIBLE CAUSECORRECTION
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