engine FORD FESTIVA 1991 Manual PDF

Fig. 3: Testing Voltage Drop

Courtesy of FORD MOTOR CO.
STARTER GROUND CIRCUIT TEST
1. Disconnect and ground coil wire from distributor cap to prevent engine from starting. Connect remote starter switch between starter
solenoid terminal "S" and battery positive terminal. See Fig. 1
.
2. Using a digital voltmeter set on low scale, connect positive voltmeter to starter motor housing. Ensure connection point is clean and free
of rust and grease. Connect negative voltmeter lead to negative battery terminal.
3. Engage remote starter switch and crank engine. Observe and record voltmeter reading. Voltmeter should read .2 volt or less. If voltage
drop is greater than .2 volt, clean negative battery cable connections at battery and body connections. Retest to ensure problem has been
corrected.
4. If voltage drop is still excessive, replace negative battery cable(s) as necessary. If battery cables test okay, and starter still cranks slowly
or not at all, remove and repair starter motor.
BENCH TESTING
STARTER NO-LOAD TEST
Remove starter. Place starter on bench. Connect a fully charged 12-volt battery, voltmeter, ammeter and remote starter switch to starter. See
Fig. 4
. Engage remote starter switch. Starter should rotate smoothly. Ensure voltage and amperage draw is less than maximum specification at
5000 RPM minimum. See NO-LOAD TEST SPECIFICATIONS table. If voltage and/or amperage is higher than specifications, disassemble
starter and determine cause.
NO-LOAD TEST SPECIFICATIONS
NOTE:Make all voltm eter connections at com ponent term inal rather than at cable or wire end.
ApplicationMaximum AmpsVolts
Capri & Festiva6011.5
Page 3 of 6 MITCHELL 1 ARTICLE - STARTER 1991 ELECTRICAL Starters
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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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D - ADJUSTMENTS
1991 ENGINE PERFORMANCE Ford/Mercury - On-Vehicle Adjustm ents
ADJUSTMENTS
ENGINE MECHANICAL
Before beginning any on-vehicle adjustments to fuel or ignition systems, ensure engine mechanical condition is okay.
VALVE CLEARANCE
IGNITION TIMING
CAPRI
1. Place automatic transmission in Park or manual transmission in Neutral. Disconnect and plug hoses attached to vacuum diaphragm
assembly on distributor. Connect tachometer and timing light. Turn off all electrical loads.
2. Start engine, and warm it to operating temperature. Ensure idle speed is set to specification, adjusting if necessary. See IDLE SPEED &
MIXTURE . Determine initial timing. See IGNITION TIMING table. If base timing is not correct, loosen distributor mounting bolts
and rotate distributor until marks align. Tighten bolts to 14-18 ft. lbs. (19-25 N.m).
3. Increase engine RPM while observing timing light. Verify ignition timing advances. For Turbo models, go to step 5). For non-Turbo
models, continue with step 4).
4. On non-Turbo models, apply 16 in. Hg vacuum to chamber "A". Verify timing advances by 26-30 degrees. Remove vacuum source from
chamber "A". Apply 8 in. Hg vacuum to chamber "B" while observing timing. Verify timing advances by 3-7 degrees. Stop engine, and
remove test equipment.
5. On Turbo models, apply 20 in. Hg vacuum to advance diaphragm. Verify timing advances by 13-17 degrees. Disconnect vacuum source.
Apply 8 psi (.6 kg/cm
2 ) pressure to advance diaphragm. Verify timing retards by 3-7 degrees. Stop engine, and remove test equipment.
FESTIVA
1. Place manual transmission in Neutral or automatic transmission in Park. Turn all accessories off. Locate one-wire STI (Black) connector
near master cylinder. Using a jumper wire, connect STI terminal to ground. See Fig. 1
. Connect timing light and tachometer.

Fig. 1: Locating Self
-Test Input (STI) Connector
Courtesy of FORD MOTOR CO.
2. Start engine, and warm to operating temperature. Ensure idle speed is set to specification, adjusting if necessary. See IDLE SPEED &
MIXTURE .
3. Check initial timing. White timing mark should align with white mark on crankshaft pulley. If marks do not align, loosen distributor
mounting bolts and rotate distributor until marks align. Tighten bolts to 14-18 ft. lbs. (19-25 N.m).
4. Remove jumper wire. Increase engine RPM, and verify ignition timing advances beyond initial setting. Stop engine, and remove test
equipment.
IGNITION TIMING NOTE:All m odels are equipped with hydraulic lash adjusters. No adjustm ents are required.
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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.
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TP ADJUSTMENT

Fig. 3: Throttle Position Switch Connector Terminal ID. (Festiva)

Courtesy of FORD MOTOR CO.
Test Condition (1) Cont. Between IDL-TLCont. Between PSW-TL
.02" (.5 mm)YesNo
.03" (.7 mm)NoNo
Wide Open ThrottleNoYes
(1)Insert specified feeler gauge between throttle adjustment screw and stop lever.
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00022696
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A - ENGINE/VIN ID
1991 ENGINE PERFORMANCE Ford/Mercury - Introduction
APPLICATION
MODEL COVERAGE
VIN DEFINITION
Numbers preceding the explanations in the legend below refer to the sequence of characters as listed on VIN identification label.
SAMPLE VIN
Digit #: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17.
(VIN) K N J P T O 6 H 9 L 6 1 0 0 0 0 0.
VIN Definition
1-3 - Indicates Nation of Origin.
4 - Indicates Restraint System.
5 - Indicates Carline Code.
6-7 - Indicates Body Type.
8 - Indicates Engine Type.
9 - Indicates Check Digit.
10 - Indicates Model Year.
11 - Indicates Assembly Plant.
12-17 - Vehicle Serial Number.
ENGINE CODE LOCATION

Fig. 1: Engine Code Location

Courtesy of FORD MOTOR CO.
MODEL YEAR VIN CODE APPLICATION
ModelBody CodeEng. Type (1) Eng. IDFuel Sys.Ign. Sys.
Capri011.6LZPFIMagnetic
Capri011.6L Turbo6 (2) PFIMagnetic
Festiva05, 06, 071.3LHPFIMagnetic
(1)See vehicle engine code label affixed to timing belt cover, See Fig. 1 .
(2)XR2 model W/intercooled turbo.
VIN CodeModel Year
L1990
M1991
Copyr ight 2009 Mit chell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00022694
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EMISSION CONT ROL APPLICAT IONS
Em ission Applications - Ford Motor Co. - Im ports (1968-97)
EMISSION APPLICATIONS
1968-97 FORD MOTOR CO. - IMPORTS
Year, Model, Engine & Fuel System(1) Emission Control Systems & Devices
1968-69
Cortina 1.6L Carb.PCV, AIS
1970
Capri & Cortina (Except GT) 1.6L Carb.PCV, ACL, (2) EVAP, SPK,
EVAP-VC, SPK-DDD, DCLV
Cortina GT 1.6L Carb.PCV, (2)EVAP, AIS,
EVAP-VC
1971
Capri 1.6L Carb.PCV, ACL, EVAP, SPK,
EVAP-VC, SPK-DDD, DCLV
Pantera 5.8L V8 Carb.PCV, EVAP, SPK,
EVAP-VC, SPK-DDD
1972
Capri 1.6L Calif. Carb.PCV, ACL, EVAP, SPK,
EVAP-VC, SPK-DDD, SPK-TCS, DCLV
1.6L Fed. Carb.PCV, ACL, EVAP, SPK,
EVAP-VC, SPK-DDD, DCLV
2.0L Calif. Carb.PCV, ACL, EVAP, SPK,
EVAP-VC, SPK-DDD, DCLV
2.0L Fed. Carb.PCV, ACL, EVAP, SPK,
EVAP-VC, SPK-DDD, DCLV
2.6L Carb.PCV, ACL, EVAP, SPK,
EVAP-VC, SPK-DDD, DCLV
Courier 1.8L Calif. Carb.PCV, EVAP, AIS,
EVAP-VC, CRV
Fed. Carb.PCV, EVAP, SPK,
EVAP-VC, SPK-DPD
Pantera 5.8L V8 Carb.PCV, EVAP, SPK,
EVAP-VC, SPK-DDD
1973
Capri 2.0L Calif. Carb.PCV, ACL, EVAP, SPK,
EVAP-VC, SPK-DDD, DCLV
2.0L Fed. Carb.PCV, ACL, EVAP, SPK,
EVAP-VC, SPK-DDD, SPK-TCS, DCLV
2.6L A/T Carb.PCV, ACL, EVAP, SPK,
EVAP-VC, SPK-DDD
2.6L M/T Carb.PCV, ACL, EVAP, SPK,
EVAP-VC, SPK-DDD, SPK-TCS, DCLV
Courier 1.8L Calif. Carb.PCV, EVAP, AIS,
EVAP-VC, CRV
Fed. Carb.PCV, EVAP, SPK,
EVAP-VC, SPK-DPD, CRV
Pantera 5.8L V8 Carb.PCV, EVAP, SPK,
EVAP-VC, SPK-DDD
1974
Capri 2.0L Carb.PCV, ACL, EVAP, EGR, AIS,
EVAP-VC, DCLV
2.8L Carb.PCV, ACL, EVAP, (3) EGR, (2) AIS,
EVAP-VC, DCLV
Courier 1.8L Carb.PCV, EVAP, AIS,
EVAP-VC, CRV
Pantera 5.8L V8 Carb.PCV, ACL, EVAP, SPK,
EVAP-VC, SPK-DDD
1975
Capri II 2.3L Carb.PCV, ACL, EVAP, (2) OC, (2) FR, EGR, (3)SPK,
AIS,
EVAP-VC, SPK-DV, DCLV
2.8L Carb.PCV, ACL, EVAP, OC, FR, EGR, (2)SPK, AIS,
EFE,
EVAP-VC,
(4) SPK-CSSA, SPK-DDD, EFE-HCV, (5)
DCLV
Courier 1.8L Carb.PCV, EVAP, AP,
EVAP-VC, CRV
1976
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ABBREVIATIONS
ACL
Air Cleaner (Thermostatic Air Cleaner)
AIS
Air Injection System
AIS-ACV
AIS Air Control Valve
AIS-AMV
AIS Air Management Valve
AIS-ASS
AIS Air Switching Solenoid
AIS-ASV
AIS Air Switching Valve
AIS-BPV
AIS By-Pass Valve
AIS-CKV
AIS Check Valve
AIS-CV
AIS Combination Valve
AIS-DV
AIS Diverter Valve
AIS-RV
AIS Relief Valve
AIS-SOL
AIS Solenoid
AIS-SV
AIS Solenoid Valve
CS, EGR-PS, SPK-CC
(1)For quick reference, major emission control systems and devices are listed in bold type; components and other related devices are
listed in light type.
(2)California only.
(3)A/T only.
(4)Federal only.
(5)M/T only.
(6)2.8L & California 2.3L.
(7)Except Federal models.
(8)2.0L only.
(9)2.3L California only.
(10)M/T only.
(11)California with M/T.
(12)Some models.
(13)Federal with M/T.
(14)M/T models with engine family VBT.
(15)Electronically controlled.
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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
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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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