Ignition lock FORD FESTIVA 1991 Service Manual

Turbo Boost Gauge Always Reads High
If turbo boost gauge always reads high, check these items:
Check for damaged White/Black signal wire.
Check for defective boost sensing unit.
Check for defective boost gauge.
Turbo Boost Gauge Inaccurate
If turbo boost gauge is inaccurate, check these items:
Check for loose or corroded connections.
Check for defective boost sensing unit.
Check for defective boost gauge.
TESTING
FUEL GAUGE SENDING UNIT
Capri
Remove rear seat cushion. Disconnect fuel pump/fuel gauge sending unit electrical connector at access cover. Turn ignition on. Fuel gauge
should read empty. Using a jumper wire, connect Yellow fuel gauge wire of vehicle harness connector to ground. Fuel gauge should read full.
If fuel gauge operates as specified, replace fuel gauge sending unit.
Festiva
Remove fuel gauge sending unit from tank. See FUEL SENDING UNIT under REMOVAL & INSTALLATION. Connect an ohmmeter and
check sending unit resistance as indicated in FUEL GAUGE SENDING UNIT RESISTANCE (FESTIVA)
table. Replace sending unit if
resistance is drastically different than specification.
FUEL GAUGE SENDING UNIT RESISTANCE (FESTIVA)
OIL PRESSURE GAUGE (CAPRI)
1. Remove electrical connector from oil pressure sending unit located on right side of engine block. Turn ignition switch on. Oil pressure
gauge should read low. Install a jumper wire between Yellow/Red wire of oil pressure sending unit vehicle harness connector and
ground. Oil pressure gauge should read high.
2. If oil pressure gauge operates as specified, replace sending unit. If gauge does not operate as specified, check instrument panel power
and ground circuits.
OIL PRESSURE WARNING LIGHT (FESTIVA)
Light Stays On With Engine Running
1. Turn ignition on (DO NOT start engine). Disconnect Yellow/Red wire from oil pressure switch connector. Light should go off.
2. If light stays on, repair short in Yellow/Red wire between oil indicator light and oil pressure switch. Reconnect wire to switch. Light
should be on with ignition on. If light does not go off when engine is started, check switch or engine for low oil pressure.
Oil Light Will Not Go On With Ignition On
1. Ground Yellow/Red wire at instrument panel connector. If light goes on, repair Yellow/Red wire between oil pressure switch and
indicator light or replace defective oil pressure switch.
2. If light does not illuminate, check bulb or check instrument panel ground circuit.
TEMPERATURE GAUGE (CAPRI)
1. Remove electrical connector from temperature sending unit located at front of cylinder head. Connect one lead of Gauge System Tester
(021-00055) to connector and other tester lead to ground. Set tester to 18 ohms, turn ignition switch on and observe temperature gauge.
Gauge should read 250°F.
2. Turn tester to 60 ohms. Gauge should read 175°F. Turn tester to 223 ohms. Gauge should read 100°F. If all readings are within twice
the needle width of correct reading, gauge is functioning properly. If readings are not as specified, replace gauge.
TEMPERATURE GAUGE (FESTIVA)
See TROUBLE SHOOTING for possible service areas.
TEMPERATURE SENDING UNIT (CAPRI)
Remove sending unit from engine and place in container of water. Heat water to 176°F (80°C). Measure resistance between sending unit
connector and case. Resistance should be 49.3-57.7 ohms. If resistance is not as specified, replace sending unit. NOTE:Inspect fuel tank for distortion or dam age. If distorted or dam aged, repair or replace tank before testing.
Float PositionOhms
Full Position (Up)Approximately 7
Half-Full Position (Middle)Approximately 33
Empty Position (Down)Approximately 95
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TURBO BOOST GAUGE & SENSOR (CAPRI)
1. Disconnect 3-pin boost sensor electrical connected located on right side of firewall. Turn ignition on. Measure voltage between
Yellow/Green and Black wires. Voltage should be greater than 10 volts. Turn ignition off. If voltage is greater than 10 volts, go t o n e xt
step. If voltage is 10 volts or less, repair Yellow/Green or Black wires as necessary.
2. Remove instrument panel. See INSTRUMENT PANEL
under REMOVAL & INSTALLATION. Disconnect instrument panel 8-pin
connector. With boost sensor disconnected, measure resistance through White/Black between instrument panel and boost sensor harness
connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair or replace White/Black wire.
3. With 8-pin instrument panel connector disconnected, ground White/Black at boost gauge. Boost gauge should read low. Apply 12 vo l t s
to White/Black wire at boost gauge. Boost gauge should read high. If boost gauge operates as specified, go to next step. If boost gauge
does not operate as specified, replace boost gauge.
4. Reconnect instrument panel connectors (if removed). With ignition on and boost sensor disconnected, install jumper wire between
Yellow/Green and White/Black wires of boost sensor vehicle harness connector. Boost gauge should read high. If boost gauge reads
high, replace boost sensor. If boost gauge does not read high, go to TROUBLE SHOOTING
for other possible causes.
REMOVAL & INSTALLATION
INSTRUMENT PANEL
Removal & Installation (Capri)
1. Disconnect negative battery cable. Pull storage compartment from heater/radio bezel. Pull outward and remove trim covers located on
both sides of steering column. Remove retaining screws and carefully pull instrument panel bezel partially away from dash. Disconnect
electrical connectors from clock and switches in bezel. Remove instrument panel bezel.
2. Disconnect speedometer cable from transaxle. Remove instrument panel retaining screws and slide instrument panel outward. Press lock
tab and release speedometer cable from instrument panel. Remove electrical connectors from rear of instrument panel. Remove
instrument panel. To install instrument panel, reverse removal procedure.
Removal & Installation (Festiva)
1. Disconnect negative battery cable. Remove upper and lower steering column covers. Remove screws from panel bezel and remove bezel.
Disconnect rear wiper switch and rear defogger switch wiring harness connectors (if equipped).
2. Remove instrument panel-to-dash screws. Pull panel from dash. Reach behind panel and release speedometer drive cable lock tab. Lift
lock tabs and disconnect 2 electrical connectors from rear of panel. Remove panel. To install instrument panel, reverse removal
procedure.
INDICATOR LIGHTS
Removal & Installation
Remove instrument panel for access to indicator light bulbs. See INSTRUMENT PANEL under REMOVAL & INSTALLATION. To remove
bulb, rotate bulb counterclockwise to disengage locking tabs. When tabs release, pull bulb from printed circuit board. To install bulb, reverse
removal procedure. Install instrument panel and test lights.
SPEEDOMETER R & I
Removal & Installation (Capri)
R e mo ve n e ga t ive b a t t e r y c a b l e . R e mo ve in st r u me n t p a n e l . S e e INSTRUMENT PANEL under REMOVAL & INSTALLATION. Disassemble
instrument panel and remove speedometer/tachometer/boost gauge assembly from instrument panel. To install, apply a 3/16" (4.6 mm) b al l o f
Silicone Damping Grease (D7AZ-19A331-A) into drive hole of speedometer head. Reverse removal procedure to complete installation.
Removal & Installation (Festiva)
R e mo ve n e ga t ive b a t t e r y c a b l e . R e mo ve in st r u me n t p a n e l . S e e INSTRUMENT PANEL under REMOVAL & INSTALLATION. Disassemble
instrument panel and remove speedometer head assembly from instrument panel. Speedometer is a separate module and can be removed
independently from gauges. To install, reverse removal procedure.
SPEED SENSOR
On vehicles equipped with speed control, a speed sensor is mounted in speedometer head assembly. If replacement is necessary, speedometer
head assembly must be replaced. See SPEEDOMETER R & I
under REMOVAL & INSTALLATION.
FUEL GAUGE
Removal & Installation
Remo ve in st ru men t p an el . See INSTRUMENT PANEL under REMOVAL & INSTALLATION. Disassemble panel and remove fuel gauge.
To install gauge, reverse removal procedure. On Capri, the fuel/volt gauge must be replaced as an assembly.
FUEL SENDING UNIT
Removal & Installation
1. For Festiva, remove rear seat. For Capri, remove rear seat cushion. On Festiva, remove carpet hold-down pins and lift carpet for access
to sending unit access plate. On all models, remove access plate screws. NOTE:Federal law requires that a label stating the odom eter has been repaired or replaced be affixed to any
vehicle that has its odom eter repaired, replaced or set to zero.
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2. Lift access plate and disconnect sending unit wiring. To relieve fuel pressure, start engine and run it until engine stalls. Turn ignition off.
Disconnect and plug fuel lines at sending unit. Remove sending u n it a t t a c h in g sc r e ws. R e mo ve se n d in g u n it . To in st a l l , r e ve r se removal
procedure.
TACHOMETER
Removal & Installation
Remo ve in st ru men t p an el . See INSTRUMENT PANEL under REMOVAL & INSTALLATION. Disassemble panel and remove tachometer.
To install tachometer, reverse removal procedure. On Capri, the tachometer/speedometer/boost gauge assembly must be replaced as an
assembly.
TEMPERATURE GAUGE
Removal & Installation
Remo ve in st ru men t p an el . See INSTRUMENT PANEL under REMOVAL & INSTALLATION. Disassemble panel and remove temperature
gauge. To install gauge, reverse removal procedure. On Capri, the temperature/oil pressure gauge assembly must be replaced as an assembly.
TEMPERATURE SENDING UNIT
Removal
Disconnect sending unit wire, located on side of block below thermostat housing (Festiva) or cylinder head (Capri). Remove radiator cap to
relieve cooling system pressure. Position drain pan below sending unit. Remove temperature sending unit.
Installation
To install, apply Pipe Sealant With Teflon (D8AZ-19554-A) to threads of sending unit. Reverse removal procedure to complete installation.
Fill cooling system to proper level. Start engine and check for coolant leaks at sending unit.
WIRING DIAGRAMS
CAUT ION: T achom eter is calibrated at factory. Rough handling could disturb calibration.
NOTE:Refer to the appropriate WIRING DIAGRAMS article in the WIRING DIAGRAMS section.
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00028301
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ST EERING COLUMN SWIT CHES
1991 ACCESSORIES & SAFET Y EQUIPMENT Ford Motor Co. Steering Colum n Switches
DESCRIPTION & OPERATION
DISABLING AIR BAG SYSTEM
To disable SRS, disconnect battery cable. Unplug back-up power supply 3-way harness connector. System is now disabled. Back-up power
supply is mounted to inside of instrument panel, left of glove box opening. Glove box door must be opened past its stops and lowered toward
floor to access back-up power supply.
ACTIVATING AIR BAG SYSTEM
To activate SRS, reconnect back-up power supply connector and negative battery cable. From passenger's side of vehicle, turn ignition switch
to RUN position. System is now activated. Check AIR BAG light to ensure system is functioning properly.
TESTING
HAZARD WARNING SWITCH & TURN SIGNAL SWITCH
Capri
1. Remove steering column covers to access turn signal/hazard switch connectors. Turn ignition on. Using a 12-volt test light, ensure
battery voltage is present at Green/Red and Green/Yellow wires at turn signal/hazard switch connectors. If battery voltage is not present,
check METER and HAZARD fuses. Also check hazard and turn signal flasher units and replace as necessary.
2. If battery voltage is present at Green/Red and Green/Yellow wires, place turn signal switch in RIGHT position. Check both Green/White
wires at switch connector. Test light should flash on and off in constant cycles.
3. Place turn signal switch in LEFT position. Check both Green/Black wires at switch connector. Test light should flash on and off in
constant cycles. If turn signal/hazard switch does not function as specified, replace switch.
Festiva
1. Remove steering column covers to access turn signal/hazard switch connectors. Turn ignition on. Using a 12-volt test light, ensure
battery voltage is present at White/Black and Black/Yellow wires at hazard and turn signal switch connectors. If battery voltage is not
present, check METER and HAZARD fuses.
2. If battery voltage is present at White/Black and Black/Yellow wires, place turn signal/hazard switch in RIGHT position. Check
Green/Black wire at switch connector. Test light should flash on and off in constant cycles.
3. Place turn signal/hazard switch in LEFT position. Check Green/White wire at switch connector. Test light should flash on and off in
constant cycles. If turn signal/hazard switch does not function as specified, replace switch.
HEADLIGHT SWITCH
Capri
1. Remove instrument panel bezel to access switch connector. See HEADLIGHT SWITCH under REMOVAL & INSTALLATION.
Disconnect switch electrical connector. Measure voltage between Red and Red/White wires of headlight switch vehicle harness and
ground. If battery voltage is present, go to next step. If battery voltage is not present, check HEAD and MAIN fuses and Red and
Red/White wires between switch and fuse block.
2. Press headlight switch to first position. Using a self powered test light or ohmmeter, check continuity between switch terminals which
correspond to Red and Red/Green wires of vehicle harness connector. Continuity should not exist. If continuity exists, replace switch.
3. Press headlight switch to second position. Check continuity between switch terminals which correspond with the Red and Red/Green
wires of vehicle harness connector. Continuity should exist. If switch does not function as described, replace headlight switch. If swit ch
functions as described but headlights do not work, go to next step.
4. Remove steering column covers to access Flash-To-Pass switch connector. Using a 12-volt test light or voltmeter, place switch in
position indicated in table and check voltage between indicated wire terminals and ground. See FLASH-TO-PASS SWITCH TEST
(CAPRI) table. If switch does not function as indicated, replace switch.
FLASH-TO-PASS SWITCH TEST (CAPRI) CAUTION: On Capri m odels with Supplem ental Restraint System (SRS), observe safety precautions. T he air bag
system is powered directly from the battery and back-up power supply. Before any repairs are
perform ed, disconnect and shield battery ground cable. Disconnect the back-up power supply and wait
at least 15 m inutes BEFORE servicing ANY air bag com ponent. Use caution when working near steering
colum n. Air bag could accidentally deploy at any tim e.
NOTE:T he following disabling sequence is ONLY for com ponent replacem ent purposes.
Switch PositionWire ColorVoltage
Off
Headlights OffREDBattery
"All other wires0
Headlights OnRED, RED/GRN,
RED/BLKBattery
"All other wires0
On
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Festiva
Disconnect headlight switch. Using an ohmmeter, place switch in position indicated in table and check continuity between switch terminals
that correspond to wire colors listed. See HEADLIGHT SWITCH CONTINUITY TEST (FESTIVA) table. If switch does not function
indicated, replace switch.
HEADLIGHT SWITCH CONTINUITY TEST (FESTIVA)
IGNITION SWITCH
Capri
Remove lower steering column cover to gain access to ignition switch electrical connector. Connect a self-powered test light or ohmmeter
between blade terminals indicated in table. See IGNITION SWITCH CONTINUITY (CAPRI) table. Continuity should not exist between any
blade terminal and chassis ground in any switch position except proof circuit (162/997) in START position. See Fig. 1
.
IGNITION SWITCH CONTINUITY (CAPRI)

Fig. 1: Identifying Ignition Switch Terminals (Capri)

Courtesy of FORD MOTOR CO.
Festiva
Remove lower steering column cover to gain access to ignition switch electrical connector. Using a self-powered test light or ohmmeter, ensure
continuity exists between terminals listed in table at specified switch positions. If switch does not test as specified, replace ignition switch. See
IGNITION SWITCH CONTINUITY (FESTIVA) table. See Fig. 2
.
IGNITION SWITCH CONTINUITY (FESTIVA)
Headlights OffRED, RED/WHTBattery
"All other wires0
Headlights OnRED, RED/GRN,
RED/WHTBattery
"All other wires0
Switch PositionWire ColorContinuity
FlashRED/BLK to BLKYes
LowWHT to RED/BLKYes
HighWHT to RED/WHTYes
1RED/YEL to BLKYes
2RED/BLK to BLKYes
OffBLK to AllNo
Switch PositionContinuity Should Exist Only Between
ACC37, 297
LOCKNo Continuity
OFFNo Continuity
RUN37, 16, 687, 297
START977, 162 (Chassis Ground), 37, 32, 262
NOTE: Circuit pairs 37, 687 and 297 are connected together inside ignition switch.
TerminalPositionContinuity
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Fig. 2: Identifying Ignition Switch Terminals (Festiva)

Courtesy of FORD MOTOR CO.
WIPER SWITCH
For testing information on wiper switch, see appropriate WIPER/WASHER SYSTEMS article in the ACCESSORIES/SAFETY EQUIP
Section.
REMOVAL & INSTALLATION
STEERING WHEEL & HORN PAD
Removal (Capri)
1. Disable SRS. See SAFETY PRECAUTIONS. Ensure front wheels are in straight-ahead position. From rear of steering wheel, remove 4
retaining nuts and washers securing air bag module to steering wheel. Disconnect air bag module-to-clockspring connector.
2. Remove air bag module and place out of the way, with pad facing upward. Disconnect horn and speed control wire harness connectors
(if equipped) from steering wheel. Scribe reference mark on steering shaft and steering wheel hub for reassembly. Loosen steering wheel
retaining bolt 4-6 turns.
"A" (WHT) - "E" (BLU/RED)OFFNo
"ACCYes
"ONYes
"STARTNo
"A" (WHT) - "D" (BLK/RED)OFFNo
"ACCNo
"ONYes
"STARTNo
"A" (WHT) - "C" (BLK/WHT)OFFNo
"ACCNo
"ONYes
"STARTYes
"A" (WHT) - "B" (BLK/BLU)OFFNo
"ACCNo
"ONNo
"STARTYes
CAUTION: On Capri m odels with Supplem ental Restraint System (SRS), observe safety precautions. T he air bag
system is powered directly from the battery and back-up power supply. Before any repairs are
perform ed, disconnect and shield battery ground cable. Disconnect the back-up power supply and wait
at least 15 m inutes BEFORE servicing ANY air bag com ponent. Use caution when working near steering
colum n. Air bag could accidentally deploy at any tim e.
CAUT ION: When rem oving steering wheel, DO NOT use a knock-off type steering wheel puller, or strike the
steering wheel or shaft with a ham m er. A sudden im pact could dam age bearing, or collapse the
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3. Position Steering Wheel Remover (T67L-3600-A) on steering wheel. Tighten bolt on remover until steering wheel is loose. Remove
steering wheel puller, steering wheel retaining bolt, and steering wheel.
Installation
1. Ensure front wheels are in straight-ahead position. Route clockspring wiring harness through steering wheel opening. Position steering
wheel on steering shaft and align reference marks.
2. Ensure clockspring wire is not pinched when positioning steering wheel. Install new steering wheel retaining bolt and tighten to
specification. See TORQUE SPECIFICATIONS table at end of article. Connect horn and speed control wiring connectors (if equipped)
to steering wheel.
3. Connect air bag module-to-clockspring connector. Install air bag module. Tighten air bag module retaining nuts to specification.
Activate SRS. See SAFETY PRECAUTIONS. Check AIR BAG light to ensure system is functioning properly.
Removal (Festiva)
From back of steering wheel, remove 2 screws securing horn pad. Disconnect horn wire from horn pad and remove pad. Remove steering
wheel nut. Scribe reference mark on steering shaft and steering wheel hub for reassembly. Using Steering Wheel Puller (T67L-3600-A),
remove steering wheel.
Installation
Position steering wheel on steering shaft and align reference marks. Be sure cutouts in rear cover engage turn signal canceling cam. To
complete installation, reverse removal procedure.
COMBINATION SW ITCH
Removal (Capri)
1. Disconnect negative battery cable. Remove lower steering column cover. Remove center access panel and trim cover under steering
column. Remove left side defroster connector tube. Remove steering column upper retaining bolts. Column will pivot downward and
rest on instrument panel brace.
2. Remove 2 switch retaining screws and remove switch. Grasp switch and lever and pull lever out of switch. Disconnect switch electrical
connectors and remove switch.
Installation
Align key with slot and install lever in switch assembly. Position switch on steering column and install retaining screws. To complete
installation, reverse removal procedure.
Removal (Festiva)
1. Disconnect negative battery cable. Remove steering wheel. See STEERING WHEEL & HORN PAD under REMOVAL &
INSTALLATION. Remove 4 screws from upper half of lower steering column cover and remove cover. Remove upper steering column
cover. Remove 5 clips from lower half of lower steering column cover and remove cover.
2. Release wiring harness clip and unplug 4 harness connectors from back of combination switch. From below steering column, loosen
band clamp securing switch hub to steering column jacket. Pull switch assembly from steering column.
Installation
Slide combination switch assembly onto steering column. Make sure switch assembly is seated and level against end of column jacket. To
complete installation, reverse removal procedure.
HEADLIGHT SWITCH
Removal & Installation (Capri)
1. Headlight off/on switch is located on left side of instrument panel bezel. Disconnect negative battery cable. Pull out center storage
compartment. Remove 2 upper screws, 2 lower screws and heater/radio bezel. Pull outward and remove trim covers located on both
sides of steering column.
2. Remove retaining screws and carefully pull instrument panel bezel partially away from dash. Disconnect electrical connector from
headlight switch. Depress tangs on both sides of switch and remove switch from bezel. To install, reverse removal procedure.
IGNITION SWITCH & LOCK CYLINDER
Removal (Capri)
1. Disconnect negative battery cable. Remove lower steering column cover. Remove center access panel and trim cover under steering
column. Remove left side defroster connector tube. Remove steering column upper retaining bolts. Column will pivot downward and
rest on instrument panel brace. steering colum n.
CAUT ION: Rem ove steering wheel carefully to avoid dam aging clockspring wiring, air bag m odule connector, or
accidentally turning clockspring. After steering wheel rem oval, tape clockspring in position to prevent
dam age and keep it from being turned accidentally.
CAUTION: Ensure that no wiring is pinched beneath steering colum n when lowered.
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2. With ignition key inserted in lock assembly, rotate tumbler while pushing release pin with a .125" (3.17 mm) drift punch. Pull tumbler
assembly out of housing. Remove upper column cover. Remove column lock shield. Disconnect ignition switch electrical connector.
Remove switch retaining screws and remove switch.
Installation
Position ignition switch on column lock assembly. Make sure actuator pin of lock assembly fits into slot in ignition switch. To complete
installation, reverse removal procedure.
Removal & Installation (Festiva)
1. Disconnect negative battery cable. Remove 4 screws from upper half of lower steering column cover and remove cover. Remove upper
steering column cover. Remove 5 clips from lower half of lower steering column cover and remove cover.
2. Remove 4 steering column shield nuts and remove shield. Remove 2 shield bracket bolts and remove bracket. Remove air discharge duct
from below steering column. Remove steering column attaching nuts then lower steering column mounting bracket.
3. Remove tie strap securing key warning buzzer switch wires. Remove ignition switch attaching screw. Pull switch loose from switch
housing. Remove switch harness from routing clip and disconnect electrical connectors. Remove switch. To install, reverse removal
procedure.
TURN SIGNAL SWITCH
See COMBINATION SWITCH under REMOVAL & INSTALLATION.
WIPER SWITCH
Removal & Installation (Capri)
Remove center trim panel and lower steering column cover. Disconnect wiper switch electrical connector and pull wiring from routing clip.
Firmly grasp switch and lever and pull out to remove. To install, reverse removal procedure.
Removal & installation (Festiva)
See COMBINATION SWITCH under REMOVAL & INSTALLATION.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS CAUTION: Ensure that no wiring is pinched beneath steering colum n when it is lowered.
ApplicationFt. Lbs. (N.m)
Capri
Column Lock Shield Screw & Nut11-14 (15-19)
Ignition Lock Housing Bolt12-13 (16-18)
Steering Wheel Bolt23-33 (31-45)
Upper Column Retaining Bolts17-23 (23-31)
Festiva
Steering Wheel Nut29-36 (39-49)
Upper Column Retaining Bolts23-34 (31-46)
INCH Lbs. (N.m)
Capri
Ign it io n Swit ch Screw50-70 (5.6-7.9)
Capri & Festiva
Air Bag Module-To-Steering Wheel Nuts35-53 (4-6)
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00028303
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WIPER/WASHER SYST EM
1991 ACCESSORIES & SAFET Y EQUIPMENT Ford Motor Co. Wiper/Washer System s
DESCRIPTION & OPERATION
Capri and Festiva vehicles are equipped with a 2-speed wiper motor with an optional intermittent system. The Festiva rear wiper uses a single
speed wiper motor. Washer systems for both front and rear washers use pumps mounted near fluid reservoirs.
ADJUSTMENTS
W IPER ARM ADJUSTMENT
Remove wiper arm and blade assemblies from pivot shafts. Turn wiper switch on and allow wiper motor to cycle 2 to 3 times. Turn wiper
switch off to place pivot shafts in park position. Reinstall wiper arm and blade assemblies with tips of wiper blades at specified distance from
lower edge of windshield. See WIPER BLADE ADJUSTMENT SPECIFICATIONS
table. Tighten wiper arm retaining nut to 89-124
INCH Lbs. (10-14 N.m).
WIPER BLADE ADJUSTMENT SPECIFICATIONS
TESTING
FRONT WIPER MOTOR TEST
Capri
1. Check WIPER fuse in interior fuse block and replace if necessary. Perform FRONT INTERVAL WIPE MODULE TEST . If
wiper/washer switch and interval module are operating properly, disconnect wiper motor connector. Turn ignition on and place
wiper/washer switch in HIGH position. Measure voltage at Blue/Red and Blue wires at wiper motor vehicle harness connector.
2. If battery voltage is not present, check Blue/Red or Blue wire for open circuit. If battery voltage is present at Blue/Red and Blue wires,
check Black ground wire at wiper motor vehicle harness connector for an open circuit and repair as necessary. If Black ground wire is
okay, replace wiper motor.
Festiva
1. Place wiper in any position other than park. Remove WIPER fuse. Disconnect wiper motor electrical connector. Using an ohmmeter,
check for continuity to ground at motor case. Continuity should exist. If continuity does not exist, replace or repair wiper motor ground
strap or wire.
2. Check for continuity to ground at Blue/Black terminal of wiper motor. Continuity should exist. If continuity does not exist, replace
wiper motor.
FRONT INTERVAL WIPE MODULE TEST
Capri
1. Check WIPER fuse in interior fuse block and replace if necessary. Perform FRONT WIPER/WASHER SWITCH TEST . Access
interval wipe module connector. Interval wipe module is located below instrument panel near console. Ensure wiper switch is in OFF
position. Turn ignition on and measure voltage at Blue/White and Blue/Black wires of module connector. Battery voltage should not be
present. Turn wiper switch to LOW position. Measure voltage at Blue/White and Blue/Black wires of module connector. Battery voltage
should be present.
2. Turn wiper switch to HIGH position. Measure voltage at Blue/White, Blue/Black and Blue/Red wires of module connector. Battery
voltage should be present. Turn wiper switch to INT position. Measure voltage at Blue/White and Blue/Black wires of module
connector. Battery voltage should be present during each cycle. If module does not perform as specified, replace module.
Festiva
Information is not available from manufacturer.
FRONT WIPER/WASHER SWITCH TEST
Capri
Remove lower steering column cover to gain access to wiper switch electrical connector. Using an ohmmeter, ensure continuity exists between
terminals listed in table at specified switch positions. If switch does not test as specified, replace wiper/washer switch. See FRONT
WIPER/WASHER SWITCH CONTINUITY (CAPRI) table. See Fig. 1 .
FRONT WIPER/WASHER SWITCH CONTINUITY (CAPRI)
ApplicationIn. (mm)
Capri
Driver Side1.0 (25)
Passenger Side1.26 (32)
Festiva
Both Sides1.0 (25)
Rear(1) 3.15 (80)
(1)From left edge of liftgate window.
TerminalPositionContinuity
Page 1 of 5 MITCHELL 1 ARTICLE - WIPER/WASHER SYSTEM 1991 ACCESSORIES & SAFETY EQUIPMENT Ford Motor Co. Wip
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Fig. 2: Moving Quadrant on Drum Brake Adjuster (Festiva)

Courtesy of FORD MOTOR CO.
FRONT AXLE BEARINGS
Front bearing preload is adjusted during bearing replacement by changing preload spacer. See FRONT WHEEL BEARINGS under
REMOVAL & INSTALLATION.
REAR AXLE BEARINGS
With bearings installed, tighten NEW lock nut to 18-22 ft. lbs. (24-30 N.m) while rotating wheel. Slightly loosen lock nut so it can be turned
by hand. Install a lug nut into axle hub. Attach an inch-pound torque wrench to lug nut at 12 o'clock position. Measure bearing preload.
Tighten lock nut until bearing preload, including seal drag, is 3.5-6.2 INCH lbs. (.4-.7 N.m). Stake NEW lock nut into notch on spindle.
TESTING
POWER BRAKE UNIT
Functional Test
1. Check master cylinder fluid level and hydraulic system for leaks. Place transaxle in Neutral or Park, turn ignition off and apply parking
brake. Pump brake pedal several times to eliminate vacuum from system, and hold pedal in depressed position.
2. Start and idle engine. If vacuum system is functioning properly, pedal moves downward under constant foot pressure. If no pedal motion
is felt, vacuum booster is not functioning properly. Go to next step.
3. Run engine for at least one minute and turn ignition off. Depress brake pedal several times. Booster is okay if pedal stroke is long at first
and becomes shorter with each stroke. If stroke does not shorten, check for a damaged, restricted or improperly connected check va l ve
vacuum hose. Repair and recheck. Go to next step.
4. Restart engine. Depress and hold pedal down. Turn ignition off and wait 30 seconds. Booster is okay if pedal height remains unchanged.
If pedal height changes, check for a damaged, restricted or improperly connected check valve or vacuum hose. Go to next step.
5. Connect a pressure gauge to master cylinder output line. Connect a vacuum gauge to booster and a pedal depression force gauge to
brake pedal. Bleed air from pressure gauge. Start engine. When vacuum gauge reads 19.7 in. Hg, turn ignition off. Watch vacuum ga u ge
for 15 seconds. Booster is okay if vacuum gauge reads 18.7-19.7 in. Hg. If vacuum gauge reads less than 18.7 in. Hg, proceed to next
step.
6. Restart engine. Apply and hold 44 lbs. (196 N) force to brake pedal. When vacuum gauge reading reaches 19.7 in. Hg, turn ignition off.
Watch vacuum gauge for 15 seconds. Booster is okay if vacuum gauge reads 18.7-19.7 in. Hg. If vacuum gauge reads less than 18.7 in.
Hg, proceed to next step.
7. With engine stopped and vacuum gauge at zero, check pressure gauge. Apply 44 lbs. (196 N) force to brake pedal and check pressure
gauge. Booster is okay if pressure gauge reads 256 psi (18 kg/cm
2 ).
8. Remove pedal force and start engine. When vacuum gauge reaches 19.7 in. Hg, apply 44 lbs. (196 N) force to pedal. Booster is okay if
pressure gauge read 768 psi (54 kg/cm
2 ).
Diagnosis
If booster does not function properly, see Fig. 3 .
NOTE:Axle lock nut on right side has left-hand threads. Always install NEW lock nut when rem oved.
NOTE:Inspect all vacuum hoses for holes, collapsed areas and secure connections. Ensure all unused
vacuum ports are capped.
Page 3 of 12 MITCHELL 1 ARTICLE - BRAKE SYSTEM 1991-92 BRAKES Disc & Drum
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