alternator FORD FESTIVA 1991 Service Manual

Back To Article
ALTERNATOR & REGULATOR
1991 ELECT RICAL Alternators & Regulators
DESCRIPTION
Mitsubishi alternator is a 50-amp, conventional 3-phase, self-rectifying type unit, containing 6 diodes (3 main diodes and a smaller diode trio)
and a case-mounted Integrated Circuit (IC) regulator. A charge indicator light in the instrument panel indicates charging system mal fu n ct io n s.
See Fig. 1
.

Fig. 1: Charging System Wiring Schematic

Courtesy of FORD MOTOR CO.
ADJUSTMENTS
BELT TENSION
BELT ADJUSTMENTS
(1)
ON-VEHICLE TESTING
ALTERNATOR OUTPUT
ApplicationNew BeltUsed Belt
A/C & P/S Belts110-125 (50-57)92-110 (42-50)
Alt. Belt110-130 (50-60)95-110 (43-50)
(1)Tension in Lbs. (Kg) Using Strand Tension Gauge
NOTE:Before testing, check alternator wiring harness connections, drive belt tension and battery voltage.
Ensure battery cables and engine ground cable are clean and tight. Wait at least 30 seconds after
starting engine before m easuring voltage.
CAUT ION: DO NOT start engine with "L" and "S" term inal connectors disconnected from alternator. DO NOT allow
"L" term inal to contact ground while engine is running. See Fig. 2
.
Page 1 of 3 MITCHELL 1 ARTICLE - ALTERNATOR & REGULATOR 1991 ELECTRICAL Alternators & Regulators
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B7DD6473C%2DB5BB%2D4F20%2D9D70%2D
...

Fig. 2: Identifying Alternator Test Terminals

Courtesy of FORD MOTOR CO.
1. Turn ignition switch to OFF position. Connect positive voltmeter lead wire to alternator "B" terminal and negative wire to ground. See
Fig. 2
. Ensure voltmeter indicates battery voltage. If voltmeter indicates zero volts, an open circuit exists in wire between "B" terminal
and battery positive terminal.
2. Remove voltmeter. Disconnect negative battery cable. Remove output lead from alternator terminal "B". Connect a 100-amp ammeter in
series between "B" terminal and disconnected output lead. Connect positive lead of ammeter to "B" terminal and negative lead to
disconnected output wire.
3. Connect voltmeter in parallel between alternator "B" terminal and battery positive terminal. Connect positive lead wire of voltmeter to
"B" terminal and negative lead wire to positive terminal of battery. Reconnect negative battery cable.
4. Install tachometer (if necessary) to monitor engine RPM. Start engine. Turn all lights and accessories on and depress brake pedal to load
system. Increase engine speed to 2500-3000 RPM. Ensure alternator output is at least 35 amps.
5. Observe voltmeter reading. If voltmeter indicates .2 volt and amperage output is at least 35 amps, system is okay. If voltage drop is
greater than .2 volt, wiring is defective between alternator "B" terminal and battery positive terminal.
6. Allow engine to idle. Turn off all accessories to remove load from system. Disconnect voltmeter. Connect negative lead of voltmeter to
ground. Using positive lead of voltmeter, backprobe "S" terminal connector at rear of alternator. See Fig. 2
.
7. Increase engine speed to 2500-3000 RPM. With no load on system, ammeter should read 5 amps or more. Battery voltage with no load
at indicated speed should be 14.1-14.7 volts. If amperage output is less than indicated with or without load and no external faults exist
in alternator circuit, overhaul or replace alternator.
BENCH TESTING
Rotor
Check continuity across rotor slip rings. If no continuity exists, replace rotor. Check continuity between individual slip rings and rotor
core/shaft. If continuity exists, rotor coil or slip ring is grounded. Replace rotor.
Stator
Ensure no continuity exists between stator coil leads and stator core. Check continuity between leads of stator coil. If continuity does not
exist, replace stator.
Brushes
Inspect brushes. Replace brushes if worn to wear line (leading edge of small square cast into brush). Use a spring pressure gauge to push each
NEW brush into its holder until .079" (2 mm) projects from holder. Spring force should be 10.6-15.6 oz. (.3-.4 kg). If spring force is not
within specification, replace brush spring.
Rectifier
1. Using an ohmmeter, check for continuity between positive side of diode leads and heat sink. If no continuity exists from any positive
diode lead to heat sink, replace rectifier assembly.
2. Reverse ohmmeter leads, and check for continuity between negative side of diodes and heat sink. If continuity exists from any n e ga t ive
diode lead to heat sink, replace rectifier assembly.
3. Check diode trio (smaller diodes between main diode leads) for continuity in both directions. Continuity should exist in one direction
only. If any diode shows continuity in both directions or does not show continuity in either direction, replace diode trio.
Page 2 of 3 MITCHELL 1 ARTICLE - ALTERNATOR & REGULATOR 1991 ELECTRICAL Alternators & Regulators
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B7DD6473C%2DB5BB%2D4F20%2D9D70%2D
...

TROUBLE SHOOTING
OVERHAUL

Fig. 3: Exploded View of Mitsubishi Alternator

Courtesy of FORD MOTOR CO.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS NOTE:See T ROUBLE SHOOT ING - BASIC PROCEDURES article in the GENERAL T ROUBLE SHOOT ING
section.
NOTE:For exploded view of alternator, see Fig. 3
.
ApplicationFt. Lbs. (N.m)
Alternator Adjustment Bolt14-18 (19-25)
Alternator Mount Bolt27-38 (37-52)
Idler Pulley Attaching Nut23-34 (31-46)
Power Steering Pump Adjustment Lock Nut27-38 (37-52)
Power Steering Pump Mounting Bolt27-40 (37-54)
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00058012
Page 3 of 3 MITCHELL 1 ARTICLE - ALTERNATOR & REGULATOR 1991 ELECTRICAL Alternators & Regulators
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B7DD6473C%2DB5BB%2D4F20%2D9D70%2D
...

Fig. 2: Ground Numbers & Locations (2001 & Prior Model Years)

WIRING DIAGRAM COMPONENT LOCATIONS
When trying to locate a component in a wiring diagram and you don't know the specific system where it is located, use this handy component
locator to find the system wiring diagram in which the component is located. Then, go to that system and locate the component within the
wiring diagram.
For example, if you don't know the specific system in which the ignition switch is located, look up ignition switch in the wiring diagram
component location tables and go to the appropriate wiring diagram(s) which contain either full or partial views of the ignition switch. The full
view of the ignition switch is located in Power Distribution.
The first listing for the component will be the full or most complete view of the component. Additional listings will be partial views of the
component. Not all components are used on all models.
All components will have a partial view in Ground Distribution and Power Distribution. Data Link Connectors show connecting circuits
between modules. Alternate names for components may be listed in wiring diagram component locations tables.
WIRING DIAGRAM COMPONENT LOCATIONS
ComponentWiring Diagram
ABS Electronic Control UnitAnti-Lock Brakes; Data Link Connectors
ABS Hydraulic UnitAnti-Lock Brakes
Acceleration SensorAnti-Lock Brakes
Accessory Delay RelayPower Windows
A/C Compressor Clutch RelayEngine Performance
A/C SensorEngine Performance
A/C Pressure SwitchEngine Performance
Adaptive Lamp Control ModuleExterior Lights
Air Bag(s)Air Bag Restraint System
Air Bag ModuleAir Bag Restraint System
Air Bag Sensor(s)Air Bag Restraint System
Air Injection Pump RelayEngine Performance
Air Temperature SensorOverhead Console
Alternator (Generator)Generators & Regulators
Anti-Theft Control ModuleAnti-Theft System; Starters
Page 3 of 6 MITCHELL 1 ARTICLE - GENERAL INFORMATION Using Mitchell1's Wiring Diagrams
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B959286D2%2D3A85%2D4BFC%2D9C5C%2D
...

Back To Article
WIRING DIAGRAMS
1991 WIRING DIAGRAMS Ford Motor Co.
IDENTIFICATION
COMPONENT LOCATION MENU
COMPONENT LOCATIONS
WIRING DIAGRAMS
ComponentFigure No. (Location)
A/C RELAY3 (B 8)
A/T SELECT LIGHT3 (E 8)
ALTERNATOR1 (C 3)
BACK-UP LIGHT SWITCH5 (D 19)
BATTERY1 (A 2)
BLOWER SWITCH3 (C 9)
BRAKE WARNING SWITCH1 (C 2)
CIG LTR4 (E 14)
CLUTCH INTERLOCK SWITCH (M/T)1 (B 2)
CONDENSER FAN (A/T)3 (C 8)
COOLANT FAN MOTOR1 (D 3)
COOLANT FAN RELAY1 (D 3)
DEFOG SWITCH5 (C 16)
DIR/HAZARD SWITCH4 (B-C 12)
ELECT CONTROL ASSY (ECA)2 (A 4-7)
FRONT WASHER MOTOR1 (E 3)
FRONT WIPER MOTOR1 (E 3)
FRONT WIPER/WASHER SWITCH5 (A 16)
FUEL PUMP INERTIA SWITCH2 (D 4)
FUEL PUMP RELAY2 (C 4)
FUSE BLOCK3 (D-E 9-10)
HEADLIGHT RELAY4 (D 14)
HORN RELAY3 (E 11)
HORN SWITCH4 (E 15)
IGNITION COIL2 (E 5)
IGNITION KEY REMINDER SWITCH4 (E 13)
IGNITION SWITCH3 (C-D 11)
INSTRUMENT CLUSTER4 (A-E 15)
INSTRUMENT PANEL LIGHT CONTROL4 (D-E 12)
INTERIOR LIGHT SWITCH4 (E 14)
LIGHT SWITCH4 (C-D 12)
MAIN FUSE PANEL1 (A 3)
MAIN RELAY2 (D 5)
NEUTRAL SAFETY SWITCH (A/T)1 (B 2)
PARKING LIGHT RELAY4 (C 14)
PASSIVE RESTRAINT CONTROL MODULE3 (A 11)
REAR WASHER MOTOR5 (D 17)
REAR WIPER/WASHER SWITCH5 (E 16)
SHIFT LOCK SERVO ASSY4 (A 12)
STARTER1 (B 3)
STOP LIGHT SWITCH5 (D 19)
TIMER/BUZZER UNIT4 (E 12)
TRUNK LIGHT5 (B 16)
WAC RELAY3 (B 8)
Page 1 of 6 MITCHELL 1 ARTICLE - WIRING DIAGRAMS 1991 WIRING DIAGRAMS Ford Motor Co.
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B959286D2%2D3A85%2D4BFC%2D9C5C%2D
...

Back To Article
DRIVE BELT ROUTING
1991-92 ENGINE COOLING BELT ROUT ING
BELT ADJUSTMENT
Tensioners may be used to automatically adjust belt tension to specification. Check belt for fraying. If fraying exists, ensure both belt and
tensioner are properly aligned. See Fig. 1
. Tensioners may contain a belt-wear indicator. See Fig. 2 . If tensioner reaches travel limit, as
indicated by marks on tensioner, replace belt. Ensure serpentine belts are properly installed. See Fig. 3
-Fig. 7 . On models without
tensioners, ensure belt tension is within specification. See BELT ADJUSTMENT SPECIFICATIONS table.
BELT TENSION ADJUSTMENT SPECIFICATIONS
(1)
ApplicationNew Belt(2) Used Belt
Continental(3) (3)
Cougar & Thunderbird(3) (3)
Crown Victoria & Grand Marquis
5.0L & 5.8L
1/4" "V" Belt70 (32)50 (23)
6 Rib Belt170 (77)150 (68)
Escort & Tracer
1.8L(4) (5) (4) (5)
1.9L(3) (3)
Mark VII(3) (3)
Mustang(3) (3)
Probe
2.2L & 2.2L Turbo
Alternator(4) (6) (4) (6)
A/C90 (41)90 (41)
Sable & Taurus
2.5L(3) (3)
3.0L (7)
Alternator140-160 (63-67)110-130 (50-59)
P/S & A/C(3) (3)
3.0L SHO
A/C & Alt.220-265(100-120) 148-192 (67-
87)
P/S & W/P154-198 (70-90)112-157 (51-71)
3.8L(3) (3)
Tempo & Topaz
2.3L
Alternator150-170 (68-77)130-150 (59-68)
W/P150-90 (23-41)40-60 (18-27)
Town Car(3) (3)
(1)Tension is measured in Lbs. (kg) using tension gauge.
(2)Used belt is a belt in operation for at least 10 minutes.
(3)Belt tension is automatically adjusted by tensioner.
(4)Manufacturer lists only belt deflection with 22 lbs. applied on belt.
(5)Belt deflection on new belt is .31-.35" (7.9-8.9 mm) or .35-.39" (8.9-9.9 mm) on used belt.
(6)Belt deflection on new belt is .24-.31" (6.1-7.9 mm) or .27-.35" (6.9-8.9 mm) on used belt.
(7)Specification is for models without belt tensioner.
Page 1 of 11 MITCHELL 1 ARTICLE - DRIVE BELT ROUTING 1991-92 ENGINE COOLING BELT ROUTING
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B959286D2%2D3A85%2D4BFC%2D9C5C%2D
...

Back To Article
DRIVE BELT ROUTING
1991-92 ENGINE COOLING BELT ROUT ING
BELT ADJUSTMENT
Tensioners may be used to automatically adjust belt tension to specification. Check belt for fraying. If fraying exists, ensure both belt and
tensioner are properly aligned. See Fig. 1
. Tensioners may contain a belt-wear indicator. See Fig. 2 . If tensioner reaches travel limit, as
indicated by marks on tensioner, replace belt. Ensure serpentine belts are properly installed. See Fig. 3
-Fig. 7 . On models without
tensioners, ensure belt tension is within specification. See BELT ADJUSTMENT SPECIFICATIONS table.
BELT TENSION ADJUSTMENT SPECIFICATIONS
(1)
ApplicationNew Belt(2) Used Belt
Continental(3) (3)
Cougar & Thunderbird(3) (3)
Crown Victoria & Grand Marquis
5.0L & 5.8L
1/4" "V" Belt70 (32)50 (23)
6 Rib Belt170 (77)150 (68)
Escort & Tracer
1.8L(4) (5) (4) (5)
1.9L(3) (3)
Mark VII(3) (3)
Mustang(3) (3)
Probe
2.2L & 2.2L Turbo
Alternator(4) (6) (4) (6)
A/C90 (41)90 (41)
Sable & Taurus
2.5L(3) (3)
3.0L (7)
Alternator140-160 (63-67)110-130 (50-59)
P/S & A/C(3) (3)
3.0L SHO
A/C & Alt.220-265(100-120) 148-192 (67-
87)
P/S & W/P154-198 (70-90)112-157 (51-71)
3.8L(3) (3)
Tempo & Topaz
2.3L
Alternator150-170 (68-77)130-150 (59-68)
W/P150-90 (23-41)40-60 (18-27)
Town Car(3) (3)
(1)Tension is measured in Lbs. (kg) using tension gauge.
(2)Used belt is a belt in operation for at least 10 minutes.
(3)Belt tension is automatically adjusted by tensioner.
(4)Manufacturer lists only belt deflection with 22 lbs. applied on belt.
(5)Belt deflection on new belt is .31-.35" (7.9-8.9 mm) or .35-.39" (8.9-9.9 mm) on used belt.
(6)Belt deflection on new belt is .24-.31" (6.1-7.9 mm) or .27-.35" (6.9-8.9 mm) on used belt.
(7)Specification is for models without belt tensioner.
Page 1 of 11 MITCHELL 1 ARTICLE - DRIVE BELT ROUTING 1991-92 ENGINE COOLING BELT ROUTING
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B959286D2%2D3A85%2D4BFC%2D9C5C%2D
...

Back To Article
ENGINE OVERHAUL
1991-92 FORD MOT OR CO. ENGINES 1.3L & 1.6L 4-Cylinder
ENGINE IDENTIFICATION
Engine can be identified by Vehicle Identification Number (VIN) on metal tab attached to instrument panel. Tab is close to windshield on
driver's side and is visible through windshield. VIN has 17 characters. The 8th character identifies engine.
ENGINE IDENTIFICATION CODES
ADJUSTMENTS
VALVE ARRANGEMENT
Firewall Side
In t ake val ves.
Radiator Side
Exhaust valves.
VALVE CLEARANCE ADJUSTMENT
Hydraulic lifters are used. Adjustment is NOT possible nor necessary.
REMOVAL & INSTALLATION
FUEL PRESSURE RELEASE
Remove rear seat. Remove fuel pump access panel. Disconnect fuel pump electrical connector. Start engine and allow to idle until engine dies.
ENGINE
Removal (1.3L)
1. Remove battery and battery tray. Index hood-to-hinge and remove hood. Drain coolant. Drain engine oil and transaxle fluid. Disconnect
vane airflow meter connector, vane airflow meter and hose.
2. Remove oil dipstick, cooling fan and radiator assembly. Disconnect accelerator cable from mounting bracket and throttle lever.
Disconnect speedometer cable at transaxle. Mark and disconnect fuel lines at fuel pump. Plug fuel lines. Remove heater hoses. Remove
brake booster vacuum hose. Disconnect transaxle vacuum hose.
3. Remove charcoal canister hoses from engine. Disconnect engine wiring harness. Remove alternator and brackets. Remove engine ground
strap. Raise vehicle and remove catalytic converter.
4. Disconnect A/C compressor without removing hoses, and set compressor aside. Disconnect distributor wiring at coil. On automatic
transaxle models, remove shift lever-to-manual shaft assembly nut. Remove shift cable from transaxle. Loosen front wheel bolts. Raise
vehicle and remove wheel assemblies.
5. Remove stabilizer mounting nuts and brackets. Remove lower arm clamp bolts and nuts. Pull lower arms downward, separating lower
arms from knuckles. Separate halfshafts and install Differential Plugs (T87C-7025-C) between differential side gears. See FWD AXLE
SHAFTS article in DRIVE AXLES Section.
6. On manual transaxle vehicles, disconnect clutch control cable and shift control cable rod. Remove stabilizer bar from transaxle. Remove
catalytic converter inlet pipe. Support engine assembly with hoist. Remove rear crossmember mount bolts. Remove front and rear engine
mount nuts.
7. Remove crossmember. Lower vehicle and attach engine lift hooks. Remove right engine mount bolt. Remove engine/transaxle assembly.
Remove gusset plates. Remove starter and flywheel cover. Remove torque converter bolts on automatic transaxle. Remove engine-to-
transaxle bolts. Separate transaxle from engine.
Installation (1.3L)
1. Install transaxle to engine in reverse order of removal. Attach hoist to engine/transaxle assembly and position in vehicle. Support engine
in chassis and install engine mount bolts. Raise vehicle and install front engine mount nut. Tighten nuts to specification. See TORQUE
SPECIFICATIONS table at end of article.
2. Position crossmember onto mounts and chassis. Tighten rear nut. Install mount-to-crossmember nuts and tighten. Remove differential
plugs and install halfshafts. To complete installation, reverse removal procedure. Tighten all bolts/nuts to specifications. Fill all fluid NOTE:For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES
-
GENERAL INFORMATION
article in the GENERAL INFORMAT ION section.
ApplicationVIN Code
Festiva
1.3L SOHC PFIH
Capri
1.6L DOHC PFIZ
1.6L DOHC PFI TURBO6
NOTE:When rem oving engine m ounts, m ark and note location and position to ensure proper installation.
Engine and transaxle are rem oved as an assem bly.
Page 1 of 19 MITCHELL 1 ARTICLE - ENGINE OVERHAUL 1991-92 FORD MOTOR CO. ENGINES 1.3L & 1.6L 4-Cylinder
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B959286D2%2D3A85%2D4BFC%2D9C5C%2D
...

levels to proper level.
Removal (1.6L & 1.6L Turbo)
1. Relieve fuel pressure and discharge air conditioning system (if equipped). See FUEL PRESSURE RELEASE under REMOVAL &
INSTALLATION. Disconnect and remove battery, battery tray and battery tray support bracket.
2. Release wiring harness retaining straps from battery support tray. Disconnect windshield washer supply hose between fluid reservoir and
hood. Mark hinge locations and remove hood.
3. Disconnect intake air tube and wiring to ignition coil and vane airflow meter. Remove air cleaner/vane airflow meter assembly. Remove
air cleaner assembly support brackets. Disconnect intercooler hoses from turbocharger (if equipped).
4. Drain engine coolant and remove radiator. Disconnect accelerator cable, and remove retaining bracket from cam cover. Position cable to
one side.
5. Disconnect and plug fuel lines at fuel filter and pressure regulator. Disconnect power brake booster manifold vacuum hose from
manifold. Disconnect heater hoses at heater core tubes. Label and remove vacuum hoses located at throttle body.
6. For manual transaxle turbocharged vehicles, disconnect clutch cable and remove support bracket and cable from transmission. On non-
turbo vehicles, disconnect clutch slave hydraulic line. For automatic transaxle, remove transaxle cooler lines.
7. Disconnect starter wiring at starter. Remove harness from locating strap on bracket. Disconnect alternator wiring. Disconnect wiring
from engine coolant sensors located on rear of engine block. Remove ground connection at bracket on thermostat cover. Disconnect O2
sensor wire, main wiring harness connector, TPS connector (turbocharged only), knock sensor connector, distributor wiring and
transaxle wiring. Disconnect ground wire and strap at front of engine, and reinstall lifting eye.
8. Remove engine oil dipstick and retaining clip. Remove power steering pump from mounting bracket. Remove power steering pump
mounting bracket. With hoses attached, position pump aside. Remove upper air conditioning compressor retaining bolts (if equipped).
9. Raise vehicle on hoist. Drain engine oil and cooling system. On vehicles with air conditioning, remove lower air conditioning
compressor mounting bolts, and position compressor out of way.
10. Remove front wheels and tires. Remove front ball joints-to-ste e r in g kn u c kl e s r e t a in in g b o l t s. R e mo ve sp l a sh gu a r d s. Dr a in t ransmission
oil and remove half shafts from differential. Remove front exhaust pipe bracket located on lower side of engine. Disconnect front
exhaust pipe from exhaust manifold, or turbocharger (if equipped).
11. Remove frame support bar-to-engine support bolt. Loosen right control arm bolt and, pivot support bar downward. Disengage rubber
exhaust hangers located directly behind catalytic converter. Allow exhaust system to hang down 6 inches, and support system with
mechanic's wire. Unbolt shift linkage and stabilizer bar at transaxle. Remove nuts from front and rear engine mounts, and lower vehicle.
12. Attach chains onto lift eyes at ends of cylinder head, and support engine with hoist. Remove RH engine mount through bolt. Raise
engine off mounts and slightly pivot engine/transaxle assembly. Disconnect oil pressure sensor and route starter/alternator wiring
harness from engine. Carefully lift engine/transaxle assembly, turn assembly while raising to clear brake master cylinder, shift linkage
universal joint, radiator support and air conditioning lines (if equipped).
13. Remove intake manifold support bracket. Remove gusset plate(s) (if equipped). Remove starter. Remove transaxle-to-engine retaining
bolts. Identify bolts to ensure correct installation. Separate transaxle from engine. On manual transaxle, remove pressure plate, clutch
disc and flywheel. On automatic transaxle, remove flexplate.
Installation (1.6L & 1.6L Turbo)
1. Install transaxle to engine in reverse order of removal. Attach hoist to engine/transaxle assembly and position assembly in vehicle.
Before engine contacts mounts, route starter, alternator and oil pressure sensor wiring, and connect oil pressure sensor. Lower engine
until front mount seats on crossmember. Install through bolt on RH engine mount. DO NOT tighten bolt.
2. Remove hoist. Raise vehicle and support with jackstands. Align rear engine mount to crossmember, and install retaining nuts to front
and rear engine mounts. Tighten nuts to specification. See TORQUE SPECIFICATIONS
table at end of article.
3. On manual transaxles, connect shift coupling and stabilizer. Tighten to specification. On automatic transaxles, connect shift linkage and
oil cooler lines. Tighten linkage retaining bolt, shift cable pivot and oil cooler hose clamps to specification. Connect front exhaust pipe
to manifold (or turbocharger). Install exhaust pipe to support bracket. Tighten bolts to specification. Tighten manifold (or turbocharger)
to specification. Attach rubber exhaust hangers. Position cross brace. Tighten retaining nut and bolt and right control arm front bolt.
4. Install drive axles. Install ball joint retaining bolts and tighten to specification. Mount A/C Compressor to engine (if equipped). Tighten
lower retaining bolts to specification. Install splash guards. Install tire and wheel assemblies. Tighten retaining nuts to specification.
5. Lower vehicle. Install upper A/C compressor retaining bolts (if equipped). Tighten bolts to specification. Tighten RH engine mo u n t
through bolt to specification. Connect alternator wiring.
6. Position power steering pump bracket on stud. Lower pump into engine compartment. Install power steering pump bracket retaining
bolts and nut. Tighten to specification. Install power steering pump and belt. Tighten adjustment nut and pivot bolt to specification.
7. Install engine oil dipstick and retaining clip. Install ground strap and ground wire to cylinder head. Install clutch cable (if equipped).
Connect clutch hydraulic line if equipped with manual transaxle or naturally aspirated. Connect transmission electrical connectors.
Connect fuel lines to fuel filter and pressure regulator. Install intake air tube to throttle body.
8. Install intercooler hoses on turbocharged models. Install air cleaner assembly brackets. Install air cleaner assembly with airflow meter
attached. Install intake air tube. Install coil and airflow meter connectors. Connect coolant crankcase and air bypass hoses. Install
vacuum hoses as noted in disassembly.
9. Connect accelerator cable. Install retaining bracket. Install power brake booster hose. Remove speedometer cable from transaxle. Fill
transaxle to specification. See CAPACITIES in SERVICE & ADJUSTMENT SPECIFICATIONS article. Install speedometer cable.
Connect speedometer cable connector. Fill engine oil to capacity.
10. Install radiator/fan assembly. Tighten bracket retaining bolts to specification. Connect coolant hoses and fan electrical connector. Fill
coolant to specification.
11. Install hood and connect washer hose. Install battery tray support, battery tray, battery and battery hold-down. Connect battery
terminal. Evacuate and charge air conditioning system (if equipped). Road test vehicle and inspect for leaks.
INTAKE MANIFOLD
Removal (1.3L)
CAUT ION: DO NOT allow com pressor to hang by hoses. T ie up com pressor with m echanic's wire.
Page 2 of 19 MITCHELL 1 ARTICLE - ENGINE OVERHAUL 1991-92 FORD MOTOR CO. ENGINES 1.3L & 1.6L 4-Cylinder
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B959286D2%2D3A85%2D4BFC%2D9C5C%2D
...

Remove timing belt covers, See TIMING BELT COVER procedure to remove timing belt from this engine.
Installation (1.6L)
1. Ensure timing belt and sprockets are clean and not worn or damaged. Ensure timing marks are properly positioned on camshafts and
crankshaft. Intake cam should have letter "I" aligned with arrow on belt cover. Exhaust cam should have letter "E" aligned with arrow on
belt cover. Crankshaft key should align with arrow. See Fig. 4
.
2. Tighten tension pulley with tension spring fully extended. Install timing belt. Keep tension on opposite side of tensioner as tight as
possible. Ensure rotation mark on belt is correct.
3. Turn crankshaft 2 full turns. Check alignment of timing marks. If any mark is not aligned, remove timing belt and reset timing. Lo o se n
tension pulley retaining bolt allowing tension spring to tighten belt. Tighten tension pulley to specification and rotate engine 2 full
turns. Verify timing mark alignment.
4. Measure timing belt tension between camshaft pulleys. Belt deflection should be 0.33-0.45" (8.5-11.5 mm). If incorrect, loosen tension
pulley and repeat procedure. If correct tension cannot be achieved, replace tension spring.
5. Install lower, center and upper timing belt covers, and tighten bolts to specification. See TORQUE SPECIFICATIONS
table at end of
article. Install RH engine mount. Lower engine. Tighten retaining nuts to specification. Install crankshaft pulley, damper and baffle.
Tighten baffle and damper screws and pulley retaining bolts to specification. Install water pump pulley and tighten retaining bolts to
specification.
6. Install alternator and power steering belts. Install oil dipstick. Raise vehicle and install splash guard and RF wheel and tire assembly.
Lower vehicle, install spark plugs and start engine. Inspect for leaks and check operation.

Fig. 4: Aligning Camshaft & Crankshaft Timing Marks (1.6L)

Courtesy of FORD MOTOR CO.
FRONT COVER & OIL SEAL
Removal & Installation
Front cover is the housing for the oil pump. See OIL PUMP under ENGINE OILING.
CAMSHAFT
Removal (1.3L)
Remove cylinder head. Remove rocker arm assemblies if not previously removed. Carefully remove camshaft thrust plate. Remove camsh aft
Page 7 of 19 MITCHELL 1 ARTICLE - ENGINE OVERHAUL 1991-92 FORD MOTOR CO. ENGINES 1.3L & 1.6L 4-Cylinder
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B959286D2%2D3A85%2D4BFC%2D9C5C%2D
...