transmission FORD FESTIVA 1991 Service Manual

If temperature gauge always reads hot, check these items:
Check for temperature gauge wire shorted to ground.
Check for defective temperature sender.
Check for defective temperature gauge.
Check for defective instrument panel voltage regulator (Festiva).
Temperature Gauge Inaccurate
If temperature gauge is inaccurate, check these items:
Check for faulty (loose or corroded) wire connections.
Check for defective temperature sender.
Check for defective instrument panel voltage regulator (Festiva).
SPEEDOMETER
Speedometer Does Not Operate
If speedometer does not operate, check these items:
Check for broken speedometer drive cable.
Check for broken drive gear in transmission.
Check for defective speedometer head.
Speedometer Needle Bounces
If speedometer needle bounces, check these items:
Check for binding speedometer drive cable.
Check for missing teeth on drive gear in transmission.
Check for defective speedometer head.
Speedometer Does Not Indicate Correct Vehicle Speed
If speedometer does not indicate correct vehicle speed, check these items:
Check for incorrect size tires.
Check for improper tire inflation.
Check for defective speedometer head.
TACHOMETER (CAPRI)
Tachometer Does Not Work, But All Other Gauges Work Properly
-If tachometer does not work, but all other gauges function properly, check these items:
Check for defective tachometer.
Check for open Yellow/Black tachometer signal wire from ignition coil to instrument panel.
Check for faulty Black ground wire to instrument panel.
Tachometer & All Gauges Do Not Function
If tachometer and all other gauges do not function properly, check these items:
Check for blown 10-amp METER fuse in fuse panel.
Check for open in Black/Yellow wire to fuse panel to instrument panel and Black/White wire from ignition switch to fuse panel
Tachometer Reading Low
If tachometer reading is lower than normal, check these items:
Check for defective tachometer.
Check for faulty Black ground wire at instrument panel.
TURBO BOOST GAUGE (CAPRI)
Turbo Boost Gauge Always Reads Low
If turbo boost gauge always reads low, check these items:
Check boost gauge for open or damaged wires.
Check for defective boost sensing unit.
Check for defective boost gauge.
Check for blown 10-amp METER fuse in fuse panel.
Check for loose or corroded connections.
Page 2 of 5 MITCHELL 1 ARTICLE - INSTRUMENT PANEL 1991 ACCESSORIES & SAFETY EQUIPMENT Ford Motor Co. Switches
...
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B959286D2%2D3A85%2D4BFC%2D9C5C%2D
...

Back To Article
BRAKE SYST EM
1991-92 BRAKES Disc & Drum
DESCRIPTION & OPERATION
On Capri, vehicle braking is provided by front and rear disc brakes. Front and rear brakes are a full-floating, single piston design. The rear
caliper houses a self-adjusting parking brake.
On Festiva, vehicle braking is provided by front disc brakes and rear drum brakes. Rear brakes are a standard non-servo, self-en e r giz in g d e sign .
Front brakes are a full-floating, single piston design with caliper attached to steering knuckle.
BLEEDING BRAKE SYSTEM
BLEEDING PROCEDURES
Manual Bleeding
1. Exhaust vacuum from power brake unit by depressing brake pedal several times. Fill master cylinder with clean brake fluid. Install clear
vinyl bleeder hose onto first bleeder valve to be serviced. See BRAKE LINE BLEEDING SEQUENCE table. Place other end of hose in
clean transparent container.
2. Partially fill container with clean brake fluid. Open the bleeder valve 3/4 turn. Slowly depress brake pedal through its full travel. Close
bleeder valve and release pedal. Pump pedal several times to push air toward wheel cylinders. Repeat procedure until flow of brake
fluid is clear and shows no signs of air bubbles. Proceed to next bleeder valve in sequence and repeat procedure.
BRAKE LINE BLEEDING SEQUENCE
Pressure Bleeding
1. Exhaust vacuum from power brake unit by depressing brake pedal several times. Fill master cylinder with clean brake fluid. With
pressure bleeder at least 1/2 full, connect pressure bleeder to master cylinder using appropriate adaptor.
2. Install clear vinyl bleeder hose onto first bleeder valve to be serviced. See BRAKE LINE BLEEDING SEQUENCE table. Place other
end of hose in clean transparent container. Partially fill container with clean brake fluid. Open bleeder valve 1-2 turns. Allow fluid to
run until flow of fluid is clear and shows no signs of air bubbles. Proceed to next bleeder valve in sequence and repeat procedure.
Remove pressure bleeder and fill master cylinder with clean brake fluid.
ADJUSTMENTS
BRAKE PEDAL HEIGHT (FESTIVA)
1. Block wheels to prevent vehicle from rolling. Start engine and place transmission in Neutral. Fully release parking brake. Move carpet
and insulation away from firewall and brake pedal. Measure distance horizontally between upper center of brake pedal pad and firewall.
Distance should be 8.03-8.23" (204-209 mm).
2. If pedal height is incorrect, inspect pedal assembly for missing, worn or damaged bushings or for loose attaching bolts. Ensure firewall is
not distorted and pedal is not bent. If pedal height is still not within specifications, check brake pedal, booster or master cylinder for
correct and/or correctly installed parts
BRAKE PEDAL FREE PLAY (FESTIVA)
Pump brake pedal several to bleed vacuum from power brake booster. Gently depress brake pedal by hand and measure and measure play
before resistance is felt. Free play should be .16-.28" (4-7 mm). If free play is not within specifications, adjust brake pedal push rod.
BRAKE PEDAL FLOOR CLEARANCE
Capri
1. Move carpet and insulation away from floor board and brake pedal. With engine running and using Brake Pedal Effort Gauge (021-
00001), apply 132 lbs. (59.9 kg) of force to brake pedal. Measure distance from upper surface of brake pedal pad to floor board. If
distance is less than 3.27" (83 mm), inspect pedal assembly for missing, worn or damaged bushings or for loose attaching bolts.
2. Verify that floor board is not distorted and pedal is not bent. If pedal height is still not within specifications, check brake pedal, booster
or master cylinder for correct and/or correctly installed parts. Check for air in hydraulic system.
Festiva
Move carpet and insulation away from floor board and brake pedal. Using Brake Pedal Effort Gauge (021-00001) or equivalent, apply 132
lbs. (59.9 kg) of force to brake pedal. Measure distance from upper surface of brake pedal pad to floor board. If distance is less than 2.68" (68
mm), check for air in hydraulic system, faulty automatic adjusters or excessive shoe clearance.
POWER BRAKE UNIT PUSH ROD
Capri
ApplicationSequence
CapriRR, LF, LR & RF
FestivaRR, LR, RF & LF
NOTE:Check fluid level in m aster cylinder frequently during the bleeding sequence.
Page 1 of 12 MITCHELL 1 ARTICLE - BRAKE SYSTEM 1991-92 BRAKES Disc & Drum
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B7DD6473C%2DB5BB%2D4F20%2D9D70%2D
...

3. If voltage is not present or is less than 8 volts at starter solenoid terminal "S", malfunction in circuit to terminal "S" is indicated. Proceed
to the following tests.
IGNITION SWITCH TEST
1. Locate ignition switch connector under dash. Using a 12-volt test light or voltmeter, ensure voltage is present on Black/Yellow wire
when ignition switch is turned to RUN or ON position. This will verify proper operation of ignition switch.
2. If there is no voltage on Black/Yellow wire, the problem is either ignition switch or circuit between battery and ignition switch.
CLUTCH ENGAGE SWITCH (M/T) TEST
Unplug clutch engage switch from main wiring harness. Using an ohmmeter, check for continuity across switch terminals. Continuity should
exist when switch plunger is pushed in and should not exist when switch plunger is released. If clutch engage switch does not operate as
specified, replace switch.
NEUTRAL SAFETY SWITCH (A/T) TEST
Unplug neutral safety switch from main wiring harness. Using an ohmmeter, check for continuity across switch terminals "A" and "B". See Fig.
2 . Place transmission shift selector in Park or Neutral position. Continuity should exist between terminals "A" and "B". Continuity should not
exist in any other transmission shift selector positions. If switch does nor operate as specified, replace switch.

Fig. 2: Identifying Neutral Safety Switch Terminals

Courtesy of FORD MOTOR CO.
VOLTAGE DROP 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. 3
.
2. Using a digital voltmeter set on low scale, connect positive voltmeter lead to battery positive terminal. Connect negative lead to starter
solenoid terminal "M". See Fig. 3
.
3. Engage remote starter switch. Observe and record voltmeter reading. Voltmeter reading should be less than .5 volt. If voltage at terminal
"M" is greater than .5 volt, move negative voltmeter lead to solenoid terminal "B", and repeat test.
4. If voltage at terminal "B" is less than .5 volt, inspect solenoid cable connections and solenoid contacts for problem.
5 . Cl ean so l en o id t ermin al s "B", "M" an d "S", an d rep eat st ep s 1 ) through 4). If voltmeter still reads greater than .5 volt at termin al "M"
and less than .5 volt at terminal "B", solenoid contacts are bad.
6. If voltmeter reads greater than .5 volt at terminal "B", clean cables and connections at solenoid. If voltmeter still reads greater than .5
volt, check for poor positive battery cable connection or bad cable. Repair or replace as necessary.
7. To locate excessive voltage drop, move negative voltmeter lead toward battery, and check each connection point. When high voltmeter
reading is no longer present, last connection point is bad.
NOTE:Make all voltm eter connections at com ponent term inal rather than at cable or wire end.
Page 2 of 6 MITCHELL 1 ARTICLE - STARTER 1991 ELECTRICAL Starters
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B7DD6473C%2DB5BB%2D4F20%2D9D70%2D
...

Shift Lock ActuatorShift Interlock Systems
Side Marker LightsExterior Lights
SIR Coil Assembly (Clockspring)Air Bag Restraint System
Slip Ring (Clockspring)Air Bag Restraint System; Steering Column Switches
SRS Control ModuleAir Bag Restraint System
Starter MotorStarters
Starter Interrupt RelayStarters
Starter SolenoidStarters
Starter RelayStarters
Steering Wheel Position SensorAnti-Lock Brakes
StoplightsExterior Lights
Stoplight SwitchEngine Performance; Cruise Control Systems; Anti-Lock Brakes
Sun Roof ECUPower Sun Roof
Sun Roof MotorPower Sun Roof
Sun Roof Position SensorPower Sun Roof
TaillightsExterior Lights
Throttle Position (TP) SensorEngine Performance
Torque Converter Clutch Solenoid/SwitchEngine Performance
Traction Control SwitchAnti-Lock Brakes
Trailer Tow ConnectorExterior Lights
Trailer Tow RelayExterior Lights
Transmission/TransaxleEngine Performance
Transmission Control Module (TCM)Engine Performance; Starters
Transmission Range SensorStarters; Back-Up Lights; Engine Performance
Transmission Range SwitchBack-Up Lights; Engine Performance; Anti-Theft System
Turn Signal FlasherExterior Lights
Tu r n S ign a l Ligh t sExterior Lights
Twilight Sentinel SwitchHeadlight Systems; Daytime Running Lights
Vapor Canister Leak Detection PumpEngine Performance
Vehicle Control Module (VCM)Engine Performance
Vehicle Dynamic ModuleElectronic Suspension
Vehicle Speed Control ServoCruise Control Systems
Vehicle Speed SensorData Link Connectors; Analog Instrument Panels; Cruise Control
Systems; Electronic Suspension
Voltage RegulatorGenerators & Regulators
Water-In-Fuel SensorEngine Performance; Analog Instrument Panels
Wheel Speed SensorsAnti-Lock Brakes
Window Timer ModulePower Convertible Top
Windshield Intermittent Wiper RelayWiper/Washer Systems
Windshield Washer MotorWiper/Washer Systems
Wiper MotorWiper/Washer Systems
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00130983
Page 6 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
...

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
...

Fig. 7: Measuring Camshaft (1.3L Shown; 1.6L Similar)

Courtesy of FORD MOTOR CO.
CAMSHAFT END PLAY
1. Measure camshaft end play with thrust plate in position. Install dial indicator to front of head, with pointer on camshaft center. Pry
camshaft fully rear, and zero dial indicator.
2. Pry camshaft fully forward and note dial indicator reading. Standard end play is .002-.007" (.05-.18 mm) with a limit of .008" (.2 0 mm).
If end play exceeds specification on 1.3L engines, replace thrust plate and recheck end play. If end play is exceeded on 1.6L engines,
replace camshaft and/or cylinder head.
CAMSHAFT OIL SEAL
See CAMSHAFT
.
REAR MAIN BEARING OIL SEAL
Removal (1.3L)
Remove transaxle. See TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. Remove flywheel or
flexplate. Remove rear engine plate (if equipped). Remove rear main bearing oil seal retainer and press out rear main bearing oil seal.
Installation (1.3L)
Clean seal surface in retainer. Lubricate oil seal inside and outside. Install seal retainer on engine. Install seal in retainer with hollow side of
seal facing engine. Using Rear Main Seal Installer (T87C-6701-A), install rear main bearing oil seal. To complete installation, reverse removal
procedure.
Removal (1.6L)
Remove transaxle. See TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. Remove clutch cover and
disc (if equipped). Remove flywheel or flexplate. Remove rear seal using Seal Remover (T78P-3504-N).
Installation (1.6L)
Lubricate oil seal lip with engine oil. Using Rear Main Seal Installer (T87C-6701-A) and Screw Set (T90P-6701-AH), install rear main
Page 10 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
...

3. If voltage is not present or is less than 8 volts at starter solenoid terminal "S", malfunction in circuit to terminal "S" is indicated. Proceed
to the following tests.
IGNITION SWITCH TEST
1. Locate ignition switch connector under dash. Using a 12-volt test light or voltmeter, ensure voltage is present on Black/Yellow wire
when ignition switch is turned to RUN or ON position. This will verify proper operation of ignition switch.
2. If there is no voltage on Black/Yellow wire, the problem is either ignition switch or circuit between battery and ignition switch.
CLUTCH ENGAGE SWITCH (M/T) TEST
Unplug clutch engage switch from main wiring harness. Using an ohmmeter, check for continuity across switch terminals. Continuity should
exist when switch plunger is pushed in and should not exist when switch plunger is released. If clutch engage switch does not operate as
specified, replace switch.
NEUTRAL SAFETY SWITCH (A/T) TEST
Unplug neutral safety switch from main wiring harness. Using an ohmmeter, check for continuity across switch terminals "A" and "B". See Fig.
2 . Place transmission shift selector in Park or Neutral position. Continuity should exist between terminals "A" and "B". Continuity should not
exist in any other transmission shift selector positions. If switch does nor operate as specified, replace switch.

Fig. 2: Identifying Neutral Safety Switch Terminals

Courtesy of FORD MOTOR CO.
VOLTAGE DROP 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. 3
.
2. Using a digital voltmeter set on low scale, connect positive voltmeter lead to battery positive terminal. Connect negative lead to starter
solenoid terminal "M". See Fig. 3
.
3. Engage remote starter switch. Observe and record voltmeter reading. Voltmeter reading should be less than .5 volt. If voltage at terminal
"M" is greater than .5 volt, move negative voltmeter lead to solenoid terminal "B", and repeat test.
4. If voltage at terminal "B" is less than .5 volt, inspect solenoid cable connections and solenoid contacts for problem.
5 . Cl ean so l en o id t ermin al s "B", "M" an d "S", an d rep eat st ep s 1 ) through 4). If voltmeter still reads greater than .5 volt at termin al "M"
and less than .5 volt at terminal "B", solenoid contacts are bad.
6. If voltmeter reads greater than .5 volt at terminal "B", clean cables and connections at solenoid. If voltmeter still reads greater than .5
volt, check for poor positive battery cable connection or bad cable. Repair or replace as necessary.
7. To locate excessive voltage drop, move negative voltmeter lead toward battery, and check each connection point. When high voltmeter
reading is no longer present, last connection point is bad.
NOTE:Make all voltm eter connections at com ponent term inal rather than at cable or wire end.
Page 2 of 6 MITCHELL 1 ARTICLE - STARTER 1991 ELECTRICAL Starters
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B959286D2%2D3A85%2D4BFC%2D9C5C%2D
...

Back To Article
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.
Page 1 of 3 MITCHELL 1 ARTICLE - D - ADJUSTMENTS 1991 ENGINE PERFORMANCE Ford/Mercury - On-Vehicle Adjustments
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B959286D2%2D3A85%2D4BFC%2D9C5C%2D
...

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.
Page 2 of 3 MITCHELL 1 ARTICLE - D - ADJUSTMENTS 1991 ENGINE PERFORMANCE Ford/Mercury - On-Vehicle Adjustments
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B959286D2%2D3A85%2D4BFC%2D9C5C%2D
...

Connect BOB. Remove dust cover from BP sensor, located on passenger side cowl. Turn ignition on. Connect vacuum pump to BP sensor.
Measure voltage between pins BP and SIGRTN on BOB while applying vacuum to BP sensor. See BAROMETRIC PRESSURE SENSOR
OUTPUT VOLTAGE . Replace BP sensor if voltage is not as specified.
BAROMETRIC PRESSURE SENSOR OUTPUT VOLTAGE
BRAKE ON-OFF (BOO) SWITCH
Unplug connector from BOO switch at brake pedal. Connect ohmmeter to switch terminals. With pedal released, ohmmeter should indicate no
continuity. Ohmmeter should indicate continuity with pedal depressed.
CLUTCH ENGAGE SWITCH (CES)
Unplug connector from CES switch at clutch pedal. Connect ohmmeter to switch terminals. With pedal released, ohmmeter should indicate
continuity. Ohmmeter should indicate no continuity with pedal depressed.
CRANKSHAFT POSITION SENSOR (CPS) (1.3L)
Unplug 3-wire connector from distributor. Measure resistance between CPS terminal on distributor (Yellow/Blue wire) and ground. Replace
CPS if resistance is not 210-250 ohms.
CYLINDER IDENTIFICATION (CID) SENSOR (1.6L)
Turn ignition off. Connect BOB, leaving ECA connected. Turn ignition on, but DO NOT start engine. Measure voltage at BOB pin No. 34
(Yellow wire). Volt- meter should indicate less than one volt or more than 10 volts. Start engine and run at idle. Voltmeter should indicate 3-
5 volts. Replace CID sensor if voltage is not as specified.
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
1. Remove ECT sensor. ECT sensor is threaded into top of lower intake manifold on 1.3L, and on underside of intake manifold on 1.6L.
Place ECT sensor and thermometer into container of coolant.
2. Connect ohmmeter to coolant temperature sensor terminals. Cool or heat container. Note resistance at specified temperatures. See
ENGINE COOLANT TEMPERATURE SENSOR RESISTANCE
. Replace ECT sensor if resistance is not within specification.
ENGINE COOLANT TEMPERATURE SENSOR RESISTANCE
EXHAUST GAS OXYGEN (EGO) SENSOR
With engine at normal operating temperature, unplug connector from EGO in exhaust manifold. Measure voltage between EGO sensor
terminal and ground. Voltage should increase with increasing engine speed and decrease with decreasing engine speed. Voltage at idle should
fluctuate within a range of .2-.8 volt.
IDLE SW ITCH (1.6L)
Unplug connector from throttle position sensor on throttle body. Connect ohmmeter to switch terminals IDL and ground (Green/Orange and
Blue/Yellow wires on mating connector). Resistance must be less than 5 ohms with throttle in idle position, and more than 10,000 ohms with
throttle pedal depressed.
KNOCK SENSOR (1.6L TURBO)
Disconnect vacuum hose at distributor. Connect timing light. Start engine and record ignition timing. Tap intake plenum with a plastic mallet.
Knock sensor is okay if timing retards. If timing does not retard, check associated circuitry and components. See TIMING CONTROL
SYSTEMS under IGNITION SYSTEM.
NEUTRAL GEAR SWITCH (M/T)
1. Unplug connector near transmission. Place transmission in Neutral. Resistance across switch should be infinite.
2. Place transmission in any other gear. Resistance across switch should be zero ohms. If necessary, replace switch.
Vacuum In. Hg.(1) Voltage
03.84
53.36
102.66
151.93
201.26
25.58
(1)Voltage may vary by plus or minus 15 percent.
Temperature °F (°C)Ohms
-4 (-20)14,600-17,800
68 (20)2200-2700
104 (40)1000-1300
140 (60)500-650
176 (80)290-350
NOTE:A steady voltage higher than .55 volt indicates a continuously rich condition. A steady voltage lower
than .55 volt indicates a continuously lean condition.
Page 2 of 7 MITCHELL 1 ARTICLE - I - SYSTEM/COMPONENT TESTS 1991 ENGINE PERFORMANCE Ford Motor Co. - Ford/Merc
...
3/10/2009 http://www.eautorepair.net/app/PrintItems.asp?S0=2097152&S1=0&SG=%7B7DD6473C%2DB5BB%2D4F20%2D9D70%2D
...