1991 FORD FESTIVA Service Manual

1991 Ford Festiva
Service Manual
courtesy of www.bntbtc.com
www.bntbtc.com/festiva

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INST RUMENT PANEL
1991 ACCESSORIES & SAFET Y EQUIPMENT Ford Motor Co. Switches & Instrum ent Panels - Standard
DESCRIPTION & OPERATION
Instrument panel on Capri contains a speedometer, tachometer, fuel, water temperature, oil pressure and voltmeter gauges. A boost gauge is
incorporated into the tachometer on turbo models. Instrument panel is equipped with indicator/warning lights for charging system, air b ag,
manual shift, seat belt, turn signals, high beam and brakes. A CHECK ENGINE light, located on instrument panel, illuminates if a
computerized engine control fault occurs with engine running.
Instrument panel on Festiva contains a speedometer, fuel and water temperature gauges. Instrument panel is equipped with indicator/warning
lights for charging system, oil pressure, seat belt, rear defogger, turn signals, high beam and brakes. A CHECK ENGINE light, located on
instrument panel, illuminates if a computerized engine control fault occurs with engine running.
TROUBLE SHOOTING
FUEL GAUGE
Fuel Gauge Always Reads Empty
If fuel gauge always reads empty, check these items:
Check fuel gauge for open or damaged wires.
Check for open ground at fuel gauge sending unit.
Check for defective fuel sending unit.
Check for defective fuel gauge.
Check for defective instrument panel voltage regulator (Festiva).
Check for blown 10-amp METER fuse in fuse panel.
Check for open in Black/Yellow power feed wire from fuse panel instrument panel.
Check for fuel tank float full of fuel (sunk).
Fuel Gauge Always Reads Full
If fuel gauge always reads full, check these items:
Check for fuel gauge Yellow wire shorted to ground.
Check for defective fuel sending unit.
Check for defective fuel gauge.
Check for defective instrument panel voltage regulator (Festiva).
Fuel Gauge Inaccurate
If fuel gauge is inaccurate, check these items:
Check for faulty (loose or corroded) wire connections.
Check for defective fuel sending unit.
Check for defective instrument panel voltage regulator (Festiva).
TEMPERATURE GAUGE
Temperature Gauge Always Reads Cold
If temperature gauge always reads cold, check these items:
Check temperature gauge for open wire.
Check for defective temperature sender.
Check for defective temperature gauge.
Check for defective instrument panel voltage regulator (Festiva).
Check for blown 10-amp METER fuse in fuse panel.
Check for open in Black/Yellow power feed wire from fuse panel to instrument panel.
Temperature Gauge Always Reads Hot
CAUT ION: On 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 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:Ensure continuity exists between chassis ground and Black wire of instrum ent panel connector,
especially if fault exists in m ultiple gauge circuits. See appropriate chassis wiring diagram in the
WIRING DIAGRAMS Section.
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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.
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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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DEFOGGER - REAR WINDOW
1991 ACCESSORIES & SAFET Y EQUIPMENT Rear Window Defoggers - Rear Window
DESCRIPTION & OPERATION
The rear window defogger consists of an electrical grid on rear window glass. The rear window defogger switch is located in the instrument
cluster bezel. On Capri, the switch is a push type and includes a small indicator light in the switch to indicate when rear defogger is on. On
Festiva, the switch is a rocker type and includes a small indicator light in instrument cluster to indicate when rear defogger is on.
On Capri, the defogger circuit includes a 10-amp METER fuse which receives battery power from ignition switch and a 20-amp HTD B-
LIGHT fuse which has battery power at all times. The wire from the METER fuse goes to the rear defogger switch and then to the relay. The
wire from the HTD B-LIGHT fuse goes to the rear defogger relay and then to the grid. See Fig. 1
.

Fig. 1: Rear Window Defogger Wiring Diagram (Capri)

Courtesy of FORD MOTOR CO.
On Festiva, the defogger circuit includes a 15-amp DEFOG fuse which receives battery power from ignition switch. The wire from the fuse
goes to the rear defogger switch and then to the grid. The defogger circuit does not contain a relay. See Fig. 2
.
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Fig. 2: Rear Window Defogger Wiring Diagram (Festiva)
Courtesy of FORD MOTOR CO.
TROUBLE SHOOTING
DEFOGGER DOES NOT OPERATE
Blown fuse(s) or poor contact. Defogger switch defective. Defogger relay defective. Poor connections. Broken wire. Defective grid filament.
INDICATOR LIGHT DOES NOT WORK BUT DEFOGGER DOES WORK
Open circuit from rear defogger switch to instrument panel (Festiva). Defective light bulb. Defective flexible circuit on instrument cluster.
TESTING
SYSTEM TESTING
1. Ensure all in-line fuses or circuit breakers are okay. Turn ignition and control switches to ON position. Glass should feel warm after a
few min u t es.
2. If glass is not warm, use a test light or voltmeter to check for battery voltage at grid feed wire. If voltage is not correct, check wiring
harness, control switch and flexible circuit on instrument cluster. See FILAMENT TESTING.
REAR DEFOGGER SWITCH TESTING
Capri
Remove rear defogger switch. Using an ohmmeter, ensure continuity exists between terminals listed in table at specified switch positions. If
switch does not test as specified, replace rear defogger switch. See REAR DEFOGGER SWITCH CONTINUITY (CAPRI) table.
REAR DEFOGGER SWITCH CONTINUITY (CAPRI)
Festiva
Remove rear defogger switch. Using an ohmmeter, ensure continuity exists between terminals listed in table at specified switch positions. If
switch does not test as specified, replace rear defogger switch. See REAR DEFOGGER SWITCH CONTINUITY (FESTIVA) table. See Fig.
3 .
REAR DEFOGGER SWITCH CONTINUITY (FESTIVA)

Fig. 3: Identifying Rear Defogger Switch Terminals (Festiva)

Courtesy of FORD MOTOR CO.
REAR DEFOGGER RELAY TESTING
Unplug rear window defroster relay. Relay is located in left rear corner of luggage compartment. Apply battery voltage and ground to NOTE:On Capri, if indicator light is not working, replace switch.
TerminalPositionContinuity
BLK/YEL - BLK/WHTOffNo
BLK/YEL - BLK/WHTOnYes
TerminalPositionContinuity
BLK/WHT - BLK/BLUOffNo
BLK/WHT - BLK/BLUOnYes
RED/GRN - BLKOffNo
RED/GRN - BLKOnYes
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