1991 FORD FESTIVA Service Manual

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D - ADJUSTMENTS
1991 ENGINE PERFORMANCE Ford/Mercury - On-Vehicle Adjustm ents
ADJUSTMENTS
ENGINE MECHANICAL
Before beginning any on-vehicle adjustments to fuel or ignition systems, ensure engine mechanical condition is okay.
VALVE CLEARANCE
IGNITION TIMING
CAPRI
1. Place automatic transmission in Park or manual transmission in Neutral. Disconnect and plug hoses attached to vacuum diaphragm
assembly on distributor. Connect tachometer and timing light. Turn off all electrical loads.
2. Start engine, and warm it to operating temperature. Ensure idle speed is set to specification, adjusting if necessary. See IDLE SPEED &
MIXTURE . Determine initial timing. See IGNITION TIMING table. If base timing is not correct, loosen distributor mounting bolts
and rotate distributor until marks align. Tighten bolts to 14-18 ft. lbs. (19-25 N.m).
3. Increase engine RPM while observing timing light. Verify ignition timing advances. For Turbo models, go to step 5). For non-Turbo
models, continue with step 4).
4. On non-Turbo models, apply 16 in. Hg vacuum to chamber "A". Verify timing advances by 26-30 degrees. Remove vacuum source from
chamber "A". Apply 8 in. Hg vacuum to chamber "B" while observing timing. Verify timing advances by 3-7 degrees. Stop engine, and
remove test equipment.
5. On Turbo models, apply 20 in. Hg vacuum to advance diaphragm. Verify timing advances by 13-17 degrees. Disconnect vacuum source.
Apply 8 psi (.6 kg/cm
2 ) pressure to advance diaphragm. Verify timing retards by 3-7 degrees. Stop engine, and remove test equipment.
FESTIVA
1. Place manual transmission in Neutral or automatic transmission in Park. Turn all accessories off. Locate one-wire STI (Black) connector
near master cylinder. Using a jumper wire, connect STI terminal to ground. See Fig. 1
. Connect timing light and tachometer.

Fig. 1: Locating Self
-Test Input (STI) Connector
Courtesy of FORD MOTOR CO.
2. Start engine, and warm to operating temperature. Ensure idle speed is set to specification, adjusting if necessary. See IDLE SPEED &
MIXTURE .
3. Check initial timing. White timing mark should align with white mark on crankshaft pulley. If marks do not align, loosen distributor
mounting bolts and rotate distributor until marks align. Tighten bolts to 14-18 ft. lbs. (19-25 N.m).
4. Remove jumper wire. Increase engine RPM, and verify ignition timing advances beyond initial setting. Stop engine, and remove test
equipment.
IGNITION TIMING NOTE:All m odels are equipped with hydraulic lash adjusters. No adjustm ents are required.
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IDLE SPEED & MIXTURE
IDLE MIXTURE
IDLE SPEED
1. Turn off all accessories. Place automatic transmission in Park or manual transmission in Neutral. Set parking brake. Connect tachometer
to engine. Warm engine to normal operating temperature. Connect a jumper wire between single-wire STI test connector (Green on
Capri; Black on Festiva) and ground. See Fig. 1
.
2. Locate idle speed control by-pass air (ISC-BPA) valve on intake manifold. Remove cap, and adjust idle speed to specification by turning
idle air adjust screw on ISC-BPA valve. See Fig. 2
. Remove jumper wire.
IDLE RPM

Fig. 2: Locating Idle Air Adjust Screw

Courtesy of FORD MOTOR CO.
THROTTLE POSITION SWITCH (TP)
CAPRI
Throttle position sensor is preset at factory. No adjustment is required.
FESTIVA
1. Ensure idle speed and ignition timing are adjusted to specification. Stop engine. Disconnect negative battery cable.
2. Unplug TP connector at throttle body. Insert appropriate feeler gauge between throttle stop screw and stop lever. Check for continuity
between specified terminals on TP connector. See TP ADJUSTMENT table.
3. To adjust, loosen TP attaching screws. Connect ohmmeter between terminals IDL and TL. See Fig. 3
. Insert a .020" (.5 mm) feeler
gauge between throttle stop screw and stop lever.
4. Rotate TP until ohmmeter indicates continuity. Insert a .028" (.7 mm) thickness gauge between stop screw and stop lever. Ohmmeter
should indicate no continuity. If ohmmeter indicates continuity, repeat adjustment procedure.
ApplicationAuto. Trans.Man. Trans.
1.3L9-11 @ 8509-11 @ 700
1.6L Non-Turbo1-3 @ 8500-4 @ 850
1.6L Turbo10-14 @ 8500-4 @ 850
NOTE:Idle m ixture is controlled by ECA and is not adjustable.
ApplicationAuto. Trans.Man. Trans.
1.3L830-870680-720
1.6L800-900800-900
CAUT ION: DO NOT tam per with throttle stop screw at throttle lever. Doing so m ay result in dam age to throttle
body.
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TP ADJUSTMENT

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

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

Fig. 1: Engine Code Location

Courtesy of FORD MOTOR CO.
MODEL YEAR VIN CODE APPLICATION
ModelBody CodeEng. Type (1) Eng. IDFuel Sys.Ign. Sys.
Capri011.6LZPFIMagnetic
Capri011.6L Turbo6 (2) PFIMagnetic
Festiva05, 06, 071.3LHPFIMagnetic
(1)See vehicle engine code label affixed to timing belt cover, See Fig. 1 .
(2)XR2 model W/intercooled turbo.
VIN CodeModel Year
L1990
M1991
Copyr ight 2009 Mit chell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00022694
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EMISSION CONT ROL APPLICAT IONS
Em ission Applications - Ford Motor Co. - Im ports (1968-97)
EMISSION APPLICATIONS
1968-97 FORD MOTOR CO. - IMPORTS
Year, Model, Engine & Fuel System(1) Emission Control Systems & Devices
1968-69
Cortina 1.6L Carb.PCV, AIS
1970
Capri & Cortina (Except GT) 1.6L Carb.PCV, ACL, (2) EVAP, SPK,
EVAP-VC, SPK-DDD, DCLV
Cortina GT 1.6L Carb.PCV, (2)EVAP, AIS,
EVAP-VC
1971
Capri 1.6L Carb.PCV, ACL, EVAP, SPK,
EVAP-VC, SPK-DDD, DCLV
Pantera 5.8L V8 Carb.PCV, EVAP, SPK,
EVAP-VC, SPK-DDD
1972
Capri 1.6L Calif. Carb.PCV, ACL, EVAP, SPK,
EVAP-VC, SPK-DDD, SPK-TCS, DCLV
1.6L Fed. Carb.PCV, ACL, EVAP, SPK,
EVAP-VC, SPK-DDD, DCLV
2.0L Calif. Carb.PCV, ACL, EVAP, SPK,
EVAP-VC, SPK-DDD, DCLV
2.0L Fed. Carb.PCV, ACL, EVAP, SPK,
EVAP-VC, SPK-DDD, DCLV
2.6L Carb.PCV, ACL, EVAP, SPK,
EVAP-VC, SPK-DDD, DCLV
Courier 1.8L Calif. Carb.PCV, EVAP, AIS,
EVAP-VC, CRV
Fed. Carb.PCV, EVAP, SPK,
EVAP-VC, SPK-DPD
Pantera 5.8L V8 Carb.PCV, EVAP, SPK,
EVAP-VC, SPK-DDD
1973
Capri 2.0L Calif. Carb.PCV, ACL, EVAP, SPK,
EVAP-VC, SPK-DDD, DCLV
2.0L Fed. Carb.PCV, ACL, EVAP, SPK,
EVAP-VC, SPK-DDD, SPK-TCS, DCLV
2.6L A/T Carb.PCV, ACL, EVAP, SPK,
EVAP-VC, SPK-DDD
2.6L M/T Carb.PCV, ACL, EVAP, SPK,
EVAP-VC, SPK-DDD, SPK-TCS, DCLV
Courier 1.8L Calif. Carb.PCV, EVAP, AIS,
EVAP-VC, CRV
Fed. Carb.PCV, EVAP, SPK,
EVAP-VC, SPK-DPD, CRV
Pantera 5.8L V8 Carb.PCV, EVAP, SPK,
EVAP-VC, SPK-DDD
1974
Capri 2.0L Carb.PCV, ACL, EVAP, EGR, AIS,
EVAP-VC, DCLV
2.8L Carb.PCV, ACL, EVAP, (3) EGR, (2) AIS,
EVAP-VC, DCLV
Courier 1.8L Carb.PCV, EVAP, AIS,
EVAP-VC, CRV
Pantera 5.8L V8 Carb.PCV, ACL, EVAP, SPK,
EVAP-VC, SPK-DDD
1975
Capri II 2.3L Carb.PCV, ACL, EVAP, (2) OC, (2) FR, EGR, (3)SPK,
AIS,
EVAP-VC, SPK-DV, DCLV
2.8L Carb.PCV, ACL, EVAP, OC, FR, EGR, (2)SPK, AIS,
EFE,
EVAP-VC,
(4) SPK-CSSA, SPK-DDD, EFE-HCV, (5)
DCLV
Courier 1.8L Carb.PCV, EVAP, AP,
EVAP-VC, CRV
1976
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Capri II 2.3L Carb.PCV, ACL, EVAP, (2) OC, (2) FR, EGR, (12)SPK,
AIS,
EVAP-VC,
(12)SPK-DV, DCLV
2.8L Carb.PCV, ACL, EVAP, OC, FR, EGR, (10)SPK, AIS,
EFE,
EVAP-VC,
(13) SPK-CSSA, SPK-DDD, (10)SPK-DV,
EFE-HCV,
(4) DCLV
Courier 1.8L Carb.PCV, ACL, EVAP, (12) OC, (12) FR, (14)EGR,
AIS,
EVAP-VC,
(13) CRV, (11) TR
1977
Capri II 2.3L & 2.8L Carb.PCV, ACL, EVAP, (6) OC, (6)FR, EGR, SPK, AIS,
EFE,
EVAP-VC, SPK-CSSA, SPK-DDD, EFE-HCV,
DCLV
Courier 1.8L CarbPCV, ACL, EVAP, (2) OC, (2) FR, EGR, SPK, AIS,
EVAP-VC, SPK-DV, DCLV,
(2) TOS
1978
Capri II 2.3L & 2.8L Carb.PCV, ACL, EVAP, (7) OC, (7)FR, EGR, SPK, AIS,
EFE,
EVAP-VC, SPK-CSSA, SPK-DDD, EFE-HCV,
DCLV
Courier 1.8L Carb.PCV, ACL, EVAP, (2) OC, (2) FR, EGR, SPK, AIS,
EVAP-VC, SPK-DV, AIS-ACV, DCS
2.3L Carb.PCV, EVAP, (2) OC, (2) FR, EGR, SPK,
EVAP-VC
1979
Courier 2.0L & 2.3L Carb.PCV, ACL, EVAP, OC, FR, EGR, SPK, (2) AP, (4)
PAIR,
EVAP-VC,
(8) SPK-ITCS, DCS
Fiesta 1.6L Carb.PCV, ACL, EVAP, OC, FR, EGR, AIS,
EVAP-VC
1980
Courier 2.0L & 2.3L Carb.PCV, ACL, EVAP, OC, FR, EGR, (8) SPK, (2)AP,
(4) PAIR,
EVAP-VC, DCS
Fiesta 1.6L Carb.PCV, ACL, EVAP, OC, FR, EGR, AP,
EVAP-VC
1981
Courier 2.0L & 2.3L Carb.PCV, ACL, EVAP, OC, FR, EGR, (9) SPK, AP, (4)
PAIR,
EVAP-VC,
(8) SPK-DV, DCS
1982
Courier 2.0L & 2.3L Carb.PCV, ACL, EVAP, OC, FR, EGR, SPK, AIS,
EVAP-VC, DCS
1985-86
Merkur XR4Ti 2.3L MFIPCV, EVAP, TWC, FR, EGR, O2S, CEC, MIL,
EVAP-VC, EGR-C
1987
Merkur XR4Ti 2.3L MFIPCV, EVAP, TWC, FR, EGR, O2S, CEC, MIL,
EVAP-VC
1988
Festiva 1.3L Carb.PCV, ACL, EVAP, OC, FR, EGR, AIS, O2S, CEC,
(2) MIL,
EVAP-VC
Merkur Scorpio 2.9L V6 MFIPCV, EVAP, TW C, FR, EGR, (10)AIS, O2S, CEC,
MIL,
EVAP-VC
Merkur XR4Ti 2.3L MFIPCV, EVAP, TWC, FR, EGR, O2S, CEC, MIL,
EVAP-VC
Tracer 1.6L MFIPCV, EVAP, TWC, FR, SPK, O2S, CEC, MIL,
EVAP-VC, EVAP-CPCV, EVAP-VSV, VA
1989
Festiva 1.3L 2-Bbl.PCV, ACL, EVAP, OC, FR, EGR, PAIR, O2S,
CEC, EFE, MIL,
EVAP-VC, EGR-PS, PAIR-ACV
Festiva 1.3L MFIPCV, EVAP, TWC, FR, SPK, O2S, CEC, MIL,
EVAP-VC, EVAP-CPCV, VA
Merkur Scorpio 2.9L V6 MFI
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PCV, EVAP, TWC, FR, EGR, (10)AP, O2S, CEC,
MIL,
EVAP-VC

Merkur XR4Ti 2.3L MFIPCV, EVAP, TWC, FR, EGR, O2S, CEC, MIL,
EVAP-VC
Tracer 1.6L MFIPCV, EVAP, TWC, FR, SPK, O2S, CEC, MIL,
EVAP-VC, EVAP-CPCV, EVAP-VSV, VA
1990
Tracer 1.8L MFIPCV, EVAP, TWC, FR, SPK, O2S, CEC, MIL,
EVAP-VC, EVAP-CPCV, SPK-CC
Festiva 1.3L MFIPCV, EVAP, TWC, FR, SPK, O2S, CEC, MIL,
EVAP-VC, EVAP-CPCV, SPK-CC
1991
Capri 1.6L MFI Non-Turbo & TurboPCV, EVAP, TWC, FR, SPK, O2S, CEC, MIL

Tracer 1.8L MFIPCV, EVAP, TWC, FR, SPK, O2S, CEC, MIL,
EVAP-VC, EVAP-CPCV, SPK-CC
1.9L MFIPCV, ACL, EVAP, TWC, FR, (15)EGR, SPK,
O2S, CEC, MIL,
EVAP-VC, EVAP-PVS, EGR-SOL, SPK-CC
Festiva 1.3L MFIPCV, EVAP, TWC, FR, SPK, O2S, CEC, MIL,
EVAP-VC
1992
Capri 1.6L MFI Non-Turbo & TurboPCV, EVAP, TWC, FR, SPK, O2S, CEC, MIL,
EVAP-VC, EVAP-CPCS, EVAP-CPCV
Tracer 1.8L 4-Cyl. MFIPCV, EVAP, TWC, FR, SPK, O2S, CEC, MIL,
EVAP-VC, EVAP-CPCS, SPK-CC
1.9L 4-Cyl. MFI-MAFPCV, EVAP, TW C, FR, (15)EGR, SPK, O2S,
CEC, MIL,
EVAP-VC, EVAP-CPCS, EGR-SOL, SPK-CC
Festiva 1.3L MFIPCV, EVAP, TWC, FR, SPK, O2S, CEC, MIL,
EVAP-CPCS, EVAP-CPCV, SPK-CC
1993
Capri 1.6L MFI Non-Turbo & TurboPCV, EVAP, TWC, FR, SPK, O2S, CEC, MIL,
EVAP-VC, EVAP-CPCS, EVAP-CPCV
Tracer 1.8L 4-Cyl. MFIPCV, EVAP, TWC, FR, SPK, O2S, CEC, MIL,
EVAP-VC, EVAP-CPCS, SPK-CC
1.9L 4-Cyl. MFI-MAFPCV, EVAP, TWC, FR, (15)EGR, SPK, HO2S,
CEC, MIL,
EVAP-VC, EVAP-CPCS, EGR-SOL, SPK-CC
Festiva 1.3L MFIPCV, EVAP, TWC, FR, SPK, O2S, CEC, MIL,
EVAP-VC, EVAP-CPCS, EVAP-CPCV, SPK-CC
1994
Aspire 1.3L SFIPCV, EVAP, TWC, FR, EGR, SPK, O2S, CEC,
MIL,
EVAP-VC, EVAP-CPCS, EVAP-CPCV, EGR-SOL,
SPK-CC
Capri 1.6L MFI Non-Turbo & TurboPCV, EVAP, TWC, FR, SPK, O2S, CEC, MIL,
EVAP-VC, EVAP-CPCS, EVAP-CPCV, SPK-CC
Tracer 1.8L 4-Cyl. SFIPCV, EVAP, TWC, FR, SPK, O2S, CEC, MIL,
EVAP-VC, EVAP-CPCS, SPK-CC
1.9L 4-Cyl. SFI-MAFPCV, EVAP, TWC, FR, (15)EGR, SPK, HO2S,
CEC, MIL,
EVAP-VC, EVAP-CPCS, EGR-SOL, SPK-CC
1995
Aspire 1.3L SFIPCV, EVAP, TWC, FR, EGR, SPK, O2S, CEC,
MIL,
EVAP-VC, EVAP-CPCS, EVAP-CPCV, EGR-SOL,
SPK-CC
Tracer 1.8L 4-Cyl. SFIPCV, EVAP, TWC, FR, SPK, O2S, CEC, MIL,
EVAP-VC, EVAP-CPCS, SPK-CC
1.9L 4-Cyl. SFI-MAFPCV, EVAP, TWC, FR, (15)EGR, SPK, HO2S,
CEC, MIL,
EVAP-VC, EVAP-CPCS, EGR-SOL, SPK-CC
1996
Aspire 1.3L SFIPCV, EVAP, TWC, FR, EGR, SPK, HO2S, CEC,
MIL,
EVAP-CPCS, EVAP-VC, EGR-CVS
1997
Aspire 1.3L SFIPCV, EVAP, TWC, FR, EGR, SPK, HO2S, CEC,
MIL,
EVAP-CKV, EVAP-CPCS, EVAP-VC, EGRB, EGR-
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ABBREVIATIONS
ACL
Air Cleaner (Thermostatic Air Cleaner)
AIS
Air Injection System
AIS-ACV
AIS Air Control Valve
AIS-AMV
AIS Air Management Valve
AIS-ASS
AIS Air Switching Solenoid
AIS-ASV
AIS Air Switching Valve
AIS-BPV
AIS By-Pass Valve
AIS-CKV
AIS Check Valve
AIS-CV
AIS Combination Valve
AIS-DV
AIS Diverter Valve
AIS-RV
AIS Relief Valve
AIS-SOL
AIS Solenoid
AIS-SV
AIS Solenoid Valve
CS, EGR-PS, SPK-CC
(1)For quick reference, major emission control systems and devices are listed in bold type; components and other related devices are
listed in light type.
(2)California only.
(3)A/T only.
(4)Federal only.
(5)M/T only.
(6)2.8L & California 2.3L.
(7)Except Federal models.
(8)2.0L only.
(9)2.3L California only.
(10)M/T only.
(11)California with M/T.
(12)Some models.
(13)Federal with M/T.
(14)M/T models with engine family VBT.
(15)Electronically controlled.
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