1991 FORD FESTIVA engine

"J"
J/B
Junction Block
"K"
KAPWR
Keep Alive Power
k/ohms
kilo-ohms (1000 ohms)
kg
Kilograms (weight)
kg/cm
2
Kilograms Per Square Centimeter
KM/H
Kilometers Per Hour
KOEO
Key On, Engine Off
KOER
Ke y On , E n gin e R u n n in g
KS
Knock Sensor
kW
Kilowatt
kV
Kilovolt
"L"
L
Liter
lbs. (Lbs. when used in table)
Pounds
LCD
Liquid Crystal Display
L/D
Light Duty
LDP
Leak Detection Pump (Part of EVAP system.)
LED
Light Emitting Diode
LH
Left Hand
"M"
Page 9 of 15 MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations
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SBC
Single Bed Converter
SBEC
Single Board Engine Controller
SES
Service Engine Soon
SFI
Sequential (Port) Fuel Injection
SIL
Shift Indicator Light
SIR
Supplemental Inflatable Restraint
SOHC
Single Overhead Cam
SOL or Sol.
Solenoid
SPFI
Sequential Port Fuel Injection
SPK
Spark Control
SPOUT
Spark Output
SRI
Service Reminder Indicator
SRS
Supplemental Restraint System (Air Bag)
STAR
Self-Test Automatic Readout
STO
Self-Test Output
SUB-O
2
Sub Oxygen Sensor
Sw.
Switch
Sys.
System
"T"
TAB
Thermactor Air By-Pass
TAC
Page 13 of 15 MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations
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Back To Article
GENERAL INFORMATION
T rouble Shooting - Basic Procedures
* PLEASE READ THIS FIRST *
ACCESSORIES & ELECTRICAL
CHARGING SYSTEM TROUBLE SHOOTING
BASIC CHARGING SYSTEM TROUBLE SHOOTING CHART NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
CONDITION & POSSIBLE CAUSECORRECTION
Vehicle Will Not Start
Dead batteryCheck battery cells, alternator
belt tension and alternator
output
Loose or corroded battery connectionsCheck all charging system
connections
Ignition circuit or switch malfunctionCheck and replace as necessary
Alternator Light Stays On With Engine Running
Loose or worn alternator drive beltCheck alternator drive tension
and condition, See Belt
Adjustment in TUNE-UP article
in the TUNE-UP section
Loose alternator wiring connectionsCheck all charging system
connections
Short in alternator light wiringSee Indicator Warning Lights in
STANDARD INSTRUMENTS
in the ACCESSORIES &
EQUIPMENT section
Defective alternator stator or diodesSee Bench Tests in
ALTERNATOR article
Defective regulatorSee Regulator Check in
ALTERNATOR article
Alternator Light Stays Off With Ignition Switch ON
Blown fuseSee WIRING DIAGRAMS
Defective alternatorSee Testing in ALTERNATOR
article
Defective indicator light bulb or socketSee Indicator Warning Lights in
STANDARD INSTRUMENTS
in the ACCESSORIES &
EQUIPMENT section
Alternator Light Stays OFF With Ignition Switch ON
Short in alternator wiringSee On-Vehicle Tests in
ALTERNATOR article
Defective rectifier bridgeSee Bench Tests in
ALTERNATOR article
Lights or Fuses Burn Out Frequently
Defective alternator wiringSee On-Vehicle Tests in
ALTERNATOR article
Defective regulatorSee Regulator Check in
ALTERNATOR article
Defective batteryCheck and replace as necessary
Ammeter Gauge Shows Discharge
Loose or worn drive beltCheck alternator drive belt
tension and condition. See Belt
Adjustment in TUNE-UP article
in the TUNE-UP section
Defective wiringCheck all wires and wire
Page 1 of 36 MITCHELL 1 ARTICLE - GENERAL INFORMATION Trouble Shooting - Basic Procedures
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Fig. 2: Ignition Primary Trouble Shooting Chart

STARTER TROUBLE SHOOTING
BASIC STARTER TROUBLE SHOOTING CHART
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
CONDITION & POSSIBLE CAUSECORRECTION
Starter Fails to Operate
Dead battery or bad connections between starter and batteryCheck battery charge and all
wires and connections to
starter
Ignition switch faulty or misadjustedAdjust or replace ignition
switch
Open circuit between starter switch ignition terminal on starter relayCheck and repair wires and
connections as necessary
Starter relay or starter defectiveSee Testing in STARTER
article
Open solenoid pull-in wireTesting in STARTER article
Starter Does Not Operate and Headlights Dim
Weak battery or dead cellCharge or replace battery as
necessary
Loose or corroded battery connectionsCheck that battery connections
are clean and tight
Internal ground in starter windingsSee Testing in STARTER
article
Grounded starter fieldsSee Testing in STARTERS
Armature rubbing on poleSee STARTER article shoes
Starter Turns but Engine Does Not Rotate
Starter clutch slippingSee STARTER article
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Broken clutch housingSee STARTER article
Pinion shaft rusted or drySee STARTER article
Engine basic timing incorrectSee Ignition Timing in TUNE-
UP article
Broken teeth on engine flywheelReplace flywheel and check for
starter pinion gear damage
Starter Will Not Crank Engine
Faulty overrunning clutchSee STARTER article
Broken clutch housingSee STARTER article
Broken flywheel teethReplace flywheel and check for
starter pinion gear damage
Armature shaft sheared or reduction gear teeth strippedSee STARTER article
Weak batteryCharge or replace battery as
necessary
Faulty solenoidSee On-Vehicle Tests in
STARTER article
Poor groundsCheck all ground connections
for tight and clean connections
Ignition switch faulty or misadjustedAdjust or replace ignition
switch as necessary
Starter Cranks Engine Slowly
Battery weak or defectiveCharge or replace battery as
necessary
Engine overheatedSee ENGINE COOLING
SYSTEM article
Engine oil too heavyCheck that proper viscosity oil
is used
Poor battery-to-starter connectionsCheck that all between battery
and starter are clean and tight
Current draw too low or too highSee Bench Tests in STARTER
article
Bent armature, loose pole shoes screws or worn bearingSee STARTER article
Burned solenoid contactsReplace solenoid
Faulty starterReplace starter
S t a r t e r E n ga ge s E n gin e On l y M o me n t a r il y
Engine timing too far advancedSee Ignition Timing in TUNE-
UP article
Overrunning clutch not engaging properlyReplace overrunning clutch.
See STARTER article
Broken starter clutchSee STARTER article
Broken teeth on engine flywheelReplace flywheel and check
starter pinion gear for damage
Weak drive assembly thrust springSee STARTER article
Weak hold-in coilSee Bench Tests in STARTER
article
Starter Drive Will Not Engage
Defective point assemblySee Testing in STARTER
article
Poor point assembly groundSee Testing in STARTER
article
Defective pull-in coilReplace starter solenoid
Starter Relay Does Not Close
Dead batteryCharge or replace battery as
necessary
Faulty wiringCheck all wiring and
connections leading to relay
Neutral safety switch faultyReplace neutral safety switch
Starter relay faultyReplace starter relay
Starter Drive Will Not Disengage
Starter motor loose on mountingsTighten starter attach bolts
Worn drive end bushingSee STARTER article
Damaged engine flywheel teethReplace flywheel and starter
pinion gear for damage
Drive yolk return spring broken or missingReplace return spring
Faulty ignition switchReplace ignition switch
Insufficient clearance between winding leads to solenoid terminal and main contact in solenoidReplace starter solenoid
Starter clutch not disengagingReplace starter clutch
Ignition starter switchReplace ignition switch
contacts sticking
Starter Relay Operates but Solenoid Does Not
Faulty solenoid switch, switch connections or relayCheck all wiring between relay
and solenoid or replace relay
or solenoid as necessary
Page 5 of 36 MITCHELL 1 ARTICLE - GENERAL INFORMATION Trouble Shooting - Basic Procedures
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AIR CONDITIONING & HEAT
AIR CONDITIONING TROUBLE SHOOTING
BASIC AIR CONDITIONING TROUBLE SHOOTING CHART
HEATER SYSTEM TROUBLE SHOOTING
BASIC HEATER SYSTEM TROUBLE SHOOTING CHART
Broken lead or loose soldered connectionsRepair wire or wire
connections as necessary
Solenoid Plunger Vibrates When Switch is Engaged
Weak batteryCharge or replace battery as
necessary
Solenoid contacts corrodedClean contacts or replace
solenoid
Faulty wiringCheck all wiring leading to
solenoid
Broken connections inside switch coverRepair connections or replace
solenoid
Open hold-in wiresolenoid
Low Current Draw
Worn brushes or weak brush springsReplace brushes or brush
springs as necessary
High Pitched Whine During Cranking Before Engine Fires but Engine Fires and Cranks Normally
Distance too great between starter pinion and flywheelAlign starter or check that
correct starter and flywheel are
being used
High Pitched Whine After Engine Fires With Key released. Engine Fires and Cranks Normally
Distance too small between starter pinion and flywheelFlywheel runout contributes to
the intermittent nature
WARNING:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
CONDITIONPOSSIBLE CAUSE
Compressor Not WorkingCompressor clutch circuit open.
.....Compressor clutch coil inoperative.
.....Poor clutch ground connection.
.....Fan belts loose.
.....Thermostatic switch inoperative.
.....Thermostatic switch not adjusted.
.....Ambient temperature switch open.
.....Superheat fuse blown.
Excessive Noise or VibrationMissing or loose mounting bolts.
.....Bad idler pulley bearings.
.....Fan belts not tightened correctly.
.....Compressor clutch contacting body.
.....Excessive system pressure.
.....Compressor oil level low.
.....Damaged clutch bearings.
.....Damaged reed valves.
.....Damaged compressor.
In su fficien t o r No Co o l in g; Co mp resso r
WorkingExpansion valve inoperative.
.....Heater control valve stuck open.
.....Low system pressure.
.....Blocked condenser fins.
.....Blocked evaporator fins.
.....Vacuum system leak.
.....Vacuum motors inoperative.
.....Control cables improperly adjusted.
.....Restricted air inlet.
.....Mode doors binding.
.....Blower motor inoperative.
.....Temperature above system capacity.
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to DIAGNOST IC,
or T EST ING articles available in the section(s) you are accessing.
Page 6 of 36 MITCHELL 1 ARTICLE - GENERAL INFORMATION Trouble Shooting - Basic Procedures
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ENGINE MECHANICAL
COOLING SYSTEM TROUBLE SHOOTING
COOLING SYSTEM TROUBLE SHOOTING
Malfunctioning power unitSee POWER BRAKES or
BRAKE SYSTEM
Partial system failureCheck fluid and pipes
Worn disc pad or liningReplace pad or lining
Caliper piston stuck or sluggishSee DISC BRAKES or
BRAKE SYSTEM
Master cylinder piston stuckSee MASTER CYLINDERS
or BRAKE SYSTEM
Brake fade due to incorrect pads for liningsReplace pads or linings
Linings or pads glazedReplace pads or linings
Worn drumsReface or replace drums
Excessive Pedal Travel
Partial brake system failureCheck fluid and pipes
Insufficient fluid in master cylinderSee MASTER CYLINDERS
or BRAKE SYSTEM
Air trapped in systemSee BRAKE BLEEDING or
BRAKE SYSTEM
Rear brakes not adjustedSee Adjustments in DRUM
BRAKES or BRAKE
SYSTEM
Bent shoe or liningSee DRUM BRAKES or
BRAKE SYSTEM
Plugged master cylinder capSee MASTER CYLINDERS
or BRAKE SYSTEM
Improper brake fluidReplace brake fluid
Pedal Travel Decreasing
Compensating port pluggedSee MASTER CYLINDERS
or BRAKE SYSTEM
Swollen cup in master cylinderSee MASTER CYLINDERS
or BRAKE SYSTEM
Master cylinder piston not returningSee MASTER CYLINDERS
or BRAKE SYSTEM
Weak shoe retracting springsSee DRUM BRAKES BRAKE
SYSTEM
Wheel cylinder piston stickingSee DRUM BRAKES or
BRAKE SYSTEM
Dragging Brakes
Master cylinder pistons not returningSee MASTER CYLINDERS
BRAKE SYSTEM
Restricted brake lines or hosesCheck line routing
Incorrect parking brake adjustmentSee DRUM BRAKES BRAKE
SYSTEM
Parking Brake cables frozenSee DRUM BRAKES BRAKE
SYSTEM
Incorrect installation of inboard disc padRemove and replace correctly
Power booster output rod too longSee POWER BRAKE UNITS
BRAKE SYSTEM
Brake pedal not returning freelySee DISC, DRUM BRAKES
BRAKE SYSTEM
Brakes Grab or Uneven Braking Action
Malfunction of combination valveSee CONTROL VALVE or
BRAKE SYSTEM
Malfunction of power brake unitSee POWER BRAKE UNITS
or BRAKE SYSTEM
Binding brake pedalSee DISC, DRUM BRAKES
or BRAKE SYSTEM
Pulsation or Roughness
Uneven pad wear caused by caliperSee DISC BRAKES or
BRAKE SYSTEM
Uneven rotor wearSee DISC BRAKES or
BRAKE SYSTEM
Drums out-of-roundReface or replace drums
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
CONDITION & POSSIBLE CAUSECORRECTION
Page 8 of 36 MITCHELL 1 ARTICLE - GENERAL INFORMATION Trouble Shooting - Basic Procedures
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GASOLINE ENGINE - MECHANICAL TROUBLE SHOOTING
BASIC GASOLINE ENGINE - MECHANICAL TROUBLE SHOOTING CHART
Overheating
Coolant LeakFill/Pressure Test System
A/C Condenser Fins CloggedRemove/Clean Condenser
Radiator Fins CloggedRemove/Clean Radiator
Thermostat Stuck ClosedReplace Thermostat
C l o gge d C o o l in g S yst e m P a ssa ge sClean/Flush Cooling System
Water Pump MalfunctionReplace Water Pump
Fan Clutch MalfunctionReplace Fan Clutch
Retarded Ignition TimingReset Ignition Timing
Cooling Fan MalfunctionTest Cooling Fan/Circuit
Cooling Fan Motor MalfunctionTest Fan Motor
Cooling Fan Relay MalfunctionTest Fan Relay
Faulty Radiator CapReplace Radiator Cap
Broken/Slipping Fan BeltReplace Fan Belt
Restricted ExhaustRepair Exhaust System
Corrosion
Impurities In CoolantClean/Flush System
Coolant Leakage
Damaged hoseReplace Hose
Leaky Water PumpReplace Water Pump
Damaged Radiator SeamReplace/Repair Radiator
Leaky Thermostat CoverReplace Thermostat Cover
Cylinder Head ProblemCheck Head/Head Gasket
Leaky Freeze PlugsReplace Freeze Plugs
Recovery System Inoperative
Loose and/or Defective Radiator CapReplace Radiator Cap
Overflow Tube Clogged and/or LeakingRepair Tube
Recovery Bottle Vent RestrictedClean Vent
No Heater Core Flow
Collapsed Heater HoseReplace Heater Hose
Pl u gge d He a t e r C o r eClean/Replace Heater Core
Faulty Heater ValveReplace Heater Valve
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
CONDITION & POSSIBLE CAUSECORRECTION
Engine Lopes At Idle
In t ake man ifo l d -t o -h ead l eaksReplace manifold gasket, See
ENGINES
Blown head gasketReplace head gasket, See
ENGINES
Worn timing gears, chain or sprocketReplace gears, chain or
sprocket
Worn camshaft lobesReplace camshaft, See
ENGINES
Overheated engineCheck cooling system, See
COOLING
Blocked crankcase vent valveRemove restriction
Le a kin g E GR va l veRepair leak and/or replace
va l ve
Faulty fuel pumpReplace fuel pump
Engine Has Low Power
Leaking fuel pumpRepair leak and/or replace
fu el p u mp
Excessive piston-to-bore clearanceInstall larger pistons, See
ENGINES
Sticking valves or weak valve springsCheck valve train components,
See ENGINES
Incorrect valve timingReset valve timing, See
ENGINES
Worn camshaft lobesReplace camshaft, See
ENGINES
Blown head gasketReplace head gasket. See
ENGINES.
Clutch slippingAdjust pedal and/or replace
components, See ENGINES
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