1991 FORD FESTIVA check engine

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
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GENERAL INFORMATION
Using Mitchell1's Wiring Diagram s
INTRODUCTION
Mitchell1(R) obtains wiring diagrams and technical service bulletins, containing wiring diagram changes, from the domestic and import
manufacturers. These are checked for accuracy and are all redrawn into a consistent format for easy use. All system wiring diagrams are
available in color format and may be viewed and or printed in color or black and white, depending on your program settings and available
printer hardware.
In the past, when cars were simpler, diagrams were simpler. All components were connected by wires, and diagrams seldom exceeded 4 pages
in length. Today, some wiring diagrams require more than 16 pages. It would be impractical to expect a service technician to trace a wire from
page 1 across every page to page 16.
Removing some of the wiring maze reduces eyestrain and time wasted searching across several pages. Today, the majority of Mitchell1(R)
diagrams follow a much improved format, which permits space for internal switch details, and component and ground locations.
Components shown with a dashed line instead of a solid line indicate not all circuits are shown in this particular diagram (circuits shown in
system diagrams are typically applicable to that system only). The remaining circuits connected to that component will be shown in the
appropriate system that they apply to.
Today, the wiring diagram necessary to support a given repair procedure is included within that article or a link is provided to the appropriate
SYSTEM WIRING DIAGRAM article. For example, the wiring diagram for a Ford EEC-IV system may be included in ENGINE
PERFORMANCE and WIRING DIAGRAMS articles for Ford Motor Co. The wiring diagram for a cruise control system may be included in
ACCESSORIES & EQUIPMENT section for the specific vehicle manufacturer, and the wiring diagram for an anti-lock brake system may be
included in BRAKES and WIRING DIAGRAMS for the specific manufacturer.
WIRING DIAGRAMS contains all wiring diagrams not included in STARTING & CHARGING SYSTEMS and ACCESSORIES &
EQUIPMENT. This includes: Data Link Connectors, Ground Distribution, Power Distribution, Engine Performance, Electric Cooling Fans,
Anti-Lock Brakes, Electronic Suspension and Electronic Steering wiring diagrams. The Data Link Connectors wiring diagrams show the
circuits by which the various on-board computers exchange information, and the diagnostic connectors used for diagnosis and their location.
The Ground Distribution wiring diagrams show all vehicle ground points, their location, and the components common to those ground points.
The Power Distribution wiring diagrams show the power feed circuits and the components common to those power feeds.
Wiring diagrams used to support the information in ACCESSORIES & EQUIPMENT are drawn in a "top-down" format. The diagrams are
drawn with the power source at the top of the diagram and the ground point at the bottom of the diagram. Component locations are identified
on the wiring diagrams. Any wires that do not connect directly to a component are identified on the diagram to indicate where they go.
WIRING DIAGRAM COLOR ABBREVIATIONS
COLOR ABBREVIATIONS
WIRING DIAGRAM SYMBOLS
ColorNormalOptional
BlackBLKBK
BlueBLUBU
BrownBRNBN
ClearCLRCR
Dark BlueDK BLUDK BU
Dark GreenDK GRNDK GN
GreenGRNGN
GrayGRYGY
Light BlueLT BLULT BU
Light GreenLT GRNLT GN
OrangeORGOG
PinkPNKPK
PurplePPLPL
RedREDRD
TanTANTN
VioletVIOVI
WhiteWHTWT
YellowYELYL
Page 1 of 6 MITCHELL 1 ARTICLE - GENERAL INFORMATION Using Mitchell1's Wiring Diagrams
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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.
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ENGINE COOLING FAN
1990-92 ENGINE COOLING Ford Motor Co. Engine Cooling Fans
DESCRIPTION
Power for cooling fan is provided by the 20-amp COOLING fuse (Capri) or C-FAN fuse (Festiva). Cooling fan is activated when ground is
supplied for fan motor. On Festiva, ground can be supplied by fuel system ECA (located under the left side of dash), A/C cooling fan relay (if
equipped) or cooling fan relay. See Fig. 1
. On all models, when cooling fan is energized, relay contacts are open; when cooling fan is NOT
energized, relay contacts are closed, providing ground through closed contacts to activate cooling fan. See Fig. 2
.
Cooling fan relay is energized when coolant temperature switch is closed. This occurs when coolant temperature is less than 212°F (1 00 °C)
for Capri or 207°F (97°C) for Festiva. At temperatures greater than 212°F (100°C) for Capri or 207°F (97°C) for Festiva, coolant temperature
switch opens and cooling fan relay is de-energized, closing relay contacts and energizing cooling fan.
When ECA senses A/C request, it energizes A/C cooling fan relay by providing a ground for relay windings on ECA pin 1Q. Power for the
A/C cooling fan relay is provided by the HEATER fuse. On Capri, when A/C cooling fan relay is energized, it opens the power circuit for the
cooling fan relay. On Festiva, when A/C cooling fan relay is energized, it provides an alternate path to ground for cooling fan mo t o r. E CA al so
provides an alternate path to ground (at ECA pin 1R) for cooling fan motor based on input from coolant temperature sensor to ECA pin 2Q.

Fig. 1: Locating Cooling Fan & A/C Relays

Courtesy of FORD MOTOR CO.
TROUBLE SHOOTING
COOLING FAN DOES NOT OPERATE OR OPERATES ERRATICALLY
If cooling fan does not run at any time, or operates erratically, check the following items to help locate fault.
Check power fuse.
Check cooling fan relay.
Check coolant temperature switch.
Check cooling fan wiring harness.
Check cooling fan motor.
Check A/C cooling fan relay.
COOLING FAN RUNS CONTINUOUSLY
If cooling fan runs continuously, check the following items to help locate fault.
Check cooling fan relay.
Check coolant temperature switch.
Check cooling fan wiring harness.
Check cooling fan motor.
Check A/C cooling fan relay.
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COOLING FAN DOES NOT RUN WITH A/C ON
If cooling fan does not run with A/C on, check the following items to help isolate fault.
Check A/C cooling fan relay.
Check cooling fan wiring harness.
TESTING
VOLTAGE SUPPLY TEST
Disconnect cooling fan motor connector. Turn ignition on. Check for voltage at Yellow wire terminal of connector. If voltage is NOT present,
check for blown 20-amp COOLING fuse (Capri) or C-FAN fuse (Festiva) or open in Yellow wire between cooling fan and fuse.
Disconnect cooling fan relay connector. Cooling fan relay is located in the left front corner of engine compartment. Turn ignition on. Check
for voltage at Yellow (Capri) or Black/Yellow (Festiva) wire terminal of connector. If voltage is NOT present, check for blown 30-amp
HEATER fuse on Capri or 10-amp METER fuse on Festiva or open in Black/Yellow wire between cooling fan relay and fuse.
Disconnect A/C cooling fan relay connector. On Capri, A/C relay is located in the left rear corner of the engine compartment, on firewall. On
Festiva, A/C relay is located in the left front corner of engine compartment, under a triple relay cover. Relay may be identified by wire colors
to relay connector. See Fig. 2
and Fig. 3 . Turn ignition on. Check for voltage at Blue wire terminal of connector. If voltage is NOT present,
check for blown 15-amp HEATER fuse or open in Blue wire between A/C cooling fan relay and fuse.
GROUND CIRCUIT TEST
Turn ignition off. Unplug connectors from cooling fan and A/C cooling fan relays. Check for continuity between ground and Black wire
terminal of relay connectors. If continuity is NOT present, repair Black ground wire.
FAN MOTOR TEST
Disconnect fan motor wire connector. Apply ground and battery voltage to motor connector. Fan should run. If fan does not run, replace
cooling fan motor.
COOLING FAN RELAY TEST
Unplug cooling fan relay connector. Apply battery voltage and ground to Yellow and Green/Red (Capri) or Black/Yellow and Green/Yellow
(Festiva) wire terminals of relay. Check continuity of relay across Yellow/Green (Capri) or Yellow/Red and Black (Festiva) wire connector
terminals. Ensure continuity is NOT present while relay is energized. When relay is de-energized, continuity should exist.
A/C COOLING FAN RELAY TEST
Unplug A/C relay connector. Apply battery voltage and ground to Blue and White (Capri) or Blue and Green (Festiva) wire terminals of relay.
Check continuity of relay across Blue and Red (Capri) or Yellow/Red and Black (Festiva) wire connector terminals. On Capri, ensure
continuity does NOT exist while relay is energized. On Festiva, ensure continuity exists while relay is energized. On Capri, when relay is de-
energized continuity should exist. On Festiva, when relay is de-energized, continuity should NOT exist.
COOLANT TEMPERATURE SWITCH TEST
Disconnect connector from coolant temperature switch located in thermostat housing. With coolant temperature less than 200°F (93°C) for
Capri or 194°F (90°C) for Festiva, check continuity between ground and coolant temperature switch. Ensure continuity exists. Start engine
and allow coolant temperature to reach 200°F (93°C) for Capri or 207°F (97°C) for Festiva. Check continuity between ground and coolant
temperature switch terminal. Continuity should NOT be present. If switch does not test as indicated, replace switch.
HARNESS & CIRCUIT CHECK TEST
Turn ignition off. Disconnect harness connectors of the following components: ECA, cooling fan motor, coolant temperature switch, cooling
fan relay and A/C cooling fan relay. Using an ohmmeter, check for continuity on the related harness leads of each connector. See Fig. 2
and
Fig. 3
.
WIRING DIAGRAMS
For further detail, see appropriate chassis wiring diagram in the WIRING DIAGRAMS article in the WIRING DIAGRAMS section.
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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.
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Disconnect negative battery cable. Drain cooling system. Remove air cleaner. Remove intake manifold bracket. Disconnect throttle cable.
Mark and disconnect vacuum hoses, fuel hoses and wiring. Remove intake manifold bolts. Remove intake manifold and gasket.
Installation (1.3L)
Clean all gasket mating surfaces. Ensure surface is free of burrs, scratches and cracks. Replace all gaskets. Position gasket and manifold to
cylinder head. Install bolts and tighten to specification. To complete installation, reverse removal procedure.
Removal (1.6L)
1. Disconnect negative battery terminal. Relieve fuel pressure. See FUEL PRESSURE RELEASE under REMOVAL &
INSTALLATION. Drain cooling system. Disconnect intercooler tube and/or air intake tube. Disconnect air by-pass hoses. Disconnect
main engine harness electrical connection and TPS connector. Disconnect vacuum hoses from throttle body.
2. Disconnect fuel lines from fuel filter and pressure regulator. Disconnect throttle cable. Disconnect hoses from By-pass Air Control valve
( B AC ) . R e mo ve B AC va l ve r e t a in in g n u t a n d b o l t . R e mo ve in t a ke manifold retaining nuts and bolts from support bracket and cylinder
head. Remove intake manifold and throttle body assembly.
Installation (1.6L)
1. Install new intake manifold gasket, ensuring coolant passage openings align with openings in cylinder head and manifold. Install intake
manifold. Tighten retaining nut and bolts and support bracket bolts to specification. See TORQUE SPECIFICATIONS
table at end of
article.
2. Install BAC valve and connect air hoses. Connect throttle cable. Connect fuel lines to fuel filters and pressure regulator. Connect main
engine harness connector and TPS connector. Connect vacuum lines to throttle body. Install intake air tube. Connect intercooler tube
and/or intake air tube. Connect air by-pass hoses. Fill cooling system. Connect negative battery terminal. Start engine and check for
fluid leaks and correct operation.
EXHAUST MANIFOLD
Removal (1.3L)
1. Raise vehicle. Remove catalytic converter inlet pipe at exhaust manifold. Remove pulse air tube nuts at inlet pipe. Remove inlet pipe
support bracket bolts. Lower vehicle. Remove air intake duct. Remove exhaust manifold heat shroud bolts and remove shroud.
2. Disconnect oxygen sensor connector. Remove exhaust manifold nuts and remove exhaust manifold. Remove gasket from inlet pipe and
cylinder head.
Installation
Position new gasket on cylinder head and inlet pipe. Install exhaust manifold and nuts. Tighten nuts to specification. See, at end of article,
TORQUE SPECIFICATIONS
table. To complete installation, reverse removal procedure. Tighten all bolts and nuts to specification.
Removal (1.6L Non-Turbo)
Remove intake air tube. Remove front exhaust pipe to exhaust manifold retaining nuts. Remove exhaust support bracket (if equipped). Remove
heat shield. Disconnect O2 sensor electrical connector. Remove exhaust manifold.
Installation (1.6L Non-Turbo)
Install exhaust manifold gaskets. Install heavier gasket first. Install exhaust manifold and tighten retaining nuts to specification. See TORQUE
SPECIFICATIONS table at end of article. Connect O2 sensor electrical connector. Install manifold heat shield. Install intake air tube.
Connect front exhaust pipe to intake manifold and tighten retaining nuts to specification. Install exhaust support bracket, if removed, and
tighten engine mount bolt to specification. Start engine and check for leaks.
Removal (1.6L Turbo)
1. Disconnect negative battery cable. Drain cooling system. Remove throttle body air intake tube. Disconnect intercooler hose from
turbocharger assembly and position both intercooler hoses out of the way. Remove O2 sensor connector from its retaining clip, and
disconnect O2 sensor. Remove lower heat shield and then upper heat shield. Remove turbocharger side heat shield.
2. Remove power steering pump (leave hoses attached) and lay aside. Disconnect lower radiator hose from water pump. Position power
steering pump to access mounting bracket retaining bolts and nut. Remove both bolts and one nut, and remove bracket from engine.
Remove 2 screws retaining air cleaner duct tube, loosen clamp at turbocharger and position duct tube out of the way. Disconnect
coolant return hose at turbocharger. Remove bolt and brass sealing washers from oil supply line at engine block.
3. Raise vehicle. Remove retaining nuts and washers from exhaust pipe flange. Remove 2 bolts retaining exhaust hangers to engine block.
Slide off two rubber exhaust hangers at catalytic converter. Pull exhaust pipe downward and to LH side of vehicle. Disconnect oil return
hose at turbocharger. Disconnect coolant return hose at turbocharger. Remove 2 retaining bolts from turbocharger support bracket.
Remove 2 bolts retaining coolant by-pass tube outlet to water pump. Lower vehicle.
4. Loosen retaining clamp bolt on coolant by-pass tube at rear of cylinder head. Remove 11 retaining nuts from exhaust manifold. Pull
coolant by-pass tube bracket from exhaust stud, and position tube out of way. Grasp manifold, pull off studs and move assembly slightly
to RH side of engine compartment to clear cooling fan, and remove assembly from vehicle.
5. Working on bench, remove 4 nuts retaining turbocharger to exhaust manifold, separate assembly and discard gasket.
Installation (1.6L Turbo)
NOTE:Feed O2 sensor wire and guide through upper heat shield.
NOTE:When reinstalling turbocharger, thoroughly rem ove all gaskets and sealant. Use new gaskets. Add .85
oz. (25 cc) of engine oil in the oil passage of the turbocharger.
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1. Position new gasket on exhaust manifold, and install turbocharger onto studs. Install 4 retaining nuts and tighten to specification. See
TORQUE SPECIFICATIONS
table at end of article.
2. Remove oil supply line from turbocharger. Position new (2-piece) exhaust gasket on cylinder head with heavy gasket installed first .
Carefully position turbocharger assembly in engine compartment and slide exhaust manifold on studs. Position heater tube bracket onto
exhaust stud. Install 11 retaining nuts onto exhaust manifold and tighten to specification. See TORQUE SPECIFICATIONS
table at
end of article. Tighten heater tube clamp bolt securely.
3. Raise vehicle. Position new gasket and install 2 retaining bolts on heater tube outlet. Install 2 retaining bolts into turbocharger support
bracket and tighten bolts to specification.
4. Connect coolant return hose. Connect oil return hose and secure with clamp. Position exhaust pipe onto turbocharger, and start nuts
and washers. Install 2 retaining bolts on exhaust hanger at engine. Slide on 2 rubber exhaust hangers at catalytic converter. Tighten
exhaust pipe retaining nuts to specification. Lower vehicle.
5. Install retaining bolt and brass washers on oil supply line, carefully position oil line into vehicle and hand-start bolt into engine block.
Connect and finger tighten oil line to turbocharger. Tighten oil line bolt and oil supply line on turbocharger to specification.
6. Connect coolant supply hose. Position air cleaner duct tube on turbocharger and tighten clamp. Install 2 screws retaining air cleaner
duct tube. Position power steering pump bracket on engine, and install 2 retaining bolts and one retaining nut. Tighten to specification.
Position power steering pump on mounting bracket, and install though bolt and adjuster. Connect lower radiator hose. Install power
steering belt. Position upper heat shield and install 2 retaining bolts finger tight.
7. Position lower heat shield and install three retaining bolts finger tight. Tighten all heat shield bolts to specification. Connect O2 sensor
and install connector into its retaining clip. See TORQUE SPECIFICATIONS
table at end of article. Position intercooler hose on
turbocharger and secure with clamp. Install throttle body air intake tube. Connect negative battery cable. Refill cooling system.
CYLINDER HEAD
Removal (1.3L)
1. Disconnect battery ground cable. Mark and disconnect fuel lines at fuel pump. Remove accessory belts, water pump pulley, crankshaft
pulley, timing belt covers, timing belt tensioner, timing belt, valve cover and exhaust and intake manifolds. Drain cooling system.
2. Mark and remove electrical connectors and vacuum hoses. Remove spark plug wires from spark plugs, and remove spark plugs. Remove
distributor cap. Disconnect vacuum hoses and distributor wiring.
3. Index distributor-to-mount position and remove hold-down bolt. Remove distributor assembly. Remove engine ground strap. Remove
front and rear engine lifting hooks. Remove upper radiator hose, by-pass hose and bracket.
4. Remove bolts retaining rocker arm shaft. Remove rocker arm assemblies. Remove cylinder head bolts. Remove head and gasket.
Inspection (1.3L)
1. Thoroughly clean and check gasket mating surface of cylinder head and block. Check cylinder for cracks, nicks, burrs or damage. Using
a straightedge and feeler gauge, check warpage over entire gasket area. Ensure cylinder head and/or block warpage does not
exceed .006" (.15 mm).
2. If warpage exceeds .006" (.15 mm), machine cylinder head and/or block gasket surface. Maximum machining allowed is .008" (.20 mm).
If more machining is required, replace block and/or cylinder head.
Installation (1.3L)
1. Place new head gasket properly on block. Carefully place cylinder head in position on block. Install head bolts. Tighten bolts in
sequence and in 2 steps. See Fig. 1
.
2. While tightening rocker arm shaft, slide shaft springs away from retaining bolt to prevent pinching springs. Tighten rocker arm shaft bolts
in sequence and to specification. See Fig. 5
. To complete installation, reverse removal procedure. Tighten all bolts/nuts to
specification. Fill all fluids to proper levels. NOTE:T urbocharger-to-exhaust m anifold m ounting nuts are of special quality. Ensure correct nuts are
used.
NOTE:Ensure one brass washer is positioned on each side of oil line fitting.
NOTE:Feed O2 sensor wire through upper heat shield. Install wire retainer under LH bolt.
NOTE:If turbocharger was replaced: Disconnect ignition coil, crank engine for 20 seconds, connect ignition
coil, start engine and run at idle for 30 seconds and check for leaks.
NOTE:If original tim ing belt is being reused, m ark direction of rotation for installation reference.
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