1991 FORD FESTIVA engine

Fig. 2: Identifying Alternator Test Terminals

Courtesy of FORD MOTOR CO.
1. Turn ignition switch to OFF position. Connect positive voltmeter lead wire to alternator "B" terminal and negative wire to ground. See
Fig. 2
. Ensure voltmeter indicates battery voltage. If voltmeter indicates zero volts, an open circuit exists in wire between "B" terminal
and battery positive terminal.
2. Remove voltmeter. Disconnect negative battery cable. Remove output lead from alternator terminal "B". Connect a 100-amp ammeter in
series between "B" terminal and disconnected output lead. Connect positive lead of ammeter to "B" terminal and negative lead to
disconnected output wire.
3. Connect voltmeter in parallel between alternator "B" terminal and battery positive terminal. Connect positive lead wire of voltmeter to
"B" terminal and negative lead wire to positive terminal of battery. Reconnect negative battery cable.
4. Install tachometer (if necessary) to monitor engine RPM. Start engine. Turn all lights and accessories on and depress brake pedal to load
system. Increase engine speed to 2500-3000 RPM. Ensure alternator output is at least 35 amps.
5. Observe voltmeter reading. If voltmeter indicates .2 volt and amperage output is at least 35 amps, system is okay. If voltage drop is
greater than .2 volt, wiring is defective between alternator "B" terminal and battery positive terminal.
6. Allow engine to idle. Turn off all accessories to remove load from system. Disconnect voltmeter. Connect negative lead of voltmeter to
ground. Using positive lead of voltmeter, backprobe "S" terminal connector at rear of alternator. See Fig. 2
.
7. Increase engine speed to 2500-3000 RPM. With no load on system, ammeter should read 5 amps or more. Battery voltage with no load
at indicated speed should be 14.1-14.7 volts. If amperage output is less than indicated with or without load and no external faults exist
in alternator circuit, overhaul or replace alternator.
BENCH TESTING
Rotor
Check continuity across rotor slip rings. If no continuity exists, replace rotor. Check continuity between individual slip rings and rotor
core/shaft. If continuity exists, rotor coil or slip ring is grounded. Replace rotor.
Stator
Ensure no continuity exists between stator coil leads and stator core. Check continuity between leads of stator coil. If continuity does not
exist, replace stator.
Brushes
Inspect brushes. Replace brushes if worn to wear line (leading edge of small square cast into brush). Use a spring pressure gauge to push each
NEW brush into its holder until .079" (2 mm) projects from holder. Spring force should be 10.6-15.6 oz. (.3-.4 kg). If spring force is not
within specification, replace brush spring.
Rectifier
1. Using an ohmmeter, check for continuity between positive side of diode leads and heat sink. If no continuity exists from any positive
diode lead to heat sink, replace rectifier assembly.
2. Reverse ohmmeter leads, and check for continuity between negative side of diodes and heat sink. If continuity exists from any n e ga t ive
diode lead to heat sink, replace rectifier assembly.
3. Check diode trio (smaller diodes between main diode leads) for continuity in both directions. Continuity should exist in one direction
only. If any diode shows continuity in both directions or does not show continuity in either direction, replace diode trio.
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ELECT RICAL COMPONENT LOCAT OR
1991-92 ELECT RICAL COMPONENT LOCAT ION Ford Motor Co. Electrical Com ponents
BUZZERS, RELAYS & TIMERS
BUZZERS, RELAYS & TIMERS LOCATION
CIRCUIT PROTECTION DEVICES
CIRCUIT PROTECTION DEVICES LOCATION
CONTROL UNITS
CONTROL UNITS LOCATION
SENDING UNITS & SENSORS
SENDING UNITS & SENSORS LOCATION
MOTORS
MOTORS LOCATION
ComponentLocation
A/C Clutch Relay (1991)On right front of engine bay, near power
steering pump.
A/C RelayOn left front corner of engine bay, left of
cooling fan. See Fig. 1
& Fig. 2
A/C Wide Open Throttle (WAC) RelayOn left front corner of engine bay, left of
cooling fan. See Fig. 1
& Fig. 2 .
Cooling Fan RelayOn left front fender panel, near
headlight. See Fig. 1
& Fig. 2 .
Condenser Fan RelayOn left front of engine bay, left of
cooling fan. See Fig. 1
& Fig. 2 .
Daytime Running Light (DRL) Relay (Canada) (1992)On left front corner of engine bay, near
headlight. See Fig. 1
.
Fuel Pump RelayBehind left side of dash, near ECA.
Headlight RelayBehind left headlight. See Fig. 1 .
Horn RelayUnder left side of dash. See Fig. 3 .
Main RelayIn left front corner of engine bay, near
battery.
P a r kin g Ligh t R e l a yOn right front corner of engine bay. See
Fig. 1
.
Turn Signal/Flasher RelayUnder left side of dash, behind ECA.
See Fig. 3
.
ComponentLocation
A/C In-Line FuseOn left side of heater case.
Condenser Fan In-Line FuseOn right side of steering column.
Fuse PanelBehind access panel, to left of steering column.
Fusible LinksOn left front strut tower. See Fig. 1 .
ComponentLocation
Electronic Control Assembly (ECA)Behind left side of dash, left of steering column.
Passive Restraint ModuleUnder driver's seat.
ComponentLocation
Airflow MeterOn right front corner of engine bay. See Fig. 1 .
Coolant Temperature Sending UnitBelow thermostat housing.
Crankshaft Position SensorInside distributor. See Fig. 1 .
EGR Temperature Sensor (1991)In exhaust manifold, near EGR valve.
Engine Coolant Temperature (ECT) SensorOn top of engine, near injector No. 1.
Fuel Gauge Sending Unit (1992)In fu el t an k.
Throttle Position Sensor (TPS)On left side of throttle body. See Fig. 1 .
ComponentLocation
Blower MotorUnder center of dash, behind
radio.
Windshield Washer Motors:
Front (1991)On right front fender panel,
bottom of washer reservoir.
Front (1992)On left front corner of engine
bay, in front of battery.
RearOn body panel, behind right
rear quarter panel.
Windshield Wiper Motor
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SOLENOIDS & SOLENOID VALVES
SOLENOIDS & SOLENOID VALVES LOCATION
SWITCHES
SWITCHES LOCATION
MISCELLANEOUS
MISCELLANEOUS LOCATION
COMPONENT LOCATION GRAPHICS

Fig. 1: Component Locations (1 Of 3)

FrontOn left rear corner of engine
bay, on firewall. See Fig. 1
.
RearIn liftgate, behind trim panel.
ComponentLocation
Canister Purge SolenoidOn center of firewall, to right of wiper motor. See Fig. 1 .
Idle-Up Speed Control (ISC) SolenoidOn left rear of engine, left of injector No. 4.
Kickdown Solenoid Valve (A/T)On lower right front corner of transaxle. See Fig. 1 .
ComponentLocation
A/C Pressure SwitchOn A/C line, near right front strut tower. See Fig. 1 .
A/C Thermostatic Switch (1992)On bottom of evaporator housing, below glove box.
Back-Up Light SwitchMounted on transaxle. See Fig. 1 .
Brake Fluid Level SwitchOn brake fluid reservoir.
Brake On-Off Switch (1992)On bracket, above brake pedal.
Clutch Interlock SwitchOn bracket, above clutch pedal.
Cooling Fan SwitchIn thermostat housing. See Fig. 1 .
Inertia SwitchIn left rear quarter panel.
Kickdown Switch (A/T)Mounted on accelerator pedal.
Neutral Safety SwitchOn right rear side of transaxle.
Oil Pressure SwitchOn rear center of engine block.
Parking Brake SwitchOn base of parking brake lever.
Passive Restraint Limit SwitchAt top of left & right "A" pillar.
Power Steering Pressure SwitchMounted on power steering pump assembly.
Seat Belt Switch (1991)On driver's seat belt buckle.
Stoplight SwitchOn brake pedal lever.
Wide Open Throttle A/C Cut-Off (WAC) Switch (1991)On left corner of engine bay, left of cooling fan.
ComponentLocation
Blower ResistorNear blower motor.
RPM Test ConnectorOn left rear of engine bay, next to ignition module. See Fig. 1 .
NOTE:Figures m ay show m ultiple com ponent locations. Refer to appropriate table for proper figure
references.
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FUSES & CIRCUIT BREAKERS
Fuses & Circuit Breakers 1988-93 Festiva
FUSES & FUSIBLE LINKS
FUSE PANEL & FUSIBLE LINK BLOCK LOCATIONS
The vehicle has a fuse block with fusible links and a fuse panel with circuit fuses. The fuse panel is located behind the instrument panel, left o
f
the steering column. The fuse block is located under the hood.
FUSE PANEL IDENTIFICATION

Fig. 1: Fuse Panel Identification

Courtesy of FORD MOTOR CO.
Fuse & Circuit Breaker Identification
1 - 15 Amp License Plate Light, Rear Side Marker Ligh t , Fr o n t P a r kin g Ligh t s, C l u st e r a n d Ta il Ligh t s
2 - 15 Amp Horn, Brakelights, High-Mount Brakelight
3 - 15 Amp (1988-89) Safety Belt Warning, Turn & Hazard Warning Flasher Lights, Radio, Trunk Light, Ignition Key Reminder Buzzer
3 - 15 Amp (1990-93) Safety Belt Warning, Turn & Hazard Warning Flasher Lights, Ignition Key Reminder Buzzer
4 - 15 Amp Audio System, Cigarette Lighter, Remote Control Mirror
5 - 15 Amp Rear Wiper/Washer, Daytime Running Light System (Canada)
6 - 15 Amp Heater & Air Conditioner
7 - 20 Amp Heater & Air Conditioner, Cooling Fan System
8 - 10 Amp (1988-89) Interior Courtesy Lights 10 Amp (1990-93) Radio, Interior Courtesy Lights, Luggage Compartment Light
9 - 15 Amp (1988-89) Front Wiper/Washer
9 - 15 Amp (1990-93) Front Wiper/Washer, Shift-Lock System (ATX), Engine Control System
10 - 10 Amp Charging System, Emission Control System
11 - 10 Amp (1988-90) Safety Belt Warning, Turn & Hazard Warning Flasher Lights, Back-Up Lights, Instrument Cluster, Warning
Lights,
11 - 10 Amp (1991-93) Safety Belt Warning, Turn & Hazard Warning Flasher Lights, Back-Up Lights, Instrument Cluster, Warning
Lights, Shift-Lock System
12 - 15 Amp Rear Window Defroster
13 - Not Used (1988-89) Spare
13 - 30 Amp (1990-93) Passive Restraint System (Automatic Seat Belt)
In-Line Fuse Identification
15 Amp (1990-93) Condenser Fan Motor (A/T Models Only)
10 Amp (1990-93) A/C System (located on left side of heater case)
FUSIBLE LINK BLOCK IDENTIFICATION
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CATALYTIC CONVERTER
Continued operation of vehicle with a severe malfunction could cause converter to overheat, resulting in possible damage to converter and
ve h ic l e .
Any modification to the exhaust system on turbo models, which reduces exhaust backpressure, will lead to lean fuel mixtures and excessive
spark advance. This could cause serious engine damage.
ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS
ENGINE OIL
FUEL PUMP SHUTOFF SWITCH
This switch stops flow of fuel to engine after a collision. The impact does not have to be great for switch to be triggered. Switch must be reset
after collision. Switch is located under left rear speaker in luggage compartment. Press button to reset switch.
FUEL SYSTEM SERVICE
HALOGEN BULBS
PASSIVE RESTRAINTS
RADIATOR CAP
RADIATOR FAN WARNING:Many solid state electrical com ponents can be dam aged by static electricity (ESD). Som e will display a
warning label, but m any will not. Discharge personal static electricity by touching a m etal ground point
on the vehicle prior to servicing any ESD sensitive com ponent.
CAUT ION: Never use non-detergent or straight m ineral oil.
WARNING:Relieve fuel system pressure prior to servicing any fuel system com ponent (fuel injection m odels).
WARNING:Halogen bulbs contain pressurized gas which m ay explode if overheated. DO NOT touch glass portion
of bulb with bare hands. Eye protection should be worn when handling or working around halogen
bulbs.
CAUT ION: Before operating vehicle, securely fasten passive shoulder restraints to the em ergency release buckles.
T he buckle fits in only one way. Ensure to position it properly.
CAUT ION: Always disconnect the fan m otor when working near the radiator fan. T he fan is tem perature controlled
and could start at any tim e even when the ignition key is in the OFF position. DO NOT loosen or rem ove
radiator cap when cooling system is hot.
WARNING:Keep hands away from radiator fan. Fan is controlled by a therm ostatic switch which m ay com e on or
run for up to 15 m inutes even after engine is turned off.
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00058075
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ST ART ER
1991 ELECT RICAL Starters
DESCRIPTION
The Nippondenso direct drive starter is a conventional 12-volt, 4-pole, brush-type starter. The integral solenoid is attached to the drive
housing. When starter is energized, starter solenoid causes the starter pinion to engage with the flywheel ring gear. The overrunning clutch
pinion drive is mounted directly on armature shaft drive end.

Fig. 1: Starter System Schematic

Courtesy of FORD MOTOR CO.
TROUBLE SHOOTING
ENGINE CRANKS SLOWLY
Undercharged battery. Loose or corroded cable connections. Bad starter.
ENGINE WILL NOT CRANK
Undercharged battery. Bad ignition switch. Bad clutch engage switch (M/T) or neutral safety switch (A/T). Loose or corroded cable
connections. Bad starter. Faulty circuit grounds.
STARTER SPINS & ENGINE DOES NOT CRANK
Bad starter. Bad flywheel ring gear and/or starter drive pinion.
ENGINE STARTS WITH CLUTCH ENGAGED (M/T)
Bad clutch engage switch. Adjust or replace.
ENGINE STARTS IN GEAR (A/T)
Bad neutral safety switch. Adjust or replace.
ON-VEHICLE TESTING
PRELIMINARY TEST
Ensure battery is fully charged and has load tested okay. If starter will not crank engine with fully charged battery, proceed with the following
test.
1. Using a digital voltmeter, connect positive voltmeter lead to starter solenoid terminal "S", and negative lead to starter housing. See Fig.
1 .
2. Turn ignition switch to START position, and observe voltmeter reading. If voltage at terminal "S" is greater than 8 volts, starter or circuit
malfunction is indicated. See VOLTAGE DROP TEST
and STARTER GROUND CIRCUIT TEST under ON-VEHICLE TESTING.
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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.
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Fig. 3: Testing Voltage Drop

Courtesy of FORD MOTOR CO.
STARTER GROUND CIRCUIT 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. 1
.
2. Using a digital voltmeter set on low scale, connect positive voltmeter to starter motor housing. Ensure connection point is clean and free
of rust and grease. Connect negative voltmeter lead to negative battery terminal.
3. Engage remote starter switch and crank engine. Observe and record voltmeter reading. Voltmeter should read .2 volt or less. If voltage
drop is greater than .2 volt, clean negative battery cable connections at battery and body connections. Retest to ensure problem has been
corrected.
4. If voltage drop is still excessive, replace negative battery cable(s) as necessary. If battery cables test okay, and starter still cranks slowly
or not at all, remove and repair starter motor.
BENCH TESTING
STARTER NO-LOAD TEST
Remove starter. Place starter on bench. Connect a fully charged 12-volt battery, voltmeter, ammeter and remote starter switch to starter. See
Fig. 4
. Engage remote starter switch. Starter should rotate smoothly. Ensure voltage and amperage draw is less than maximum specification at
5000 RPM minimum. See NO-LOAD TEST SPECIFICATIONS table. If voltage and/or amperage is higher than specifications, disassemble
starter and determine cause.
NO-LOAD TEST SPECIFICATIONS
NOTE:Make all voltm eter connections at com ponent term inal rather than at cable or wire end.
ApplicationMaximum AmpsVolts
Capri & Festiva6011.5
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