1991 FORD FESTIVA transmission

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.
Page 2 of 3 MITCHELL 1 ARTICLE - D - ADJUSTMENTS 1991 ENGINE PERFORMANCE Ford/Mercury - On-Vehicle Adjustments
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Connect BOB. Remove dust cover from BP sensor, located on passenger side cowl. Turn ignition on. Connect vacuum pump to BP sensor.
Measure voltage between pins BP and SIGRTN on BOB while applying vacuum to BP sensor. See BAROMETRIC PRESSURE SENSOR
OUTPUT VOLTAGE . Replace BP sensor if voltage is not as specified.
BAROMETRIC PRESSURE SENSOR OUTPUT VOLTAGE
BRAKE ON-OFF (BOO) SWITCH
Unplug connector from BOO switch at brake pedal. Connect ohmmeter to switch terminals. With pedal released, ohmmeter should indicate no
continuity. Ohmmeter should indicate continuity with pedal depressed.
CLUTCH ENGAGE SWITCH (CES)
Unplug connector from CES switch at clutch pedal. Connect ohmmeter to switch terminals. With pedal released, ohmmeter should indicate
continuity. Ohmmeter should indicate no continuity with pedal depressed.
CRANKSHAFT POSITION SENSOR (CPS) (1.3L)
Unplug 3-wire connector from distributor. Measure resistance between CPS terminal on distributor (Yellow/Blue wire) and ground. Replace
CPS if resistance is not 210-250 ohms.
CYLINDER IDENTIFICATION (CID) SENSOR (1.6L)
Turn ignition off. Connect BOB, leaving ECA connected. Turn ignition on, but DO NOT start engine. Measure voltage at BOB pin No. 34
(Yellow wire). Volt- meter should indicate less than one volt or more than 10 volts. Start engine and run at idle. Voltmeter should indicate 3-
5 volts. Replace CID sensor if voltage is not as specified.
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
1. Remove ECT sensor. ECT sensor is threaded into top of lower intake manifold on 1.3L, and on underside of intake manifold on 1.6L.
Place ECT sensor and thermometer into container of coolant.
2. Connect ohmmeter to coolant temperature sensor terminals. Cool or heat container. Note resistance at specified temperatures. See
ENGINE COOLANT TEMPERATURE SENSOR RESISTANCE
. Replace ECT sensor if resistance is not within specification.
ENGINE COOLANT TEMPERATURE SENSOR RESISTANCE
EXHAUST GAS OXYGEN (EGO) SENSOR
With engine at normal operating temperature, unplug connector from EGO in exhaust manifold. Measure voltage between EGO sensor
terminal and ground. Voltage should increase with increasing engine speed and decrease with decreasing engine speed. Voltage at idle should
fluctuate within a range of .2-.8 volt.
IDLE SW ITCH (1.6L)
Unplug connector from throttle position sensor on throttle body. Connect ohmmeter to switch terminals IDL and ground (Green/Orange and
Blue/Yellow wires on mating connector). Resistance must be less than 5 ohms with throttle in idle position, and more than 10,000 ohms with
throttle pedal depressed.
KNOCK SENSOR (1.6L TURBO)
Disconnect vacuum hose at distributor. Connect timing light. Start engine and record ignition timing. Tap intake plenum with a plastic mallet.
Knock sensor is okay if timing retards. If timing does not retard, check associated circuitry and components. See TIMING CONTROL
SYSTEMS under IGNITION SYSTEM.
NEUTRAL GEAR SWITCH (M/T)
1. Unplug connector near transmission. Place transmission in Neutral. Resistance across switch should be infinite.
2. Place transmission in any other gear. Resistance across switch should be zero ohms. If necessary, replace switch.
Vacuum In. Hg.(1) Voltage
03.84
53.36
102.66
151.93
201.26
25.58
(1)Voltage may vary by plus or minus 15 percent.
Temperature °F (°C)Ohms
-4 (-20)14,600-17,800
68 (20)2200-2700
104 (40)1000-1300
140 (60)500-650
176 (80)290-350
NOTE:A steady voltage higher than .55 volt indicates a continuously rich condition. A steady voltage lower
than .55 volt indicates a continuously lean condition.
Page 2 of 7 MITCHELL 1 ARTICLE - I - SYSTEM/COMPONENT TESTS 1991 ENGINE PERFORMANCE Ford Motor Co. - Ford/Merc
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memory. Intermittent failures may be caused by a sensor, connector, or wiring. See INTERMITTENTS in TESTS W/O CODES article in the
ENGINE PERFORMANCE Section.
VISUAL CHECK & VEHICLE PREPARATION
Before connecting any equipment to diagnose EEC system, perform following preparatory procedures:
Verify condition of air cleaner and air ducts.
Check all vacuum hoses for leaks, restrictions, or improper routing.
Check EEC system wiring harness electrical connections for corrosion, bent or broken pins, loose wires or terminals, or improper
routing.
Check ECA, sensors, and actuators for physical damage.
Check engine oil and coolant level.
Perform all necessary safety precautions to prevent personal injury or vehicle damage.
Set parking brake. Place shift lever in Park for automatic transmissions, or Neutral for manual transmissions. DO NOT move shift lever
during test unless specifically directed.
Turn off all lights and accessories. Ensure vehicle doors are closed when measuring voltage or resistance.
Start engine. Run at idle until upper radiator hose is hot and pressurized and engine is off fast idle. Check for leaks around exhaust
manifold, exhaust gas oxygen sensor, and vacuum hose connections.
Turn ignition off. Service items as required. Go to EQUIPMENT HOOK-UP .
EQUIPMENT HOOK-UP
VOM
1. Turn ignition off. Connect a jumper wire from STI connector to ground. Refer to SELF-TEST CONNECTOR LOCATION and
SELF
-TEST CONNECTOR WIRE COLORS tables. See Fig. 1 .
2. Connect VOM between STO terminal and engine ground. Set VOM to measure 0-20 volts DC.
CHECK ENGINE Light (MIL)
Connect a jumper wire between STI connector and ground.
SUPER STAR II Tester
Turn ignition off. Connect adapter cable leads to diagnostic tester. Connect service adapter cables to vehicle self-test connectors. Ground
adapter cable.
SELF-TEST CONNECTOR LOCATION
SELF-TEST CONNECTOR WIRE COLORS

Fig. 1: Self
-Test Connector Terminal ID
Courtesy of FORD MOTOR CO.
RETRIEVING CODES
Reading Service Codes
ApplicationLocation
1.3LLeft Rear Corner Of Engine Compartment
1.6LRight Rear Corner Of Engine Compartment
CircuitWire Color
1.3L
SMLBlue/Green
STIYellow/Green
STOYellow/White
1.6L
SMLBlack/Blue
STIYellow
STOGreen/Black
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CLEARING CODES
Clearing Codes Procedure
Disconnect negative battery cable. Press brake pedal for 5-10 seconds. Turn off VOM or Super Star II tester. Reconnect battery.
ECA LOCATION
ECA is located on center console behind kick panel on Capri, and under instrument panel on driver side of Festiva.
QUICK TESTS
KEY ON, ENGINE OFF (KOEO) SELF-TEST
KOEO
1. This is a test of electronic engine control system, conducted with power (voltage) applied and engine not running. Activate self-test, and
record all codes displayed.
2. Erase codes, and repeat self-test. Diagnose only codes occurring during repeat self-test. See TROUBLE CODE DEFINITION
table. If
no codes are present, proceed to KEY ON, ENGINE RUNNING (KOER) SELF
-TEST .
KEY ON, ENGINE RUNNING (KOER) SELF-TEST
KOER
1. Deactivate self-test. Start and run engine at 2000 RPM for 2 minutes to warm up EGO sensor. Turn off engine and wait 10 seconds.
2. Restart engine, and activate self-test. Record all service codes displayed. See TROUBLE CODE DEFINITION
table. If no codes are
present, proceed to SWITCH MONITOR TEST
.
SWITCH MONITOR TEST
This test procedure checks input signals received by ECA from individual switches. Use following procedure to perform switch monitor test:
Turn engine off and allow it to cool.
Ensure all accessories are turned off.
Deactivate self-test.
Ensure transmission is in Neutral or Park.
Turn ignition on.
SUPER STAR II Tester
Connect Super Star II tester adapter cable. Turn on tester. Latch center button. Operate each switch listed in SWITCH MONITOR TEST
table. Note output of LED on adapter cable as each switch operates. Record test results.
VOM
1. Ground STI connector. Connect VOM positive lead to SML terminal on self-test connector. Connect negative lead to ground. See Fig.
1 .
2. Operate each switch listed in SWITCH MONITOR TEST
table. Note output on VOM as each switch is operated. Go to specified
PINPOINT TEST if any switch does not meet specification.
SWITCH MONITOR TEST
(1)Festiva only.
(2)Capri only.
NOTE:DO NOT m ove throttle during KOEO self-test.
NOTE:It is necessary to clear codes in m em ory before perform ing this test. DO NOT m ove throttle during test.
NOTE:All switches m ust be tested individually. Allowing a switch to rem ain on while testing another will lead
to false test results.
NOTE:DO NOT m ove throttle, clutch, or transm ission lever unless so directed.
SwitchVOM Indication/Condition(1) Pinpoint Test
A/C SwitchLess Than 1.5 Volts; A/C & Blower Switch OnSTG
Blower Motor SwitchLess Than 1.5 Volts; Switch Set To "2" Or HigherSTG
Brake On/Off SwitchLess Than 1.5 Volts; Brake Pedal Partially
PressedSTP
Clutch Engage/Neutral Gear Switch (2) Less Than 1.5 Volts; In Gear, Clutch ReleasedSTG
Coolant Temperature SwitchLess Than 1.5 Volts; Cooling Fan OnSTP
Defrost SwitchLess Than 1.5 Volts; Defrost Switch OnSTP
Headlight SwitchLess Than 1.5 Volts; Headlight Switch OnSTP
Id l e Swit chLess Than 1.5 Volts; Accelerator Pedal PressedSTG
Page 4 of 20 MITCHELL 1 ARTICLE - G - TESTS W/CODES 1991-92 ENGINE PERFORMANCE Ford Motor Co. Self-Diagnostics
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1. Turn ignition off. Install BOB. Leave ECA disconnected. Connect test light between STI test pin on BOB and 12-volt source. If test
light comes on, go to PINPOINT TEST STO
. If light does not come on, go to next step.
2. Leave test light connected. Ground STI connector. If test light does not come on, repair open circuit between STI connector and ECA.
PINPOINT TEST STO - SELF-TEST OUTPUT

Fig. 16: Identifying STI & STO Circuit & Connector

STO CIRCUIT PIN IDENTIFICATION
1. Turn ignition off. Install BOB. Leave ECA disconnected. Measure resistance between STO test pin and STO terminal of self-test
connector. If resistance is greater than 5 ohms, repair circuit between ECA and self-test connector. If resistance is less than 5 ohms, go
to next step.
2. Measure resistance between STO test pin and all other test pins. If resistance between STO test pin and any other test pin is less than 5
ohms, repair short in STO wire to diagnostic connector. If resistance is greater than 5 ohms, go to PINPOINT TEST PGC
.
PINPOINT TEST PGC - POWER & GROUND CONNECTIONS
PGC CIRCUIT PIN IDENTIFICATION
1. Turn ignition off. Install BOB, leaving ECA disconnected. Turn ignition on. Measure voltage at BOB pin in question. Compare voltage
to specification in PGC CIRCUIT PIN IDENTIFICATION
table. If voltage is not to specification, repair wire in question.
2. Measure resistance between ground and BOB pin in question. If any measurement is greater than 5 ohms, repair associated wire to
ground. If resistance is less than 5 ohms, return to PINPOINT TEST VREF
if sent here from there, and replace ECA. If not sent here
from PINPOINT TEST VREF, return to diagnostic routine.
PINPOINT TEST STG - SWITCH TO GROUND
CircuitECA PinBOB PinWire Color
STI
1.3L1K48YEL/GRN
1.6L1W48YEL
NOTE:Enter this test only when codes cannot be retrieved or when directed by PINPOINT T EST ST I.
CircuitECA PinBOB PinWire Color
STO
1.3L1F17YEL/WHT
1.6L1B17GRN/BLK
NOTE:Enter this test only when directed here from QUICK T EST S or another PINPOINT T EST .
CircuitECA PinBOB PinWire Color
1.3L
GND2A39, 40, 44, 60BLK
GND2B20BLK
GND2C16BLK
GND2D46, 49BLK
KAPWR1A1(1) WHT/RED
MT/AT (2) 2J6BLK
1.6L
GND2R49BLK
GND3A20BLK
GND3G40BLK
KAPWR3J1(1) BLU/RED
(1)Battery voltage.
(2)Manual transmission only.
NOTE:Enter this test only when directed here from QUICK T EST S or another PINPOINT T EST .
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STG CIRCUIT PIN IDENTIFICATION
1. Turn ignition off. Install BOB, leaving ECA disconnected. Measure resistance between switch BOB test pin and ground. Cycle switch. I
f
resistance is greater than 10,000 ohms with switch open and less than 5 ohms when switch is closed, switch is okay; go to step 4). If
resistance is not greater than 10,000 ohms with switch open, or greater than 5 ohms when switch is closed, go to next step.
2. Turn ignition off. Disconnect switch. Connect ohmmeter between switch terminals on 2-pin switches, or between ground and switch
ECA terminal on multi-pin or one-pin switches. Cycle switch. If resistance is not greater than 10,000 ohms with switch open, or is
greater than 5 ohms when switch is closed, replace switch. If resistance is greater than 10,000 ohms with switch open and less than 5
ohms when switch is closed, switch is okay; go to next step.
3. Turn ignition off. Install BOB, leaving ECA disconnected. Measure resistance between BOB pin for suspected switch and BOB pins 26,
37, 57, and 60. If any measurement is less than 10,000, repair shorted wire in question. If all measurements are greater than 10,000
ohms, go to next step.
4. Turn ignition off. Install BOB, leaving ECA disconnected. Measure resistance between BOB pin for suspected switch and switch
connector. If resistance is greater than 5 ohms, repair wire in question. If sent here from SWITCH MONITOR TEST in QUICK TESTS,
replace ECA; otherwise, return to QUICK TESTS.
PINPOINT TEST STP - SWITCH TO POWER
STP CIRCUIT PIN IDENTIFICATION
1. Turn ignition off. Install BOB, leaving ECA disconnected. Turn ignition on. Cycle switch in question. Measure voltage between switch
BOB test pin and ground. If voltage changes from less than 4 volts to more than 10 volts, switch is okay. If sent here from SWITCH
MONITOR TEST in QUICK TESTS, replace ECA. If sent here from elsewhere in QUICK TESTS, return to QUICK TESTS. If voltage is
not as specified, go to next step.
2. Turn ignition on. Measure voltage at switch in question on wire to ECA. Cycle switch. If voltage changes from less than 4 volts to more
than 10 volts, repair wire from switch to ECA. If voltage does not change from less than 4 volts to more than 10 volts, go to next step.
3. Turn ignition on. Install BOB, leaving ECA disconnected. Measure resistance between BOB test pin for switch in question and ground
and between BOB test pin and BOB pins 37, 57, and 26. If resistance is greater than 10,000 ohms for all measurements, go to next step.
If resistance is not greater than 10,000 ohms for all measurements, repair wire to switch.
4. Disconnect switch. Measure resistance between switch terminals. Cycle switch. If resistance is less than 5 ohms with switch closed and
greater than 10,000 ohms with switch open, switch is okay. If sent here from SWITCH MONITOR TEST in QUICK TESTS, return to
QUICK TESTS. If sent here from elsewhere in QUICK TESTS, replace ECA. If resistance is not as specified, replace switch.
PINPOINT TEST VPWR - VEHICLE POWER
SwitchECA PinBOB PinWire Color
1.3L
ACS1Q10BLU/RED
BLMT1S23GRN
IDL1N18YEL/BLK
NGS/CES (1) 1V43BLU/WHT
PSPS1P19PNK
WOT2L27YEL
1.6L
BPS (2) 2L12LT GRN/BLK
IDL1E18GRN/ORG
NGS/CES (1) 1G8RED/BLU
PSPS1K19GRN/RED
(1)Manual transmission only.
(2)Turbo only.
NOTE:For 1.3L, blower m otor resistor m ust be disconnected, HEAT ER fuse m ust be rem oved, and blower
m otor switch m ust be in position "1" when testing ACS signal.
NOTE:Enter this test only when directed here from QUICK T EST S.
SwitchECA PinBOB PinWire Color
1.3L
ACS1Q10GRN
BOO1O2GRN/RED
DEF1T30BLK/BLU
Fan1R22YEL/RED
HLDT1U28WHT
VST1C5BLK/RED
1.6L
BOO1J3WHT/GRN
VST3B5BLK/RED
NOTE:Enter this test only when directed here from another PINPOINT T EST . T o prevent replacem ent of good
com ponents, note following non-EEC com ponents m ay be faulty: ignition switch, alternator, battery
cables, ground straps, or voltage regulator. T his test is intended to diagnose only ECA, wiring harness
circuits, and battery voltage.
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CLUTCH ENGAGE SWITCH (CES)
This switch is located on the manual transaxle and informs the ECA of transmission operating conditions. The ECA uses this data fo r id l e
speed control and canister purge valve operation.
CRANKSHAFT POSITION SENSOR (CPS) (FESTIVA)
This sensor is located in the distributor and sends engine RPM and crankshaft position data to the ECA. The ECA uses this data in calculating
fuel metering, ignition timing, idle speed control and canister purge valve operation.
CYLINDER IDENTIFICATION SENSOR (CID) (CAPRI)
This sensor is located in the distributor and provides crankshaft position data to the ECA. The ECA uses this data in calculating fuel metering
and ignition timing.
ELECTRICAL LOAD SWITCHES
Blower control, cooling fan, rear window defroster, air conditioning and headlight switches all send signals to the ECA. The ECA uses these
signals for idle speed control.
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
This sensor is located in the intake manifold and sends coolant temperature data to the ECA. The ECA uses this data in calculating fuel
metering, idle speed control and canister purge valve operation.
EXHAUST GAS OXYGEN (EGO) SENSOR
This sensor is located in the exhaust manifold and senses oxygen concentration in the exhaust gas. The ECA uses this data in calculating fuel
metering, idle speed control and canister purge valve operation.
NEUTRAL SAFETY SWITCH (A/T)
This switch is located on the automatic transaxle and sends a signal to the ECA whenever the transaxle is in Neutral or Park ranges. The ECA
uses this signal in calculating fuel metering, idle speed control and canister purge valve operation.
POWER STEERING PRESSURE SWITCH (PSPS)
This switch is located on the power steering pump and sends data about power steering operation to the ECA. The ECA uses this data for idle
speed control.
THROTTLE POSITION SENSOR (TP)
This device is located on the throttle body and contains 2 switches. The Wide Open Throttle (WOT) Switch sends a signal to the ECA when
throttle valve opening is more than 70 degrees. The ECA uses this signal in calculating fuel metering.
The Idle Switch (IDL) sends a signal to the ECA when throttle valve opening is less than 1.5 degrees. The ECA uses this signal for idle speed
control and canister purge valve operation.
VANE AIRFLOW (VAF) METER
This sensor is located in the air cleaner housing and sends intake airflow data to the ECA. The ECA uses this data in calculating fuel metering.
VANE AIR TEMPERATURE (VAT) SENSOR
This sensor is located inside the vane airflow sensor and senses intake air temperature. The ECA uses this data in calculating fu el met erin g,
idle speed control and canister purge valve operation.
CEC OUTPUT SIGNALS
CANISTER PURGE (CANP) SOLENOID
See EMISSION SYSTEMS.
CHECK ENGINE LIGHT
See SELF-DIAGNOSTIC SYSTEM.
FUEL INJECTORS
See FUEL CONTROL.
IDLE SPEED CONTROL BY-PASS AIR (ISC-BPA) VALVE
See IDLE SPEED. NOTE:Vehicles are equipped with different com binations of com puter-controlled com ponents. Not all
com ponents listed below are used on every vehicle. For theory and operation of each output
com ponent, refer to indicated system .
Page 2 of 6 MITCHELL 1 ARTICLE - E - THEORY/OPERATION 1991 ENGINE PERFORMANCE Ford/Mercury Theory & Operation
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ASCS
Air Suction Control Solenoid
ASD
Auto Shutdown
ASDM
Air Bag System Diagnostic Module
ASV
Air Suction Valve
A/T
Automatic Transmission/Transaxle
ATC
Automatic Temperature Control
ATDC
After Top Dead Center
ATF
Automatic Transmission Fluid
ATS
Air Temperature Sensor
Aux.
Auxiliary
Avg.
Average
AXOD
Automatic Transaxle Overdrive (Ford Models Only)
"B"
BAC
By-Pass Air Control
BAP
Barometric Absolute Pressure Sensor
BARO
Barometric
Batt.
Battery
Bbl.
Barrel (Example: 4-Bbl.)
BCM
Body Control Module
BHP
Brake Horsepower
BMAP
Page 2 of 15 MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations
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