1991 FORD FESTIVA Service Manual

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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Engine control system communicates malfunctions to technician through service codes. These service codes are 2-digit numbers representing a
particular defect. Service codes are transmitted through STO connector.
Service codes are displayed as timed pulses, and may be read with a VOM or Super Star II tester. VOM displays codes by needle sweeps. See
Fig. 2
.
Turn ignition off. Ensure all procedures of EQUIPMENT HOOK
-UP have been followed. Engine should be at normal operating
temperature.

Fig. 2: Reading Service Codes With VOM

Courtesy of FORD MOTOR CO.
VOM
Disconnect and reconnect jumper wire from STI terminal to ground. Turn ignition on. Record displayed codes. Erase codes, and repeat test
procedure to verify all codes are currently valid. See ERASING CODES & RETESTING . Service only those codes which appear during
retest. Refer to TROUBLE CODE DEFINITION
table to find appropriate pinpoint test.
MIL
Turn ignition on. Connect a jumper wire between STI connector and ground. Observe MIL, and record pulses to determine codes stored.
SUPER STAR II Tester
Set center button to TEST position. Turn ignition on. Turn tester on. When activated, tester should display 888 for 2 seconds. Release and
reset center TEST button. After all codes are displayed, release center button. All codes in tester memory may now be reviewed.
ERASING CODES & RETESTING
Erasing codes and retesting will give an indication of whether codes are hard or intermittent defects. Hard codes reset immediately and will be
displayed during retest.
Disconnect negative battery cable. Press brake pedal for 5-10 seconds. Turn off VOM or Super Star II tester. Reconnect battery. Perform tests
under RETRIEVING CODES
to again display and record codes.
TROUBLE CODE DEFINITION
TROUBLE CODE DEFINITION
NOTE:If MIL flashes continuously prior to connecting test equipm ent, go to PINPOINT T EST ST I .
Service CodeFaultCircuit & Pinpoint Test
01Ignition Diagnostic MonitorIDM
02 (1) Crankshaft Position SensorCPS
03 (2) Cylinder Identification SensorCID
06 (2) Vehicle Speed SensorVSS
08Vane Airflow MeterVAF
09Engine Coolant Temperature SensorECT
10Vane Air Temperature SensorVAT
12 (2) Throttle Position SensorTP
14Barometric Pressure SensorBP
15Exhaust Gas Oxygen SensorEGO
17Exhaust Gas Oxygen SensorEGO
25 (2) Fuel Pressure Regulator Control SolenoidPRC
26Canister Purge Control SolenoidCANP
34Idle Speed ControlISC
Codes Not ListedPower & Ground ConnectionsPGC
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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
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WIGGLE TEST
Checking Circuitry
1. Visually inspect suspected sensor, switch, or solenoid. Enter WIGGLE TEST if using Super Star II tester. If using VOM, connect it to
STO terminal on self-test connector, and ground STI self-test connector terminal. Lightly tap sensor, switch, or solenoid.
2. Push and pull on suspected sensor, switch, or solenoid connector, but DO NOT unplug it. Test and wiggle harness vigorously, working
in small sections, from suspected device toward dash panel, and from dash panel to ECA.
3. If VOM or Super Star II tester does not display a positive indication of an intermittent defect, carefully disconnect suspected device.
Remove terminals from connector.
4. Inspect terminals at both ends for corrosion, bad crimps, or improperly seated terminals. Reconnect after inspection. Unplug harness
fro m E CA.
5. Inspect ECA and harness connector terminals for corrosion, bad crimps, or improperly seated terminals. If VOM does not indicate any
intermittent defect, reconnect wiring and erase codes.
PINPOINT TESTS
HOW TO USE PINPOINT TESTS
1. DO NOT perform any PINPOINT TEST unless directed by a QUICK TESTS procedure. Ensure all non-EEC related defects are
corrected. Follow each test step in order until defect is found. DO NOT replace any part unless so directed. When more than one service
code exists, start with first code displayed.
2. PINPOINT TESTS require ensuring electrical circuits are okay before replacing sensors or any other components. Always test circuits
for continuity between sensor and ECA. Test all circuits for shorts to power, opens, or shorts to ground. VREF and VPWR circuits
should be tested with KOEO or as specified in PINPOINT TESTS.
3. DO NOT measure voltage or resistance at ECA, or connect any test light unless specified in testing procedure. DO NOT pierce wiring.
Isolate both ends of a circuit and turn key off whenever checking for shorts or continuity, unless otherwise specified.
4. Disconnect solenoids and switches before checking circuit continuity or energizing solenoids.
5. An open is defined as any resistance greater than 10,000 ohms, unless otherwise specified.
6. To help diagnose circuits to ECA, turn ignition off and disconnect ECA harness. Connect BOB between ECA and ECA harness to
perform circuit and pinpoint tests.
PINPOINT TEST IDM - IGNITION DIAGNOSTIC MONITOR

Fig. 3: Identifying IDM Circuit & Connector

IDM CIRCUIT PIN IDENTIFICATION
Manual Lever Position SwitchLess Than 1.5 Volts; Transaxle In Park Or NeutralSTP
Wide Open Throttle SwitchLess Than 1.5 Volts; Accelerator Pedal Fully
PressedSTG
(1)Proceed to PINPOINT TEST indicated if Super Star II tester/VOM indication is incorrect.
(2)Not applicable to vehicles with A/T.
NOTE:Following tests and illustrations are courtesy of Ford Motor Co. Com plete EEC system wiring diagram s
m ay be found in WIRING DIAGRAMS article in the ENGINE PERFORMANCE Section.
NOTE:Check all wiring, harnesses, connectors, and com ponents for dam age, overheating, shorting, or
looseness. If any defect is found, repair as necessary before proceeding to any PINPOINT T EST .
NOTE:Enter this test only when Code 01 is displayed during QUICK T EST S procedure or when directed here
from another PINPOINT TEST.
CircuitECA PinBOB PinWire Color
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1.3L
1. Connect spark tester between coil secondary wire and ground. Crank engine several times, leaving ignition on between cranking periods.
If continuous sparks jump tester gap, go to next step. If continuous sparks do not jump tester gap, go to step 3).
2. With ignition off, connect BOB, leaving ECA disconnected. Connect test light between test pins IDM and VPWR. Crank engine several
times. If test light flashes each time engine cranks, IDM circuit is okay. Return to QUICK TESTS if directed here from there. If test light
does not flash, repair IDM wire between ECA and coil.
3. Unplug connector from ignition coil. Connect test light between coil IDM wire and PWR wire. Crank engine several times, leaving
ignition on between cranking periods. If test light flashes continuously, go to next step. If test light does not flash continuously, go to
step 6).
4. Turn ignition on. Measure voltage between coil harness PWR wire and ground. If voltage is greater than 10 volts, replace coil. If voltage
is less than 10 volts, repair wire between ignition switch and coil.
5. Connect test light between PWR and ground terminals at coil harness connector. Turn ignition on. If test light glows, replace coil. If test
light does not glow, repair ground wire to coil.
6. Unplug connector from ignition module. Connect jumper wire between SPOUT wire on ignition module harness connector and mating
terminal on ignition module. Connect another jumper wire between ignition module GND wire and mating connector. Leave IDM wire
disconnected. Connect test light between IDM terminal on ignition module and PWR wire. Crank engine several times, leaving ignition
on between cranking periods. If test light flashes each time engine cranks, repair wire between ignition module IDM wire and coil . If t est
light does not flash, go to next step.
7. Turn ignition off. Unplug ignition module connector. Turn ignition on. Measure voltage between ignition module PWR wire and ground.
Turn ignition on. If voltage is not more than 10 volts, repair PWR wire from ignition switch. If voltage is more than 10 volts, go t o n e xt
step.
8. Turn ignition off. Unplug ignition module connector. Turn ignition on. Connect test light between ignition coil PWR wire and ignition
module GND wire. Turn ignition on. If test light glows, go to step 10). If test light does not glow, go to next step.
9. Turn ignition off. Unplug ignition module connector. Connect test light between ignition coil PWR wire and ignition module SPOUT
wire. Crank engine. If test light flashes, check ignition module SPOUT wire for short to ground; if no short exists, replace ignition
module. If test light does not flash, go to next step.
10. Turn ignition off. Unplug ignition module connector. Install BOB, leaving ECA disconnected. Check SPOUT wire for continuity
between BOB test pin and ignition module. If continuity exists, check SPOUT wire for shorts to any other wire. If no short exists,
replace ECA. If continuity does not exist, repair SPOUT wire to ECA.
1.6L
1. Connect spark tester between coil secondary wire and ground. Crank engine several times, leaving ignition on between cranking periods.
If continuous sparks do not jump tester gap, go to step 3). If continuous sparks jump tester gap, go to next step.
2. Turn ignition off. Connect BOB. Leave ECA disconnected. Connect test light between test BOB pins IDM and VPWR. Crank engine
several times. If test light flashes each time engine cranks, IDM circuit is okay. Return to QUICK TESTS if directed here from there. If
test light does not flash, repair IDM wire between ECA and coil.
3. Unplug connector from ignition coil. Connect test light between coil IDM wire and PWR wire. Crank engine several times, leaving
ignition on between cranking periods. If test light does not flash continuously, go to step 6). If test light flashes continuously, go to next
step.
4. Turn ignition on. Measure voltage between coil harness PWR wire and ground. If voltage is greater than 10 volts, replace coil. If voltage
is less than 10 volts, repair wire between ignition switch and coil.
5. Connect test light between PWR and ground terminals at coil harness connector. Turn ignition on. If test light glows, replace coil. If test
light does not glow, repair ground wire to coil.
6. Unplug connector from ignition module. Connect a jumper wire between PWR wire on ignition module harness connector and mating
terminal on ignition module. Leave IDM wire disconnected. Connect test light between IDM terminal on ignition module and PWR
wire. Crank engine several times, leaving ignition on between cranking periods. If test light flashes each time engine cranks, repair wire
between ignition module IDM wire and coil. If test light does not flash. go to next step.
7. Unplug connector from ignition module. Measure voltage between ignition module PWR wire and ground. If voltage is not higher than
10 volts, repair PWR wire from ignition switch. If voltage is higher than 10 volts, go to next step.
8. Turn ignition off. Unplug ignition module connector. Turn ignition on. Connect test light between ignition module PWR wire and
ignition module GND wire. Turn ignition on. If test light glows, replace ignition module. If test light does not glow, repair ignition
module ground wire.
PINPOINT TEST CPS - CRANKSHAFT POSITION SENSOR
1.3L
GND2A39, 40, 44, 60BLK
IDM(1) (1) YEL/GRN
PWR(1) (1) BLK/WHT
SPOUT1G36BLU/ORG
1.6L
IDM1M6YEL/BLU
PWR**********BLK/WHT
(1)ECA and BOB pins not specified.
NOTE:Enter this test only when Code 02 is displayed during QUICK T EST S procedure or when directed here
from another PINPOINT TEST.
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Fig. 4: Identifying CPS Circuit & Connector

CPS CIRCUIT PIN IDENTIFICATION
1. Turn ignition off. Install BOB. Leave ECA disconnected. Unplug distributor connector. Measure resistance of CPS, VPWR, and GND
wires between ECA and distributor. If all resistances are not less than 5 ohms, repair wire in question. If all resistances are less than 5
ohms, go to next step.
2. Turn ignition off. Unplug distributor connector. Turn ignition on. Measure voltage between distributor VPWR and GND wires. If
voltage is more than 10 volts, replace CPS sensor. If voltage is not more than 10 volts, repair distributor GND wire.
PINPOINT TEST CID - CYLINDER IDENTIFICATION SENSOR

Fig. 5: Identifying CID Circuit & Connectors

CID CIRCUIT PIN IDENTIFICATION
1. Turn ignition off. Install BOB, leaving ECA disconnected. Unplug distributor connector. Measure resistance between BOB pin No. 34
and CID terminal on distributor harness connector. Repair Yellow wire between ECA and distributor if resistance is greater than 5
ohms. If resistance is less than 5 ohms, go to next step.
2. Turn ignition on. Measure voltage between distributor VPWR and GND wires. If voltage is greater than 10 volts, replace CID sensor. If
voltage is not greater than 10 volts, repair distributor GND wire.
PINPOINT TEST KC - KNOCK CONTROL
CircuitECA PinBOB PinWire Color
CPS2E56YEL/BLU
GND2A39, 40, 44, 60BLK
GND2B20BLK
GND2C16BLK
VPWR1B37, 57YEL/BLK
NOTE:Enter this test only when Code 03 is displayed during QUICK T EST S procedure or when directed here
from another PINPOINT TEST.
CircuitECA PinBOB PinWire Color
CID1N34YEL
NOTE:Enter this test only when directed here from QUICK T EST S.
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Fig. 6: Identifying KC Circuit & Connectors

1. Disconnect and plug vacuum hose at distributor. Connect timing light. Start engine. Unplug knock control service connector, located
near ECA. If timing retards, service knock sensor and/or knock sensor wiring. If timing does not retard, go to next step.
2. Determine and record ignition timing setting. Tap intake plenum with plastic mallet. If timing does not retard, go to step 4). If t imin g
retards, go to next step.
3. Reconnect knock control service connector, located near ECA. Determine and record ignition timing setting. Tap intake plenum with
plastic mallet. If timing does not retard, knock control unit is okay; go to next step. If timing retards, replace knock control unit.
4. Turn ignition off. Unplug knock control service connector, located near ECA. Install a known good knock sensor. Start engine. Tap
intake plenum with plastic mallet. If timing retards, replace knock sensor. If timing does not retard, go to next step.
5. Check VPWR and GND (Yellow/Green and Black/Yellow wires respectively) to knock control unit for shorts or open circuits. Service
wires as necessary. If wires are okay, replace knock control unit.
PINPOINT TEST VSS - VEHICLE SPEED SENSOR

Fig. 7: Identifying VSS Circuit & Connectors

VSS CIRCUIT PIN IDENTIFICATION
1.Install 4EAT Tester Leave 4EAT module disconnected. Disconnect speedometer cable at transaxle. Measure resistance between BOB
VSS and GND test pins. Rotate speedometer cable. If resistance drops to less than 5 ohms 4 times for each revolution of speedometer
cable, VSS is okay. Return to QUICK TESTS if sent here from there; otherwise, replace 4EAT module. If resistance does not drop as
NOTE:Enter this test only when Code 06 is displayed during QUICK T EST S procedure or when directed here
from another PINPOINT TEST.
Circuit4EAT PinWire Color
GND1JBLK
VSS1PGRN/RED
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specified, go to next step.
2. Unplug VSS connector at instrument cluster. Measure resistance between VSS and GND terminals on instrument cluster. Rotate
speedometer cable. If resistance drops to less than 5 ohms 4 times for each revolution of speedometer cable, repair VSS signal wire to
4EAT. If resistance does not drop as specified, replace speedometer assembly.
PINPOINT TEST VAF - VANE AIRFLOW METER

Fig. 8: Identifying VAF Meter Circuits

VAF CIRCUIT PIN IDENTIFICATION
1.3L
1. Turn ignition off. Install BOB. Turn on ignition. Measure voltage between VAF and ground pins while moving vane in VAF meter.
Voltage should vary smoothly between .5-1.5 volts with door open, and 4.5-5.0 with door closed. If voltage is as specified, VAF met er
is okay; return to QUICK TESTS if sent here from there. If not sent here from QUICK TESTS, replace ECA. If voltage is not as
specified, go to next step.
2. Remove connector from VAF meter. Using jumper wires, connect VREF and ground terminals on VAF connector to corresponding
terminals on VAF meter. Turn ignition on. Measure voltage between VAF terminal on VAF meter and ground terminal while moving
vane in VAF meter. Voltage should vary smoothly between .5-1.5 volts with door open, and 4.5-5.0 with door closed. If voltage is
correct, repair VAF circuit between ECA and VAF meter. If voltage is not as specified, go to next step.
3. Turn ignition off. Unplug VAF meter connector. Turn ignition on. Measure voltage between VREF and ground wires. If voltage is 4.5-
5.5 volts, replace VAF meter. If voltage is not 4.5-5.5 volts, go to PINPOINT TEST VREF.
1.6L
1. Turn ignition off. Install BOB. Turn ignition on. Measure voltage between VAF and SIGRTN pins while moving vane in VAF meter.
Voltage should be as specified in VAF METER VOLTAGE table. If voltage is not as specified, go to step 3). If voltage is as specified, go
to next step.
2. Measure voltage between VMREF and SIGRTN test pins. If voltage is 7-9 volts, circuit is okay; return to QUICK TESTS if sent here
from there. If not sent here from QUICK TESTS, replace ECA. If voltage is not as specified, repair VMREF wire to VAF.
3. Unplug connector from VAF meter. Using jumper wires, connect VPWR, VMREF, and SIGRTN terminals on VAF connector to
corresponding terminals on VAF meter. Leave VAF wire disconnected. Measure voltage between VAF and SIGRTN pins on harness NOTE:Enter this test only when a Code 08 is displayed during QUICK TESTS procedure, or when directed here
from another PINPOINT T EST . T o avoid unnecessary diagnostic tim e, check for unm etered air leaks
between VAF m eter and throttle body. T his test is intended to diagnose only VAF and VREF circuits.
CircuitECA PinBOB PinWire Color
1.3L
GND2A45BLK
VAF2O25WHT
VREF2D46, 49BLK
1.6L
SIGRTN2C46BLK/YEL
VAF2E43LT GRN/BLK
VMREF2B18LT GRN/RED
VPWR3I37YEL/GRN
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