1991 FORD FESTIVA coolant

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K - SENSOR RANGE CHART S
1991 ENGINE PERFORMANCE Ford Motor Co. Sensor Operating Range Charts
INTRODUCTION
Sensor operating range information can help determine if a sensor is out of calibration. An out-of-calibration sensor may not set a trouble
code, but it may cause driveability problems.
BAROMETRIC PRESSURE SENSOR OUTPUT VOLTAGE
ENGINE COOLANT TEMPERATURE SENSOR RESISTANCE
IGNITION DIAGNOSTIC MONITOR VOLTAGE
THROTTLE POSITION SENSOR RESISTANCE
(1)
VANE AIRFLOW METER VOLTAGE NOTE:Unless stated otherwise in test procedure, perform all voltage tests using a Digital Volt-Ohm m eter
(DVOM) with a m inim um 10-m egohm input im pedance.
Vacuum In. Hg.(1) Volts
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
RPM (1) Volts
5001.103
10001.257
15001.542
20001.768
25002.06
30002.15
35002.26
40002.50
45002.47
50002.40
(1)Revolutions per minute.
Throttle Opening(2) Ohms
1/8989
1/41104
3/81278
1/21462
5/81480
3/41459
7/81144
Fully Open1072
(1)Capri only. Festiva uses throttle position switch.
(2)Resistance may vary by plus or minus 15 percent.
Door Opening(1) Volts (Capri)(1) Volts (Festiva)
Fully Closed(2) .5-1.5
1/83.24.59
1/45.601.19
3/85.621.78
1/25.832.38
5/86.022.97
3/46.573.56
7/87.464.16
Fully Open7.874.5-5.0
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C - SPECIFICATIONS
1991 ENGINE PERFORMANCE Ford/Mercury - Service & Adjustm ent Specifications
INTRODUCTION
Use this article to quickly find specifications related to servicing and on-vehicle adjustments. This is a quick-reference article to use when you
are familiar with an adjustment procedure and only need a specification.
CAPACITIES
BATTERY SPECIFICATIONS
FLUID CAPACITIES
FLUID CAPACITIES
QUICK-SERVICE
SERVICE INTERVALS & SPECIFICATIONS
REPLACEMENT INTERVALS
BELT ADJUSTMENTS
(1)
BELT ADJUSTMENTS
(1)
MECHANICAL CHECKS
ENGINE COMPRESSION
Check engine compression at specified cranking speed with engine at normal operating temperature, all spark plugs removed and throttle wide
open.
COMPRESSION SPECIFICATIONS
ApplicationAmp Hr. Rating
1.3L & 1.6L50
ApplicationQts. (L)
Crankcase (Includes Filter)3.6 (3.4)
Cooling System (Includes Heater)5.3 (5.0)
Manual Transaxle (Mercon)2.6 (2.5)
Automatic Transaxle (Mercon)6.0 (5.7)
ApplicationQts. (L)
Crankcase (Includes Filter)
Non-Turbo3.5 (3.3)
Turbo3.7 (3.5)
Cooling System (Includes Heater)
Non-Turbo5.3 (5.0)
Turbo6.3 (6.0)
Manual Transaxle (Mercon)3.4 (3.2)
Automatic Transaxle (Mercon)6.0 (5.7)
ComponentInterval (Miles)
Air Filter30,000
Camsh aft Timin g Bel t60,000
Coolant30,000
Oil & Filter3000
Spark Plugs30,000
ApplicationNew BeltUsed Belt
A/C Belt110-125 (50-57)92-110 (42-50)
Alternator Belt110-132 (50-60)95-110 (43-50)
(1)Tension in Lbs. (Kg) Using Strand Tension Gauge
ApplicationNew BeltUsed Belt
A/C Belt110-132 (50-60)110-132 (50-60)
Alternator Belt110-132 (50-60)110-132 (50-60)
(1)Tension in Lbs. (Kg) Using Strand Tension Gauge.
ApplicationSpecification
Compression Ratio
1.3L9.7:1
1.6L(1)
Compression Pressure(2)
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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.
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resistance is not within specifications. If injector resistance is okay, check for 12 volts at each injector connector. Repair or replace
connector as necessary.
FUEL INJECTOR RESISTANCE
IDLE CONTROL SYSTEM
Idle Speed Control By-pass Air (ISC-BPA) Valve
1. Remove ISC-BPA valve from engine. Connect a hose from a hot water tap to coolant inlet nipple on ISC-BPA valve. Blow through
valve air port. Note resistance to airflow.
2. Supply hot water at 130°F (56°C) minimum to ISC-BPA valve and allow time for valve to respond. Blow through valve again. If
resistance to airflow does not increase when valve is hot, replace ISC-BPA valve.
3. Apply 12 volts to solenoid terminals. If solenoid does not click, replace ISC-BPA valve.
IGNITION SYSTEM
PICK-UP COIL
Check continuity of pick-up coil. If continuity exists, replace igniter unit. If continuity does not exist, replace pick-up coil.
TIMING CONTROL SYSTEMS
Advance Components (1.3L)
Ignition timing advance is controlled by the ECA.
Advance Components (1.6L Non-Turbo)
Ignition advance is controlled by a centrifugal advance mechanism within the distributor, and by a vacuum advance mechanism. If centrifugal
advance is not within specification, service the distributor. Replace the vacuum advance mechanism if vacuum advance is not within
specification. See IGNITION TIMING
. Also see IGNITION TIMING in ADJUSTMENTS article in the ENGINE PERFORMANCE Section.
IGNITION TIMING
Retard Components (1.6L Turbo)
Positive pressure to the vacuum advance cylinder on the distributor retards ignition timing. The ECA also retards ignition timing when it
receives a signal from a Knock Sensor (KS), Knock Control Unit (KC) and related circuitry.
1. Disconnect and plug hoses at distributor. Connect timing light and start engine. Record ignition timing. Tap intake plenum with plastic
mallet while observing ignition timing. If timing retards, knock control circuitry is okay. If timing does not retard, go to step 2).
2. Unplug KC sensor service connector near ECA. Tap intake plenum with plastic mallet while observing ignition timing. If ignition timing
retards, go to step 3). If timing does not retard, go to step 4).
3. Reconnect KC service connector. Tap intake plenum with plastic mallet while observing ignition timing. If ignition timing retards,
replace knock controller. If ignition timing does not retard, go to step 4).
4. Unplug KC service connector near ECA. Temporarily install a known good KS. Tap intake plenum with plastic mallet while observing
ignition timing. If ignition timing retards, replace KS. If ignition timing does not retard, go to step 5).
5. Turn ignition off. Connect BOB. Ensure VPWR and ground wires to KC are okay. Check all KC wiring for shorts or opens. If wiring is
okay, replace KC.
EMISSION SYSTEMS & SUB-SYSTEMS
FUEL EVAPORATION
Canister Purge Solenoid
1. Disconnect vacuum hoses from solenoid. See Fig. 1 . Blow through port "A". Ensure no air exhausts from port "B".
2. Disconnect 2-wire connector from solenoid. Connect 12 volts to one terminal and ground the other terminal of solenoid. Blow air
though port "A". Ensure air exhausts through port "B".
ApplicationOhms
1.3L & 1.6L12-16
NOTE:For basic ignition checks, see BASIC T EST ING article in the ENGINE PERFORMANCE Section.
ApplicationAuto. Trans.Man. Trans.
1.6L Non-Turbo1-3 @ 8500-4 @ 850
1.6L Turbo10-14 @ 8500-4 @ 850
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G - T EST S W/CODES
1991-92 ENGINE PERFORMANCE Ford Motor Co. Self-Diagnostics
INTRODUCTION
If no faults were found while performing BASIC TESTING , proceed with self-diagnostics. If no fault codes or only pass codes are present
after entering self-diagnostics, proceed to TESTS W/O CODES article in the ENGINE PERFORMANCE Section for diagnosis by symptom
(i.e., ROUGH IDLE, NO START, etc.).
This article uses many abbreviations for devices, signal names, and wire colors. See SELF
-DIAGNOSTICS ABBREVIATIONS table.
Abbreviations for wire colors used in individual PINPOINT TEST diagrams are as follows:
BLK - Black
BLU - Blue
BRN - Brown
GRN - Green
LT GRN - Light Green
ORG - Orange
PNK - Pink
RED - Red
WHT - White
YEL - Yellow
SELF-DIAGNOSTICS ABBREVIATIONS
SELF-DIAGNOSTIC SYSTEM
Hard Failures
Hard failures cause CHECK ENGINE light (MIL) to come on and remain on until problem is repaired. If MIL comes on and remains on (light
may flash) during vehicle operation, cause of malfunction must be determined using diagnostic (code) charts. If a sensor fails, ECA will use a
substitute value in its calculations to permit continued engine operation. In this condition (limp-in mode), vehicle will run but driveability will
not be optimum.
Intermittent Failures
Intermittent failures may cause MIL to flicker or come on and go off after intermittent defect goes away. Corresponding trouble code, however,
will be retained in ECA memory. If related defect does not reoccur within a certain time frame, related trouble code will be erased from ECA
ApplicationAbbreviation
Analog Volt/OhmmeterVOM
Barometric Pressure SensorBP
Breakout BoxBOB
Canister Purge Control SolenoidCANP
CHECK ENGINE LightMIL
Crankshaft Position SensorCPS
Cylinder Identification SensorCID
Electronic Control AssemblyECA
Electronic Engine ControlEEC
Engine Coolant Temperature SensorECT
Exhaust Gas Oxygen SensorEGO
Idle Speed ControlISC
Ignition Diagnostic MonitorIDM
Keep Alive PowerKAPWR
Key On Engine OffKOEO
Key On Engine RunningKOER
Knock ControlKC
Power & Ground ConnectionsPGC
Fuel Pressure Regulator Control SolenoidPRC
Reference Voltage & Signal ReturnVREF
Self-Test InputSTI
Self-Test OutputSTO
Signal ReturnSIGRTN
Solenoid Controlled By GroundSCG
Switch Monitor LampSML
Switch To GroundSTG
Switch To PowerSTP
Throttle Position SensorTP
Vane Airflow MeterVAF
Vane Air Temperature SensorVAT
Vehicle PowerVPWR
Vehicle Speed SensorVSS
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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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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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