1991 FORD FESTIVA engine oil

Removal
Drain radiator and remove negative battery cable. Disconnect throttle cable. Remove air duct from throttle body. Disconnect throttle position
sensor/switch connector. Mark all coolant and vacuum hoses for reassembly reference and remove from throttle body. See Fig. 4
. Remove
intake plenum bolts and remove intake plenum and gasket.
Installation
To install, reverse removal procedure. Use NEW intake plenum-to-intake manifold gasket. Tighten bolts to specification, see TORQUE
SPECIFICATIONS at end of article.
OXYGEN (O2) SENSOR
Removal & Installation
Disconnect negative battery cable. Disconnect wire harness connector, and remove oxygen sensor. If exhaust sensor is difficult to remove, use
rust penetrant to avoid possible damage to exhaust threads. If new sensor is not pre-coated with anti-seize, apply anti-seize compound to
sensor threads. DO NOT remove anti-seize from sensor. To install, tighten sensor and attach wire harness connector.
THROTTLE BODY
Removal & Installation
Drain radiator and remove negative battery cable. Remove resonance chamber. Disconnect throttle cable. Remove air duct. Mark all coolant
and vacuum hoses for reassembly reference and remove from throttle body. Disconnect throttle position sensor/switch connector. Remove
throttle body nuts and bolts. Remove throttle body and gasket. To install, reverse removal procedure using NEW throttle body-to-intake
plenum gasket.
THROTTLE POSITION SENSOR/SWITCH
Removal & Installation
Disconnect negative battery cable. Disconnect throttle position sensor/switch connector. Remove attaching bolts. Remove sensor/switch from
throttle body. To install, reverse removal procedure.
TURBOCHARGER
Removal
1. Drain radiator and remove negative battery cable. Remove throttle body air intake tube. Disconnect intercooler hose from turbocharger
assembly. Disconnect O2 sensor. Remove lower heat shield retaining bolts and lower heat shield from turbocharger. Remove upper heat
shield retaining bolts and upper heat shield from exhaust manifold.
2. Slide O2 sensor wire and guide through upper heat shield. Remove side heat shield retaining bolts from turbocharger, and remove sid e
heat shield. Remove power steering belt. Remove power steering pump through bolt and adjuster nuts and bolts. Disconnect lower
radiator hose from water pump.
3. Pull pump from bracket, and position pump to access mounting bracket retaining nut and bolts. Remove mounting bracket-to-engine nut
and bolts and remove bracket. Remove air cleaner duct retaining screws. Loosen clamp at turbocharger and move duct tube out of way.
Disconnect coolant supply hose at turbocharger.
4. Remove bolt and sealing washers attaching oil supply line at engine block. Raise vehicle on hoist. Remove nuts and washers from
exhaust pipe flange. Remove bolts attaching exhaust hanger to engine block. Slide rubber exhaust hangers from catalytic converter. Pull
exhaust pipe downward and to left side of vehicle. Disconnect oil return hose from turbocharger. Disconnect coolant return hose fro m
turbocharger.
5. Remove turbocharger support bracket retaining bolts. Remove coolant by-pass tube outlet-to-water pump bolts. Lower vehicle. Loosen
retaining clamp bolt on coolant by-pass tube at rear of cylinder head. Remove 11 retaining nuts from exhaust manifold. Position coolant
by-pass tube out of way after pulling bracket from exhaust stud.
6. Remove exhaust manifold by pulling off studs and moving assembly towards right side of engine compartment, clearing cooling fan.
With assembly removed from vehicle, remove turbocharger-to-exhaust manifold nuts. Separate assembly and discard gasket.
Installation
1. Install NEW gasket on exhaust manifold and install turbocharger onto studs. Install turbocharger-to-exhaust manifold nuts. Remo ve o il
supply line from turbocharger. Install NEW exhaust gasket on cylinder head. Install turbocharger and exhaust manifold assembly onto
studs. Install coolant by-pass tube bracket onto exhaust stud. Install 11 retaining nuts onto exhaust manifold.
2. Securely tighten heater tube clamp bolt. Raise vehicle. Install coolant by-pass tube outlet-to-water pump bolts. Install turbocharger
support bracket retaining bolts. Connect coolant return hose to turbocharger. Connect oil return hose to turbocharger. Install exhaust
pipe onto turbocharger, and hand tighten nuts and washers. Install bolts attaching exhaust hanger to engine block.
3. Slide rubber exhaust hangers onto catalytic converter. Tighten exhaust pipe nuts and washers. Lower vehicle. Install bolt and sealing
washers attaching oil supply line at engine block. Install oil supply line onto turbocharger. To complete installation, reverse removal
procedure. Tighten bolts and nuts to specification, see TORQUE SPECIFICATIONS
at end of article. NOTE:T o prevent dust and dirt from entering intake m anifold ports, cover ports with clean cloth after
rem oving intake plenum .
WARNING:DO NOT rem ove oxygen sensor when engine is hot.
NOTE:Clean throttle body exterior before rem oval.
CAUT ION: Before installing turbocharger, put .8 oz. (25 m l) engine oil into turbocharger oil inlet.
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VANE AIRFLOW (VAF) METER
Removal
1. Disconnect negative battery cable. On Capri, disconnect primary and secondary wires from coil. On Festiva, disconnect VAF wire
harness connector. Remove air duct.
2. On Capri, remove retaining bolt and ground wire from air cleaner cover. Remove air cleaner cover bolts and air cleaner cover. From
inside of air cleaner cover, remove VAF meter retaining nuts. On Festiva, remove attaching bolt and 4 nuts. Remove vane airflow met er.
Installation
To install, reverse removal procedure. Position new gasket over VAF mounting studs. Tighten bolts and nuts to specification, see TORQUE
SPECIFICATIONS at end of article.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS NOTE:For all on-vehicle adjustm ents not covered in this article, see ADJUST MENT S article in the ENGINE
PERFORMANCE Section.
ApplicationFt. Lbs. (N.m)
Coolant By-Pass Tube Outlet-To-Water Pump Bolts14-19 (19-26)
Distributor Mounting Bolts14-19 (19-26)
Exhaust Manifold Retaining Nuts29-42 (39-57)
Exhaust Pipe Nuts18-25 (24-34)
Fuel Line-To-Fuel Filter Bolt18-25 (24-34)
Fuel Pressure Regulator Nut(1)
Fuel Rail Retaining Bolt14-19 (19-26)
Heat Shield Bolts14-19 (19-26)
Intake Plenum Bolts/Nuts11-16 (15-22)
Oil Supply Line-To-Turbocharger Bolt12-17 (16-23)
Oxygen Sensor(1)
Power Steering Pump Bracket-To-Engine Bolts/Nut35-48 (47-65)
Throttle Body Bolt/Nuts12-17 (16-23)
Turbocharger Support Bracket Bolts32-45 (43-61)
Turbocharger-To-Exhaust Manifold Nuts20-25 (27-34)
INCH Lbs. (N.m)
Barometric Pressure (BP) Sensor Nut54-84 (6-9)
MAP Sensor Nuts54-84 (6-9)
Oil Supply Line-To-Engine Block Bolt104-156 (12-18)
Vane Airflow Meter Nuts110-152 (12-18)
(1)Information not available from manufacturer.
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00022705
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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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VALVE CLEARANCE
IGNITION SYSTEM
IGNITION COIL
IGNITION COIL RESISTANCE
CRANKSHAFT POSITION SENSOR
CRANKSHAFT POSITION SENSOR RESISTANCE
HIGH TENSION WIRE RESISTANCE
HIGH TENSION WIRE RESISTANCE
SPARK PLUGS
SPARK PLUG TYPE
SPARK PLUG SPECIFICATIONS
FIRING ORDER & TIMING MARKS

Fig. 1: Firing Order & Distributor Rotation

IGNITION TIMING
(1)Information is not available.
(2)Lowest cylinder compression reading should not be less than 75 percent of highest cylinder compression reading.
NOTE:All m odels are equipped with hydraulic lash adjusters. No adjustm ents are required.
ApplicationPrimary (Ohms)Secondary (Ohms)
1.3L & 1.6L0.8-1.66000-30,000
ApplicationOhms
1.3L(1) 210-250
1.6L(2)
(1)Measured between CPS (Yellow/Blue) and GND terminal.
(2)Capri is equipped with Cylinder Identification (CID) sensor. Resistance is not specified.
ApplicationOhms
Coil Wire & Spark Plug Wires4000-6000 per foot
ApplicationMotorcraft
1.3LAGS32C
1.6L
Non-TurboAGSP32C
TurboAGS32C
ApplicationGap: In.- (mm)Torque: Ft.-Lbs./(N.m)
1.3L & 1.6L.039-.043 (1.0-1.1)10-17 (14-23)
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
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F - BASIC TESTING
1991-92 ENGINE PERFORMANCE Ford Motor Co. Basic Diagnostic Procedures
INTRODUCTION
The following diagnostic steps help prevent overlooking simple problems and begin diagnosis for a no-start condition.
The first step in diagnosing any driveability problem is to verify the complaint. Test drive the vehicle under the conditions in which the
problem reportedly occurred.
Before entering self-diagnostics, perform a careful and complete visual inspection. Most engine control problems result from mechanical
breakdowns, poor electrical connections or damaged/misrouted vacuum hoses. Before condemning the computerized system, perform each test
listed in this article.
PRELIMINARY INSPECTION & ADJUSTMENTS
VISUAL INSPECTION
Perform a visual inspection of all electrical wiring. Look for chafed, stretched, cut or pinched wiring. Ensure electrical connections fit tightly
and are not corroded. Ensure vacuum hoses are properly routed and are not cut or pinched. If necessary, see VACUUM DIAGRAMS article in
the ENGINE PERFORMANCE Section to verify routing and connections. Inspect air induction system for possible vacuum leaks.
MECHANICAL INSPECTION
Compression
Engine mechanical condition can be checked using a compression gauge, vacuum gauge or engine analyzer. See engine analyzer instruction
manual for specific instructions. Lowest compression reading must be not less than 75 percent of highest reading.
Exhaust System Backpressure
Exhaust system can be checked with a vacuum gauge or a 0-5 psi pressure gauge. If a pressure gauge is used, remove O2 sensor. Connect gauge
to O2 sensor port. Start engine, and run at 2500 RPM. If exhaust system backpressure is more than 2 psi, exhaust system or catalytic converter
is plugged.
If a vacuum gauge is used, connect it to intake manifold vacuum. Start engine. Observe vacuum gauge. Open throttle part way and hold steady.
If vacuum gauge drops slowly after stabilizing, check exhaust system for a restriction.
FUEL PRESSURE
Fuel Pressure Release
Start engine (if possible), and unplug VAF meter connector. When engine stalls, turn ignition off and reconnect VAF meter wiring. Usin g sh o p
towel, cover fitting to absorb leakage when opening fuel system.
Fuel Pressure Check
1. Connect fuel pressure gauge between fuel filter and fuel rail. Open main valve, and close drain valve. Locate fuel pump check connector
in engine compartment, near left strut. Connect jumper wire between fuel pump test terminals (Black and Green/White wires on Capri
or Black and Green/Red wires on Festiva).
2. Turn ignition on to activate fuel pump. If pump does not run, check fuel pump circuit. If possible, start engine. Measure and record fuel
pressure. For fuel pressure specifications, see FUEL PRESSURE SPECIFICATIONS
article. Disconnect vacuum from pressure
regulator. Turn engine off. Wait 5 minutes and ensure residual pressure is at least 21 psi (1.5 kg/cm
2 ).
3. Operate fuel pump by reconnecting jumper wire at fuel pump check connector. Check fuel pump performance. Pinch hose between
pressure gauge and fuel filter. Do not hold longer than necessary to check pressure.For fuel pressure specifications, see FUEL
PRESSURE SPECIFICATIONS article. If pump does not meet specifications, check fuel pump circuit, fuel pump, fuel tank and fuel
filter or replace fuel pump.
FUEL PUMP PERFORMANCE NOTE:Unless stated otherwise in test procedure, perform all voltage tests with a Digital Volt-Ohm m eter
(DVOM) with a m inim um 10-m egohm input im pedance.
CAUT ION: DO NOT use ignition switch during com pression tests on fuel injected vehicles. Fuel injectors are
triggered by ignition switch during cranking m ode. Use a rem ote starter to crank engine to prevent fire
hazard and catalytic converter and engine oiling system contam ination.
WARNING:ALWAYS relieve fuel pressure before disconnecting any fuel injection system com ponent. DO NOT
allow fuel to contact engine or electrical com ponents.
NOTE:For 1991 fuel pressure specifications, see FUEL PRESSURE SPECIFICAT IONS
article. For 1992 fuel
pressure specifications, see FUEL PRESSURE SPECIFICAT IONS
article.
ApplicationPressure psi (kg/cm2 )Min. Vol. in 10 sec. Ozs. (cc)
Capri(1) 5.5 (167)
Festiva(1) 7.4 (220)
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Fig. 2: Capri Fuel System Electrical Schematic
Courtesy of FORD MOTOR CO.
Fuel Pump Relay
Remove fuel pump relay (located near heater duct under carpet). Apply positive 12 volts to relay terminals "A" and "B" together. See Fig. 3 .
Measure voltage between terminal "C" and ground, while individually grounding terminals "D" and "E". Ensure voltage is as specified. See
FUEL PUMP RELAY SPECIFICATIONS
table. If voltage is not as specified, replace relay.
FUEL PUMP RELAY SPECIFICATIONS

Fig. 3: Identifying Fuel Pump Relay Terminals

Courtesy of FORD MOTOR CO.
IGNITION CHECKS
Firing Order
Inspect spark plug wiring routing. Ensure firing order is 1-3-4-2.
Spark
1. Crank engine. Check for a strong Blue spark at each spark plug wire by using a high output spark tester. Ensure resistance of each spark
plug wire is 4000-6000 ohms per foot.
2. Disconnect and inspect all related ignition system connectors and harness. Clean or repair as necessary, and recheck spark. If st il l n o
spark, go to IGNITION COIL POWER SOURCE
.
Ignition Coil Power Source
Disconnect primary wires at ignition coil. Turn ignition on. Measure voltage between Black/White wire on harness connector and ground. If
voltage is not greater than 10 volts, check battery feed, ignition switch and fusible links. If voltage is greater than 10 volts, go to IGNITION
COIL RESISTANCE .
Ignition Coil Resistance
Measure resistance between primary terminals of coil. Measure resistance between positive primary terminal and coil tower. See IGNITION
COIL RESISTANCE table. Verify resistance between coil case and primary positive terminal is infinite. Replace coil if resistance
measurements are not within specifications.
IGNITION COIL RESISTANCE
IDLE SPEED & IGNITION TIMING
Ensure idle speed and ignition timing are set to specification. For adjustment procedures, see ON-VEHICLE ADJUSTMENTS article.
SUMMARY
If no faults were found while performing BASIC TESTING , proceed to TESTS W/CODES article in the ENGINE PERFORMANCE Section.
If no hard codes are found in 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.) or intermittent diagnostic procedures.
Terminal "D"Terminal "E"Terminal "C" Voltage
OpenOpenLess than one
GroundedOpenLess than 10
OpenGroundedGreater than 10
GroundedGroundedGreater than 10
ApplicationPrimary (Ohms)Secondary (Ohms)
1.3L & 1.6L0.8-1.66000-30,000
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
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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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Fig. 1: Testing Canister Purge Solenoid

Courtesy of FORD MOTOR CO.
Carbon Canister
1. Start and run engine until it is at operating temperature. Stop engine. Remove carbon canister. Carbon canister on 1.3L is located under
brake booster. Carbon canister is located in right side of engine compartment near cowl panel on 1.6L.
2. Inspect carbon canister for presence of liquid fuel, as evidenced by odor or weight. Blow into air vent and ensure air exits fro m fu el
vapor inlet. Replace carbon canister if it contains fuel, or if air does not pass freely through it.
POSITIVE CRANKCASE VENTILATION (PCV)
1. Remove PCV valve from valve cover and disconnect it from PCV h o se . S h a ke va l ve vigo r o u sl y t o e n su r e p l u n ge r is fr e e t o mo ve .
Replace PCV valve if plunger is not free.
2. Idle engine until it is warm. Remove fresh air hose at inlet end. Plug nipple immediately to prevent stalling. Verify presence of vacuum at
inlet end of hose. If vacuum is not present, replace PCV valve or service hoses or loose oil dipstick.
THROTTLE CONTROLS
Dashpot
Disconnect PCV valve. Remove resonance chamber. Push dashpot rod in and then release it. Replace dashpot if rod does not go in slowly and
return quickly.
MISCELLANEOUS CONTROLS
A/C CLUTCH
A/C Clutch Relay
Remove relay from its socket near left headlight, in front of battery. Connect ohmmeter to contact terminals (Blue/Red and Black/White wires
on mating connector). Ohmmeter should indicate continuity. Supply 12 volts to remaining terminals (Green/Yellow and Yellow wires on
mating connector). Ohmmeter should indicate no continuity.
COOLING FAN
Cooling Fan
Unplug connector from cooling fan. Apply 12 volts to one terminal of fan connector. Ground remaining fan connector terminal. Replace fan if
it does not run.
Cooling Fan Control Relay
Remove relay from its socket near left headlight. Connect ohmmeter to contact terminals. Wire colors are Yellow/Red and Black on mating
connector on Festiva; Yellow/Green and Black on Capri. Ohmmeter should indicate continuity. Supply 12 volts to remaining 2 relay
terminals. Ohmmeter should indicate no continuity.
NOTE:Although som e of the controlled devices listed here are not technically engine perform ance
com ponents, they can affect driveability if they m alfunction.
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