1991 FORD FESTIVA lock

bolts
Noisy Pistons and Rings
Excessive piston-to-bore clearanceInstall larger pistons, See
ENGINES
Bore tapered or out-of-roundRebore block
Piston ring brokenReplace piston rings, See
ENGINES
Piston pin loose or seizedReplace piston pin, See
ENGINES
Connecting rods misalignedRealign connecting rods
Ring side clearance too loose or tightReplace with larger or smaller
rings
Carbon build-up on pistonRemove carbon
Noisy Valve Train
Worn or bent push rodsReplace push rods, See
ENGINES
Worn rocker arms or bridged pivotsReplace push rods, See
ENGINES
Dirt or chips in valve liftersRemove lifters and remove
dirt/chips
Excessive valve lifter leak-downReplace valve lifters, See
ENGINES
Valve lifter face wornReplace valve lifters, See
ENGINES
Broken or cocked valve springsReplace or reposition springs
Too much valve stem-to-guide clearanceReplace valve guides, See
ENGINES
Valve bentReplace valve, See ENGINES
Loose rocker armsRetighten rocker arms, See
ENGINES
Excessive valve seat run-outReface valve seats, See
ENGINES
Missing valve lockInstall new valve lock
Excessively worn camshaft lobesReplace camshaft, See
ENGINES
Plugged valve lifter oil holesEliminate restriction or
replace lifter
Faulty valve lifter check ballReplace lifter check ball, See
ENGINES
Rocker arm nut installed upside downRemove and reinstall correctly
Valve lifter incorrect for engineRemove and replace valve
lifters
Faulty push rod seat or lifter plungerReplace plunger or push rod
Noisy Valves
Improper valve lashRe-adjust valve lash, See
ENGINES
Worn or dirty valve liftersClean and/or replace lifters
Wo r n va l ve gu id e sReplace valve guides, See
ENGINES
Excessive valve seat or face run-outReface seats or valve face
Worn camshaft lobesReplace camshaft, See
ENGINES
Loose rocker arm studsRe-tighten rocker arm studs,
See ENGINES
Bent push rodsReplace push rods, See
ENGINES
Broken valve springsReplace valve springs, See
ENGINES
Burned,Sticking or Broken Valves
Weak valve springs or warped valvesReplace valves and/or springs,
See ENGINES
Improper lifter clearanceRe-adjust clearance or replace
lifters
Worn guides or improper guide clearanceReplace valve guides, See
ENGINES
Out-of-round valve seats or improper seat widthRe-grind valve seats
Gum deposits on valve stems, seats or guideRemove deposits
Improper spark timingRe-adjust spark timing
Broken Pistons/Rings
Undersize pistonsReplace with larger pistons,
See ENGINES
Wrong piston ringsReplace with correct rings,
See ENGINES
Out-of-round cylinder boreRe-bore cylinder bore
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BASIC WARM ENGINE DRIVEABILITY SYMPTOMS TROUBLE SHOOTING CHART
DIESEL ENGINE TROUBLE SHOOTING
BASIC DIESEL ENGINE TROUBLE SHOOTING CHART
SYSTEMS
Acceleration Sag or Stall
Defective choke control switchReplace choke control switch
Choke vacuum kick setting incorrectReset choke vacuum kick see,
FUEL SYSTEMS
Float level incorrect (too low)Adjust float level, FUEL
SYSTEMS
Accelerator pump defectiveRepair or replace pump see
FUEL SYSTEMS
Secondary throttles not closedInspect lockout adjustment,
see FUEL SYSTEMS
Sag or Stall After Warmup
Defective choke control switchReplace choke control switch,
see FUEL SYSTEMS
Defective accelerator pumpReplace pump, see FUEL
SYSTEMS
Float level incorrect (too low)Adjust float level, see FUEL
SYSTEMS
Backfiring & Black Smoke
Plugged heat crossover systemRemove restriction
CONDITION & POSSIBLE CAUSECORRECTION
Hesitation With Small Amount of Gas Pedal Movement
Vacuum leakInspect vacuum lines
Accelerator pump weak or inoperableReplace pump, see FUEL
SYSTEMS
Float level setting too lowReset float level, see,FUEL
SYSTEMS
Metering rods sticking or bindingInspect and/or replace rods,
see FUEL SYSTEMS
Carburetor idle or transfer system pluggedInspect system and remove
restriction
Frozen or binding heated air inletInspect heated air door for
binding
Hesitation With Heavy Gas Pedal Movement
Defective accelerator pumpReplace pump, see FUEL
SYSTEMS
Metering rod carrier sticking or bindingRemove restriction
Large vacuum leakInspect vacuum system and
repair leak
Float level setting too lowReset float level, see FUEL
SYSTEMS
Defective fuel pump, lines or filterInspect pump, lines and filter
Air door setting incorrectAdjust air door setting, see
FUEL
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
NOTE:Diesel engines m echanical diagnosis is the sam e as gasoline engines for item s such as noisy valves,
bearings, pistons, etc. T he following trouble shooting covers only item s pertaining to diesel engines.
CONDITION & POSSIBLE CAUSECORRECTION
Engine Won't Crank
Bad battery connections or dead batteriesCheck connections and/or
replace batteries
Bad starter connections or bad starterCheck connections and/or
replace starter
Engine Cranks Slowly, Won't Start
Bad battery connections or dead batteriesCheck connections and/or
replace batteries
Engine oil too heavyReplace engine oil
Engine Cranks Normally, But Will Not Start
Glow plugs not functioningCheck glow plug system, see
FUEL SYSTEMS
Glow plug control not functioningCheck controller, see FUEL
SYSTEMS
Page 14 of 36 MITCHELL 1 ARTICLE - GENERAL INFORMATION Trouble Shooting - Basic Procedures
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Fuel not injected into cylindersCheck fuel injectors, see FUEL
SYSTEMS
No fuel to injection pumpCheck fuel delivery system
Fuel filter blockedReplace fuel filter
Fuel tank filter blockedReplace fuel tank filter
Fuel pump not operatingCheck pump operation and/or
replace pump
Fuel return system blockedInspect system and remove
restriction
No voltage to fuel solenoidCheck solenoid and
connections
Incorrect or contaminated fuelReplace fuel
Incorrect injection pump timingRe-adjust pump timing, see
FUEL SYSTEMS
Low compressionCheck valves, pistons, rings,
see ENGINES
Injection pump malfunctionInspect and/or replace
injection pump
Engine Starts, Won't Idle
Incorrect slow idle adjustmentReset idle adjustment, see
TUNE-UP
Fast idle solenoid malfunctioningCheck solenoid and
connections
Fuel return system blockedCheck system and remove
restrictions
Glow plugs go off too soonSee glow plug diagnosis in
FUEL SYSTEMS
Injection pump timing incorrectReset pump timing, see FUEL
SYSTEMS
No fuel to injection pumpCheck fuel delivery system
Incorrect or contaminated fuelReplace fuel
Low compressionCheck valves, piston, rings, see
ENGINES
Injection pump malfunctionReplace injection pump, see
FUEL SYSTEMS
Fuel solenoid closes in RUN positionCheck solenoid and
connections
Engines Starts/Idles Rough W/out Smoke or Noise
Incorrect slow idle adjustmentReset slow idle, see TUNE-UP
Injection line fuel leaksCheck lines and connections
Fuel return system blockedCheck lines and connections
Air in fuel systemBleed air from system
Incorrect or contaminated fuelReplace fuel
Injector nozzle malfunctionCheck nozzles, see FUEL
SYSTEMS
Engines Starts and Idles Rough W/out Smoke or Noise, But Clears After Warm-Up
Injection pump timing incorrectReset pump timing, see FUEL
SYSTEMS
Engine not fully broken inPu t mo re mil es o n en gin e
Air in systemBleed air from system
Injector nozzle malfunctionCheck nozzles, see FUEL
SYSTEMS
Engine Idles Correctly, Misfires Above Idle
Bl o cked fu el fil t erReplace fuel filter
Injection pump timing incorrectReset pump timing, see FUEL
SYSTEMS
Incorrect or contaminated fuelReplace fuel
Engine Won't Return To Idle
Fast idle adjustment incorrectReset fast idle, see TUNE-UP
Internal injection pump malfunctionReplace injection pump, see
FUEL SYSTEMS
External linkage bindingCheck linkage and remove
binding
Fuel Leaks On Ground
Loose or broken fuel lineCheck lines and connections
Internal injection pump seal leakReplace injection pump, see
FUEL SYSTEMS
Cylinder Knocking Noise
Injector nozzles sticking openTest injectors, see FUEL
SYSTEMS
Very low nozzle opening pressureTest injectors and/or replace
Loss of Engine Power
Restricted air intakeRemove restriction
Page 15 of 36 MITCHELL 1 ARTICLE - GENERAL INFORMATION Trouble Shooting - Basic Procedures
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VACUUM PUMP DIAGNOSIS
FUEL INJECTION TROUBLE SHOOTING
BASIC FUEL INJECTION TROUBLE SHOOTING CHART
EGR valve malfunctionReplace EGR valve
Blocked or damaged exhaust systemRemove restriction and/or
replace components
Blocked fuel tank filterReplace filter
Restricted fuel filterRemove restriction and/or
replace filter
Block vent in gas capRemove restriction and/or
replace cap
Tank-to-injection pump fuel supply blockedCheck fuel lines and
connections
Blocked fuel return systemRemove restriction
Incorrect or contaminated fuelReplace fuel
Blocked injector nozzlesCheck nozzle for blockage, see
FUEL SYSTEMS
Low compressionCheck valves, rings, pistons,
see ENGINES
Loud Engine Noise With Black Smoke
Basic timing incorrectReset timing, see FUEL
SYSTEMS
EGR valve malfunctionReplace EGR valve
Internal injection pump malfunctionReplace injection pump, see
FUEL SYSTEMS
Incorrect injector pump housing pressureCheck pressure, see FUEL
SYSTEMS
Engine Overheating
Cooling system leaksCheck cooling system and
repair leaks
Belt slipping or damagedCheck tension and/or replace
belt
Thermostat stuck closedRemove and replace
thermostat, see ENGINE
COOLING
Head gasket leakingReplace head gasket
Oil Light on at Idle
Low oil pump pressureCheck oil pump operation, see
ENGINES
Oil cooler or line restrictedRemove restriction and/or
replace cooler
Engine Won't Shut Off
Injector pump fuel solenoid does not return fuel valve to OFF positionRemove and check solenoid
and replace if needed
CONDITION & POSSIBLE CAUSECORRECTION
Excessive Noise
Loose pump-to-drive assembly screwsTighten screws
Loose tube on pump assemblyTighten tube
Valves not functioning properlyReplace valves
Oil Leakage
Loose end plugTighten end plug
Bad seal crimpRemove and re-crimp seal
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
CONDITION & POSSIBLE CAUSECORRECTION
Engine Won't Start (Cranks Normally)
Cold start valve inoperativeTest valve and circuit
Poor connection;vacuum or wiringCheck vacuum and electrical
connections
Contaminated fuelTest fuel for water or alcohol
Defective fuel pump relay or circuitTest relay and wiring
Battery too lowCharge and test battery
Low fuel pressureTest pressure regulator and
fuel pump, check for restricted
lines and filters
No distributor reference pulsesRepair ignition system as
necessary
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TUNE-UP TROUBLE SHOOTING - GAS ENGINE VEHICLES
BASIC SPARK PLUG TROUBLE SHOOTING CHARTS
Faulty solenoid switch, switch connections or relayCheck all wiring between
relay and solenoid or replace
relay or solenoid as necessary
Broken lead or loose soldered connectionsRepair wire or wire
connections as necessary
Solenoid Plunger Vibrates When Switch is Engaged
Weak batteryCharge or replace battery as
necessary
Solenoid contacts corrodedClean contacts or replace
solenoid
Faulty wiringCheck all wiring leading to
solenoid
Broken connections inside switch coverRepair connections or replace
solenoid
Open hold-in wireReplace solenoid
Low Current Draw
Worn brushes or weakReplace brushes or brush
springs as necessary
High Pitched Whine During Cranking Before Engine Fires but Engine Fires and Cranks Normally
Distance too great between starter pinion and flywheelAlign starter or check that
correct starter and flywheel
are being used
High Pitched Whine After Engine Fires With Key released. Engine Fires and Cranks Normally
Distance too small between starter pinion and flywheelFlywheel runout contributes
to the intermittent nature
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
CONDITION & POSSIBLE CAUSECORRECTION
Normal Spark Plug Condition
Light Tan or Gray depositsNo Action
Electrode not burned or fouledNo Action
Gap tolerance not changedNo Action
Cold Fouling or Carbon Deposits
Overrich air/fuel mixtureAdjust air/fuel mixture, see
ENGINE PERFORMANCE
section
Faulty chokeReplace choke assembly, see
ENGINE PERFORMANCE
section
Clogged air filterClean and/or replace air filter
Incorrect idle speed or dirty carburetorReset idle speed and/ or clean
carburetor
Faulty ignition wiresReplace ignition wiring
Prolonged operation at idleShut engine off during long
idle
Sticking valves or worn valve guide sealsCheck valve train
Wet Fouling or Oil Deposits
Worn rings and pistonsInstall new rings and pistons
Excessive cylinder wearRebore or replace block
Excessive valve guide clearanceWorn or loose bearing
Gap Bridged
Deposits in combustion chamber becoming fused to electrodeClean combustion chamber of
deposits
Blistered Electrode
Engine overheatingCheck cooling system
Wrong type of fuelReplace with correct fuel
Loose spark plugsRetighten spark plugs
Over-advanced ignition timingReset ignition timing see
ENGINE PERFORMANCE
Pre-Ignition or Melted Electrodes
Incorrect type of fuelReplace with correct fuel
Incorrect ignition timingReset ignition timing see
ENGINE PERFORMANCE
Burned valvesReplace valves
Engine OverheatingCheck cooling system
Wrong type of spark plug, too hotReplace with correct spark
Page 21 of 36 MITCHELL 1 ARTICLE - GENERAL INFORMATION Trouble Shooting - Basic Procedures
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BASIC DRIVEABILITY PROBLEMS TROUBLE SHOOTING
Corroded spark plugsReplace spark plugs
Cylinders Not Firing
Cracked distributor cap terminalsReplace distributor cap
Shorted spark plug wireDetermine cause and repair
Mechanical problem in engineDetermine cause and repair
Defective spark plugsReplace spark plugs
Spark plugs fouledReplace spark plugs
CONDITION & POSSIBLE CAUSECORRECTION
Hard Starting
Binding carburetor linkageEliminate binding
Binding choke linkageEliminate binding
Binding choke pistonEliminate binding
Restricted choke vacuumCheck vacuum lines for
blockage
Worn or dirty needle valve and seatClean carburetor, see ENGINE
PERFORMANCE
Float stickingReadjust or replace float see
the ENGINE
PERFORMANCE section
Incorrect choke adjustmentReset choke adjustment see
ENGINE PERFORMANCE
Defective coilReplace coil
Improper spark plug gapRegap spark plugs
Incorrect ignition timingReset ignition timing see
ENGINE PERFORMANCE
Detonation
Over-advanced ignition timingReset ignition timing see
ENGINE PERFORMANCE
Defective spark plugsReplace spark plugs
Fuel lines cloggedClean fuel lines
EGR system malfunctionCheck and repair EGR system
PCV system malfunctionRepair PCV system
Vacuum leaksCheck and repair vacuum
system
Loose fan beltsTighten or replace fan belts,
see ENGINE
PERFORMANCE
Restricted airflowRemove restriction
Vacuum advance malfunctionCheck distributor operation
Dieseling
Binding carburetor linkageEliminate binding
Binding throttle linkageEliminate blinding
Binding choke linkage or fast idle camEliminate binding
Defective idle solenoidReplace idle solenoid see
ENGINE PERFORMANCE
Improper base idle speedReset idle speed, see see
ENGINE PERFORMANCE
Incorrect ignition timingReset ignition timing see
ENGINE PERFORMANCE
Incorrect idle mixture settingReset idle mixture, see
ENGINE PERFORMANCE
Faulty Acceleration
Incorrect ignition timingReset ignition timing see
ENGINE PERFORMANCE
Engine cold and choke too leanAdjust choke and allow engine
to warm-up
Defective spark plugsReplace spark plugs
Defective coilReplace coil
Faulty Low Speed Operation
Clogged idle transfer slotsClean idle transfer slots, see
FUEL
Restricted idle air bleeds and passagesDisassemble and clean
carburetor, see FUEL
Clogged air cleanerReplace air filter
Defective spark plugsReplace spark plugs
Defective ignition wiresReplace ignition wire see
ENGINE PERFORMANCE
Defective distributor capReplace distributor cap
Faulty High Speed Operation
Incorrect ignition timingReset ignition timing see
ENGINE PERFORMANCE
Page 23 of 36 MITCHELL 1 ARTICLE - GENERAL INFORMATION Trouble Shooting - Basic Procedures
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POWERTRAIN
CLUTCH TROUBLE SHOOTING
BASIC CLUTCH TROUBLE SHOOTING CHART
Gear Clash When Shifting Forward GearsClutch Out Of Adjustment, Shift linkage damaged or out of
adjustment, Gears or synchronizers damaged, Low gear oil level
Transmission Noisy When Moving (RWD Only) Quiet In Neutral
With Clutch EngagedWorn rear outputshaft bearing
Gear RattleWorn bearings, Wrong gear oil, Low gear oil, Worn gears
Steady Ticking At Idle (Increases With RPM)Broken tooth on gear
Gear Clash When Shifting Forward GearsWorn or broken synchronizers
Loud Whine In ReverseNormal condition (1)
Noise When Stepping On ClutchBad release bearing, Worn pilot bearing
Ticking Or Screeching As Clutch Is EngagedFaulty release bearing, Uneven pressure plate fingers
Click Or Snap When Clutch Is EngagedWorn clutch fork, Worn or broken front bearing retainer
Transmission Shifts HardClutch not releasing, Shift mechanism binding, Clutch installed
backwards
Will Not Shift Into One Gear, Shifts Into All OthersBent shift fork, Worn detent balls
Locked Into Gear, Cannot ShiftClutch adjustment, Worn detent balls
Transmission Jumps Out Of GearPilot bearing worn, Bent shift fork, Worn gear teeth or face,
Excessive gear train end play, Worn synchronizers, Missing detent
ball spring, Shift mechanism worn or out of adjustment, Engine or
transmission mount bolts loose or out of adjustment, Transmission
not aligned
Shift Lever RattleWorn shift lever or detents, Worn shift forks, Worn synchronizers
sleeve
Shift Lever Hops Under AccelerationWorn engine or transmission mounts
(1)Most units use spur cut gears in reverse and are noisy
NOTE:This is GENERAL inform ation. This article is not intended to be specific to any unique situation or
individual vehicle configuration. T he purpose of this T rouble Shooting inform ation is to provide a list
of com m on causes to problem sym ptom s. For m odel-specific T rouble Shooting, refer to SUBJECT ,
DIAGNOST IC, or T EST ING articles available in the section(s) you are accessing.
CONDITION & POSSIBLE CAUSECORRECTION
Chattering or Grabbing
Incorrect clutch adjustmentAdjust clutch
Oil, grease or glaze on facingsDisassemble and clean or replace
Lo o se "U" jo in t fl an geSee DRIVE AXLES article
Worn input shaft splineReplace input shaft
Binding pressure plateReplace pressure plate
Binding release leverSee CLUTCH article
Binding clutch disc hubReplace clutch disc
Unequal pressure plate contactReplace worn/misaligned
components
Loose/bent clutch discReplace clutch disc
Incorrect transmission alignmentRealign transmission
Worn pressure plate, disc or flywheelReplace damaged components
Broken or weak pressure springsReplace pressure plate
Sticking clutch pedalLubricate clutch pedal & linkage
Incorrect clutch disc facingReplace clutch disc
Engine loose in chassisTighten all mounting bolts
Failure to Release
Oil or grease on clutch facingsClean or replace clutch clutch
disc
Incorrect release lever or pedal adjustmentSee CLUTCH article
Worn or broken clutch facingsReplace clutch disc
Bent clutch disc or pressure plateReplace damaged components
Clutch disc hub binding on input shaftClean or replace clutch disc
and/or input shaft
Binding pilot bearingReplace pilot bearing
Sticking release bearing sleeveReplace release bearing and/or
sleeve
Binding clutch cableSee CLUTCH article
Defective clutch masterReplace master cylinder
Defective clutch slaveReplace slave cylinder
Air in hydraulic systemBleed hydraulic system
Rattling
Weak or broken release lever springReplace spring and check
alignment
Damaged pressure plateReplace pressure plate
Page 26 of 36 MITCHELL 1 ARTICLE - GENERAL INFORMATION Trouble Shooting - Basic Procedures
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DRIVE AXLE - NOISE DIAGNOSIS
Unrelated Noises
Some driveline trouble symptoms are also common to the engine, transmission, wheel bearings, tires, and other parts of the vehicle. Ensure
cause of trouble actually is in the drive axle before adjusting, repairing, or replacing any of its parts.
Non-Drive Axle Noises
A few conditions can sound just like drive axle noise and have to be considered in pre-diagnosis. The 4 most common noises are exhaust, tires,
CV/universal joints and wheel trim rings.
In certain conditions, the pitch of the exhaust gases may e gear whine. At other times, it may be mistaken for a wheel bearing rumble.
Tires, especially radial and snow, can have a high-pitched tread whine or roar, similar to gear noise. Also, some non-standard tires with an
unusual tread construction may emit a roar or whine.
Defective CV/universal joints may cause clicking noises or excessive driveline play that can be improperly diagnosed as drive axle problems.
Trim and moldings also can cause a whistling or whining noise. Ensure none of these components are causing the noise before disassembling
the drive axle.
Gear Noise
Broken clutch return springReplace return spring
Worn splines on clutch disc or input shaftReplace clutch disc and/or input
shaft
Worn clutch release bearingReplace release bearing
Dry or worn pilot bearingLubricate or replace pilot bearing
Unequal release lever contactAlign or replace release lever
Incorrect pedal free playAdjust free play
Warped or damaged clutch discReplace damaged components
Slipping
Pressure springs worn orRelease pressure plate
Oily, greasy or worn facingsClean or replace clutch disc
Incorrect clutch alignmentRealign clutch assembly
Warped clutch disc or pressure plateReplace damaged components
Binding release levers or clutch pedalLubricate and/or replace release
components
Squeaking
Worn or damaged releaseReplace release bearing
Dry or worn pilot or release bearingLubricate or replace assembly
Pilot bearing turning in crankshaftReplace pilot bearing and/or
crankshaft
Worn input shaft bearingReplace bearing and seal
Incorrect transmission alignmentRealign transmission
Dry release fork between pivotLubricate release fork and pivot
Heavy and/or Stiff Pedal
Sticking release bearing sleeveReplace release bearing and/or
sleeve
Dry or binding clutch pedal hubLubricate and align components
Floor mat interference with pedalLay mat flat in proper area
Dry or binding ball/fork pivotsLubricate and align components
Faulty clutch cableReplace clutch cable
Noisy Clutch Pedal
Faulty interlock switchReplace interlock switch
Self-adjuster ratchet noiseLubricate or replace self-adjuster
Speed control interlock switchLubricate or replace interlock
switch
Clutch Pedal Sticks Down
Binding clutch cableSee CLUTCH article
Springs weak in pressure plateReplace pressure plate
Binding in clutch linkageLubricate and free linkage
Noisy
Dry release bearingLubricate or replace release
bearing
Dry or worn pilot bearingLubricate or replace bearing
Worn input shaft bearingReplace bearing
Transmission Click
Weak springs in pressureReplace pressure plate plate
Release fork loose on ball studReplace release fork and/or
ball stud
Oil on clutch disc damperReplace clutch disc
Broken spring in slave cylinderReplace slave cylinder
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