1991 FORD FESTIVA engine

ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
CRANKSHAFT MAIN & CONNECTING ROD BEARINGS
Water Pump-To-Block14-19 (19-26)
Wheels66-89 (90-120)
INCH Lbs. (N.m)
Camshaft Bearing Cap Bolt97-124 (11-14)
Camshaft Cover71-97 (8-11)
Camshaft Thrust Plate Bolt71-106 (8-12)
Front Cover Housing Bolt (1.6L)71-97 (8-11)
Oil Pan Bolt
1.3L71-80 (8-9)
1.6L71-97 (8-11)
Oil Pressure Sender106-159 (12-18)
Oil Pump Cover Bolt (1.3L)89-133 (10-15)
Pickup Tube-To-Oil Pump Bolt71-97 (8-11)
Radiator Fan Bracket71-97 (8-11)
Rear Engine Plate Bolt71-97 (8-11)
Temperature Sender44-89 (5-10)
Timing Belt Cover Bolt71-97 (8-11)
Valve Cover Bolt44-79 (5-9)
Water Pump Pulley Bolts (1.6L)71-97 (8-11)
(1)This specification is INCH Lbs.
ApplicationSpecification
Displacement
1.3L80.8 Cu. In. (1.3L)
1.6L97.4 Cu. In. (1.6L)
Bore
1.3L2.80" (71.0 mm)
1.6L3.07" (78 mm)
Stroke (1.3L & 1.6L)3.29" (83.6 mm)
Compression Ratio
1.3L9.7:1
1.6LN/A
Fuel SystemPFI
HP@RPM
1.3L58 @ 5000
1.6L
(Non-Turbo)100 @ 5750
(Turbo)132 @ 6000
Torque Ft. Lbs.@RPM
1.3L73 @ 3000
1.6L
(Non-Turbo)95 @ 5500
(Turbo)136 @ 3000
ApplicationIn. (mm)
Crankshaft
End Play.0031-.0111 (.080-.282)
Runout (Maximum).002 (.05)
Main Bearings
Journal Diameter1.9661-1.9668 (49.938-
49.956)
Journal Out-Of-Round.002 (.05)
Journal Taper.002 (.05)
Oil Clearance.0009-.0017 (.024-.042)
Connecting Rod Bearings
Journal Diameter
1.3L1.5724-1.5731 (39.939-
39.957)
1.6L1.7693-1.7699 (44.940-
44.956)
Journal Out-Of-Round.002 (.05)
Journal Taper.002 (.05)
Page 16 of 19 MITCHELL 1 ARTICLE - ENGINE OVERHAUL 1991-92 FORD MOTOR CO. ENGINES 1.3L & 1.6L 4-Cylinder
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CONNECTING RODS
CONNECTING RODS
PISTONS, PINS & RINGS
PISTONS PINS & RINGS
CYLINDER BLOCK
CYLINDER BLOCK
VALVES & VALVE SPRINGS
VALVES & VALVE SPRINGS
Oil Clearance.0011-.0027 (.028-.068)
ApplicationIn. (mm)
Bore Diameter
Pin Bore
1.3L.7854-.7859 (19.948-19.961)
1.6L.7875-.7880 (20.003-20.014)
Crankpin Bore1.8897-1.8904 (48.000-48.016)
Center-To-Center Length5.230-5.234 (132.85-132.95)
Maximu m Ben d & Twist (1)
1.3L.0016 (.04)
1.6L.0078 (.198)
Side Play.012 (.30)
(1)Per 3.94" (100 mm) of length.
ApplicationIn. (mm)
Piston
Clearance (Max.).006 (.15)
Diameter
1.3L2.793-2.794 (70.954-70.974)
1.6L3.0690-3.0698 (77.954-77.974)
Pins
Outside Diameter
1.3L.7864-.7866 (19.974-19.980)
1.6L.7869-.7871 (19.987-19.993)
Inside Diameter.524 (13.309)
Pin-To-Piston Fit
1.3L.0003-.0005 (.0076-.0127)
1.6L.0004-.0012 (.0100-.0260)
Rod Fit(1) 0-.0012 (0-.030)
Rings
No. 1
End Gap.006-.012 (.15-.30)
Side Clearance.001-.003 (.03-.07)
No. 2
End Gap.006-.012 (.15-.30)
Side Clearance.001-.003 (.03-.07)
No. 3 (Oil)
End Gap.008-.028 (.20-.70)
Side Clearance
1.3L.039 (1.0)
1.6L.001-.003 (.03-.07)
(1)This is a negative clearance (interference fit).
ApplicationIn. (mm)
Cylinder Bore
Standard Diameter
1.3L2.7953-2.7961 (71.00-
71.02)
1.6L3.0709-3.0716
(78.000-78.019)
Maximu m Tap er.0007 (.018)
Maximu m Ou t -Of-Ro u n d.0007 (.018)
Maximu m Deck Warp age.006 (.15)
ApplicationIn. (mm)
In t ake Val ves
Face Angle45°
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CYLINDER HEAD
CYLINDER HEAD
CAMSHAFT SPECIFICATIONS
CAMSHAFT SPECIFICATIONS
Head Diameter
1.3LN/A
1.6L1.217-1.224 (30.90-31.10)
Min imu m Margin.020 (.50)
Stem Diameter
1.3L.2744-.2750 (6.970-6.985)
1.6L.2350-.2356 (5.970-5.985)
Exhaust Valves
Face Angle45°
Head Diameter
1.3LN/A
1.6L1.028-1.035 (26.1-26.3)
Min imu m Margin
1.3L.039 (1.0)
1.6L.020 (.5)
Stem Diameter
1.3L.2742-.2748 (6.965-6.980)
1.6L.2348-.2354 (5.965-5.980)
Valve Springs
Free Length
1.3L1.717 (43.6)
1.6L1.858 (47.2)
Out-Of-Square
1.3L.059 (1.50)
1.6L.063 (1.60)
ApplicationIn. (mm)
Maximu m Warp age.006 (.15)
Valve Seats
Intake Valve
Seat Angle45°
Seat Width
1.3L.043-.067 (1.10-1.70)
1.6L.030-.055 (.80-1.40)
Maximu m Seat Ru n o u t.0016 (.04)
Exhaust Valve
Seat Angle45°
Seat Width
1.3L.043-.067 (1.10-1.70)
1.6L.030-.055 (.80-1.40)
Maximu m Seat Ru n o u t.0016 (.04)
Valve Guides
Intake Valve
Valve Guide I.D.
1.3L.276-.277 (7.01-7.03)
1.6L.2366-.2374 (6.01-6.03)
Valve Stem-To-Guide
Oil Clearance
1.3LMaximu m Service Limit .0 0 8
(.20)
1.6L.0010-.0024 (.025-.060)
Exhaust Valve
Valve Guide I.D.
1.3L.276-.277 (7.01-7.03)
1.6L.2366-.2374 (6.01-6.03)
Valve Stem-To-Guide
Oil Clearance
1.3LMaximu m Service Limit .0 0 8
(.20)
1.6L.0012-.0026 (.300-.650)
ApplicationIn. (mm)
End Play(1) .002-.007 (.05-.18)
Journal Diameter
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1.3L
No. 1 & 31.7102-1.7109 (43.440-
43.456)
No. 21.7091-1.7100 (43.410-
43.435)
1.6L (All Journals)1.0213-1.0222 (25.940-
25.965)
Journal Runout.002 (.05)
Lobe Height
1.3L(2) 1.4332-1.4371 (36.403-
36.503)
1.6L(3) 1.6098 (40.888)
Oil Clearance
1.3L
No. 1 & 3 Journals(4) .0014-.0033 (.035-.085)
No. 2 Journal(4) .0026-.0045 (.065-.115)
1.6L (All Journals)(4) .0014-.0033 (.035-.085)
(1)End play limit is .008" (.20 mm).
(2)Wear limit is 1.4272" (36.253 mm)
(3)Wear limit is 1.5940" (40.489)
(4)Maximum clearance is .0059" (.150 mm)
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00048707
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ST ART ER
1991 ELECT RICAL Starters
DESCRIPTION
The Nippondenso direct drive starter is a conventional 12-volt, 4-pole, brush-type starter. The integral solenoid is attached to the drive
housing. When starter is energized, starter solenoid causes the starter pinion to engage with the flywheel ring gear. The overrunning clutch
pinion drive is mounted directly on armature shaft drive end.

Fig. 1: Starter System Schematic

Courtesy of FORD MOTOR CO.
TROUBLE SHOOTING
ENGINE CRANKS SLOWLY
Undercharged battery. Loose or corroded cable connections. Bad starter.
ENGINE WILL NOT CRANK
Undercharged battery. Bad ignition switch. Bad clutch engage switch (M/T) or neutral safety switch (A/T). Loose or corroded cable
connections. Bad starter. Faulty circuit grounds.
STARTER SPINS & ENGINE DOES NOT CRANK
Bad starter. Bad flywheel ring gear and/or starter drive pinion.
ENGINE STARTS WITH CLUTCH ENGAGED (M/T)
Bad clutch engage switch. Adjust or replace.
ENGINE STARTS IN GEAR (A/T)
Bad neutral safety switch. Adjust or replace.
ON-VEHICLE TESTING
PRELIMINARY TEST
Ensure battery is fully charged and has load tested okay. If starter will not crank engine with fully charged battery, proceed with the following
test.
1. Using a digital voltmeter, connect positive voltmeter lead to starter solenoid terminal "S", and negative lead to starter housing. See Fig.
1 .
2. Turn ignition switch to START position, and observe voltmeter reading. If voltage at terminal "S" is greater than 8 volts, starter or circuit
malfunction is indicated. See VOLTAGE DROP TEST
and STARTER GROUND CIRCUIT TEST under ON-VEHICLE TESTING.
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3. If voltage is not present or is less than 8 volts at starter solenoid terminal "S", malfunction in circuit to terminal "S" is indicated. Proceed
to the following tests.
IGNITION SWITCH TEST
1. Locate ignition switch connector under dash. Using a 12-volt test light or voltmeter, ensure voltage is present on Black/Yellow wire
when ignition switch is turned to RUN or ON position. This will verify proper operation of ignition switch.
2. If there is no voltage on Black/Yellow wire, the problem is either ignition switch or circuit between battery and ignition switch.
CLUTCH ENGAGE SWITCH (M/T) TEST
Unplug clutch engage switch from main wiring harness. Using an ohmmeter, check for continuity across switch terminals. Continuity should
exist when switch plunger is pushed in and should not exist when switch plunger is released. If clutch engage switch does not operate as
specified, replace switch.
NEUTRAL SAFETY SWITCH (A/T) TEST
Unplug neutral safety switch from main wiring harness. Using an ohmmeter, check for continuity across switch terminals "A" and "B". See Fig.
2 . Place transmission shift selector in Park or Neutral position. Continuity should exist between terminals "A" and "B". Continuity should not
exist in any other transmission shift selector positions. If switch does nor operate as specified, replace switch.

Fig. 2: Identifying Neutral Safety Switch Terminals

Courtesy of FORD MOTOR CO.
VOLTAGE DROP TEST
1. Disconnect and ground coil wire from distributor cap to prevent engine from starting. Connect remote starter switch between starter
solenoid terminal "S" and battery positive terminal. See Fig. 3
.
2. Using a digital voltmeter set on low scale, connect positive voltmeter lead to battery positive terminal. Connect negative lead to starter
solenoid terminal "M". See Fig. 3
.
3. Engage remote starter switch. Observe and record voltmeter reading. Voltmeter reading should be less than .5 volt. If voltage at terminal
"M" is greater than .5 volt, move negative voltmeter lead to solenoid terminal "B", and repeat test.
4. If voltage at terminal "B" is less than .5 volt, inspect solenoid cable connections and solenoid contacts for problem.
5 . Cl ean so l en o id t ermin al s "B", "M" an d "S", an d rep eat st ep s 1 ) through 4). If voltmeter still reads greater than .5 volt at termin al "M"
and less than .5 volt at terminal "B", solenoid contacts are bad.
6. If voltmeter reads greater than .5 volt at terminal "B", clean cables and connections at solenoid. If voltmeter still reads greater than .5
volt, check for poor positive battery cable connection or bad cable. Repair or replace as necessary.
7. To locate excessive voltage drop, move negative voltmeter lead toward battery, and check each connection point. When high voltmeter
reading is no longer present, last connection point is bad.
NOTE:Make all voltm eter connections at com ponent term inal rather than at cable or wire end.
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Fig. 3: Testing Voltage Drop

Courtesy of FORD MOTOR CO.
STARTER GROUND CIRCUIT TEST
1. Disconnect and ground coil wire from distributor cap to prevent engine from starting. Connect remote starter switch between starter
solenoid terminal "S" and battery positive terminal. See Fig. 1
.
2. Using a digital voltmeter set on low scale, connect positive voltmeter to starter motor housing. Ensure connection point is clean and free
of rust and grease. Connect negative voltmeter lead to negative battery terminal.
3. Engage remote starter switch and crank engine. Observe and record voltmeter reading. Voltmeter should read .2 volt or less. If voltage
drop is greater than .2 volt, clean negative battery cable connections at battery and body connections. Retest to ensure problem has been
corrected.
4. If voltage drop is still excessive, replace negative battery cable(s) as necessary. If battery cables test okay, and starter still cranks slowly
or not at all, remove and repair starter motor.
BENCH TESTING
STARTER NO-LOAD TEST
Remove starter. Place starter on bench. Connect a fully charged 12-volt battery, voltmeter, ammeter and remote starter switch to starter. See
Fig. 4
. Engage remote starter switch. Starter should rotate smoothly. Ensure voltage and amperage draw is less than maximum specification at
5000 RPM minimum. See NO-LOAD TEST SPECIFICATIONS table. If voltage and/or amperage is higher than specifications, disassemble
starter and determine cause.
NO-LOAD TEST SPECIFICATIONS
NOTE:Make all voltm eter connections at com ponent term inal rather than at cable or wire end.
ApplicationMaximum AmpsVolts
Capri & Festiva6011.5
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FORD
1.3L 4-Cylinder
MANUFACTURER'S SUGGESTED SCHEDULED MAINTENANCE
For Aspire, the manufacturer recommends the belt be replaced every 60,000 miles on Federal vehicles, and 105,000 miles on California
vehicles. For Festiva, the manufacturer recommends the belt be replaced every 60,000 miles.
REMOVAL & INSTALLATION
TIMING BELT
Removal
1. Disconnect negative battery cable. Remove accessory belts. Remove water pump pulley. Remove right inner fender panel to gain access
to crankshaft pulley. See Fig. 1
. Remove outer crankshaft pulley attaching bolts, then outer stiffener and spacer. Remove inner pulley
and baffle plate. Remove bolts retaining upper and lower cover halves to engine front. Remove both covers. See Fig. 2
.
2. Mark timing belt direction of rotation for installation reference. Remove timing belt tensioner pulley bolt. Remove tensioner pulley,
spring, and spring cover. Remove timing belt.
Installation
1. Ensure timing belt and sprockets are clean, and not worn or damaged. Align crankshaft and camshaft timing marks. See Fig. 3 . Position
belt onto sprockets in original running direction.
2. Install timing belt tensioner spring, spring cover, and pulley. To complete installation, reverse removal procedure. Tighten all bolts and
nuts to specification. See TORQUE SPECIFICATIONS
. Adjust drive belts to proper tension.

Fig. 1: Removing Right Inner Fender Panel

Courtesy of FORD MOTOR CO. NOTE:Always rotate engine in direction of norm al operation. Rotating crankshaft backwards m ay cause
belt to jum p tim ing.
CAUT ION: Never twist, turn inside out, or bend tim ing belt. Keep belt away from grease and oil.
Page 1 of 3 MITCHELL 1 ARTICLE - FORD 1.3L 4-Cylinder
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