1991 FORD FESTIVA ABS

TURBO BOOST GAUGE & SENSOR (CAPRI)
1. Disconnect 3-pin boost sensor electrical connected located on right side of firewall. Turn ignition on. Measure voltage between
Yellow/Green and Black wires. Voltage should be greater than 10 volts. Turn ignition off. If voltage is greater than 10 volts, go t o n e xt
step. If voltage is 10 volts or less, repair Yellow/Green or Black wires as necessary.
2. Remove instrument panel. See INSTRUMENT PANEL
under REMOVAL & INSTALLATION. Disconnect instrument panel 8-pin
connector. With boost sensor disconnected, measure resistance through White/Black between instrument panel and boost sensor harness
connector. If resistance is less than 5 ohms, go to next step. If resistance is 5 ohms or more, repair or replace White/Black wire.
3. With 8-pin instrument panel connector disconnected, ground White/Black at boost gauge. Boost gauge should read low. Apply 12 vo l t s
to White/Black wire at boost gauge. Boost gauge should read high. If boost gauge operates as specified, go to next step. If boost gauge
does not operate as specified, replace boost gauge.
4. Reconnect instrument panel connectors (if removed). With ignition on and boost sensor disconnected, install jumper wire between
Yellow/Green and White/Black wires of boost sensor vehicle harness connector. Boost gauge should read high. If boost gauge reads
high, replace boost sensor. If boost gauge does not read high, go to TROUBLE SHOOTING
for other possible causes.
REMOVAL & INSTALLATION
INSTRUMENT PANEL
Removal & Installation (Capri)
1. Disconnect negative battery cable. Pull storage compartment from heater/radio bezel. Pull outward and remove trim covers located on
both sides of steering column. Remove retaining screws and carefully pull instrument panel bezel partially away from dash. Disconnect
electrical connectors from clock and switches in bezel. Remove instrument panel bezel.
2. Disconnect speedometer cable from transaxle. Remove instrument panel retaining screws and slide instrument panel outward. Press lock
tab and release speedometer cable from instrument panel. Remove electrical connectors from rear of instrument panel. Remove
instrument panel. To install instrument panel, reverse removal procedure.
Removal & Installation (Festiva)
1. Disconnect negative battery cable. Remove upper and lower steering column covers. Remove screws from panel bezel and remove bezel.
Disconnect rear wiper switch and rear defogger switch wiring harness connectors (if equipped).
2. Remove instrument panel-to-dash screws. Pull panel from dash. Reach behind panel and release speedometer drive cable lock tab. Lift
lock tabs and disconnect 2 electrical connectors from rear of panel. Remove panel. To install instrument panel, reverse removal
procedure.
INDICATOR LIGHTS
Removal & Installation
Remove instrument panel for access to indicator light bulbs. See INSTRUMENT PANEL under REMOVAL & INSTALLATION. To remove
bulb, rotate bulb counterclockwise to disengage locking tabs. When tabs release, pull bulb from printed circuit board. To install bulb, reverse
removal procedure. Install instrument panel and test lights.
SPEEDOMETER R & I
Removal & Installation (Capri)
R e mo ve n e ga t ive b a t t e r y c a b l e . R e mo ve in st r u me n t p a n e l . S e e INSTRUMENT PANEL under REMOVAL & INSTALLATION. Disassemble
instrument panel and remove speedometer/tachometer/boost gauge assembly from instrument panel. To install, apply a 3/16" (4.6 mm) b al l o f
Silicone Damping Grease (D7AZ-19A331-A) into drive hole of speedometer head. Reverse removal procedure to complete installation.
Removal & Installation (Festiva)
R e mo ve n e ga t ive b a t t e r y c a b l e . R e mo ve in st r u me n t p a n e l . S e e INSTRUMENT PANEL under REMOVAL & INSTALLATION. Disassemble
instrument panel and remove speedometer head assembly from instrument panel. Speedometer is a separate module and can be removed
independently from gauges. To install, reverse removal procedure.
SPEED SENSOR
On vehicles equipped with speed control, a speed sensor is mounted in speedometer head assembly. If replacement is necessary, speedometer
head assembly must be replaced. See SPEEDOMETER R & I
under REMOVAL & INSTALLATION.
FUEL GAUGE
Removal & Installation
Remo ve in st ru men t p an el . See INSTRUMENT PANEL under REMOVAL & INSTALLATION. Disassemble panel and remove fuel gauge.
To install gauge, reverse removal procedure. On Capri, the fuel/volt gauge must be replaced as an assembly.
FUEL SENDING UNIT
Removal & Installation
1. For Festiva, remove rear seat. For Capri, remove rear seat cushion. On Festiva, remove carpet hold-down pins and lift carpet for access
to sending unit access plate. On all models, remove access plate screws. NOTE:Federal law requires that a label stating the odom eter has been repaired or replaced be affixed to any
vehicle that has its odom eter repaired, replaced or set to zero.
Page 4 of 5 MITCHELL 1 ARTICLE - INSTRUMENT PANEL 1991 ACCESSORIES & SAFETY EQUIPMENT Ford Motor Co. Switches
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Black/White and Black wire terminals of relay. Check continuity of relay across 2 Black/Yellow wire terminals of relay. Continuity should
exist when relay is energized. When relay is de-energized, continuity should not exist.
FILAMENT TESTING
1. To locate breaks in grid wire filaments, attach a voltmeter to middle portion of each filament. Attach other meter probe to vertical
section of window grid.
2. If a grid is broken, meter will register either zero volt or battery voltage, depending on if grid is broken between or outside test leads. If
wire is not broken, meter will register about one half of battery voltage. To locate break, move probe along wire until meter needle
mo ves ab ru p t l y.
REMOVAL & INSTALLATION
REAR DEFOGGER SWITCH
Removal & Installation (Capri)
1. Disconnect negative battery cable. Pull out center storage compartment. Remove 2 nuts, 2 lower screws, and heater/radio bezel. Pull
outward and remove 2 trim covers, one located on each side of steering column.
2. Remove instrument panel bezel retaining screws and pull instrument bezel from dash. Disconnect electrical connector from rear
defogger switch. Depress tangs on both sides of switch and remove switch. To install, reverse removal procedure.
Removal & Installation (Festiva)
Disconnect negative battery cable. Remove steering column covers. Remove screws securing instrument panel bezel to instrument panel. Pull
instrument bezel away from instrument panel. Disconnect electrical connectors from switches in bezel. Compress rear defogger switch lock
tabs and remove switch from bezel. To install, reverse removal procedure.
WIRING DIAGRAMS
See appropriate chassis wiring diagram in the WIRING DIAGRAMS Section.
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00028302
Page 3 of 3 MITCHELL 1 ARTICLE - DEFOGGER - REAR WINDOW 1991 ACCESSORIES & SAFETY EQUIPMENT Rear Window D
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Disconnect fluid lines and remove reservoir. To install, reverse removal procedure.
Removal & Installation (Festiva)
1. Disconnect negative battery cable. Remove washer reservoir filler neck attaching bolt. Remove coolant expansion reservoir. Disconnect
washer pump electrical connector. Remove left front splash shield.
2. Disconnect washer pump fluid lines and detach lines from reservoir clips. Remove reservoir attaching nuts and bolt. Detach washer
reservoir from filler neck and remove reservoir. To install, reverse removal procedure.
REAR WIPER MOTOR
Removal & Installation (Festiva)
Remove rear wiper arm and blade assembly. Remove boot from outer bushing attaching nut. Remove outer bushing attaching nut and remove
outer bushing. Remove liftgate trim panel. Disconnect wiper motor electrical connector. Remove 4 wiper motor mounting bolts and remove
motor. To install, reverse removal procedure.
REAR WIPER/WASHER SWITCH
Removal & Installation (Festiva)
Disconnect negative battery cable. Remove steering column covers. Remove screws securing instrument panel bezel to instrument panel. Pull
instrument bezel away from instrument panel. Disconnect electrical connectors from switches in bezel. Compress wiper/washer switch lock
tabs and remove switch from bezel. To install, reverse removal procedure.
REAR WASHER MOTOR & RESERVOIR
Removal & Installation (Festiva)
Open liftgate and detach reservoir cap. Remove rear quarter trim panel. Remove reservoir mounting bolts. Disconnect electrical connector
from washer pump. Disconnect fluid lines. Remove reservoir. To install, reverse removal procedure.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
WIRING DIAGRAMS
See appropriate chassis wiring diagram in the WIRING DIAGRAMS Section.
ApplicationINCH Lbs. (N.m)
Front Wiper Arm Retaining Nut89-124 (10-14)
Front Wiper Motor Mounting Bolts62-89 (7-10)
Rear Outer Bushing Retaining Nut27-44 (3-5)
Rear Wiper Arm Nut53-62 (6-7)
Rear Wiper Motor Mounting Bolts71-97 (8-11)
Copyr ight 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.
Article GUID: A00028304
Page 5 of 5 MITCHELL 1 ARTICLE - WIPER/WASHER SYSTEM 1991 ACCESSORIES & SAFETY EQUIPMENT Ford Motor Co. Wip
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Removal
Remove rotor and hub assembly from steering knuckle. Separate rotor, knuckle and hub. See FRONT BRAKE ROTOR & HUB under
REMOVAL & INSTALLATION. Press outer bearing from hub using Bearing Splitter (D84L-1123-A) and Shaft Protector (D80L-625-2).
Remove and discard outer grease seal. Pry inner wheel bearing grease seal from steering knuckle using a large screwdriver. Discard seal.
R e mo ve in n e r b e a r in g.
Bearing Preload
1. Use Spacer Selector Set (T87C-1104-B) to check and adjust preload. Install spacer selector into steering knuckle and clamp tool in vise
where shock absorber mounts, before installing hub/rotor assembly into steering knuckle. See Fig. 4
.

Fig. 4: Installing Preload Spacer Selector Set

Courtesy of FORD MOTOR CO.
2. Tighten center bolt from spacer selector set, in increments, to 36, 72, 108 and finally 145 ft. lbs. (49, 98, 147 and 196 N.m). Each time
center bolt is tightened, seat bearings by rotating hub by hand. Using an inch-pound torque wrench, measure torque required to turn
center bolt. Ensure torque reading is taken just as wrench starts to rotate.
3. Preload spacer thickness is correct if torque wrench indicates 2.2-16 INCH lbs. (.25-1.8 N.m). If measurement indicates less than 2.2
INCH lbs. (.25 N.m), a thinner spacer must be installed. If measurement indicates more than 16 INCH lbs. (1.8 N.m), a thicker spacer
must be installed.
4. Bearing spacers are available in various thicknesses. See PRELOAD SPACER AVAILABILITY table. Changing spacer thickness one
number changes bearing preload 1.8-3.5 INCH lbs. (.2-.4 N.m). Ensure correct spacer is installed and preload is within specification.
Remove preload spacer selector set.
PRELOAD SPACER AVAILABILITY
Stamped Mark On SpacerIn. (mm)
10.2474 (6.285)
20.2490 (6.325)
30.2506 (6.365)
40.2522 (6.405)
50.2537 (6.445)
60.2553 (6.485)
70.2569 (6.525)
80.2585 (6.565)
90.2600 (6.605)
100.2616 (6.645)
110.2632 (6.685)
120.2648 (6.725)
130.2663 (6.765)
140.2679 (6.805)
150.2695 (6.845)
160.2711 (6.885)
Page 6 of 12 MITCHELL 1 ARTICLE - BRAKE SYSTEM 1991-92 BRAKES Disc & Drum
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Fig. 2: Ground Numbers & Locations (2001 & Prior Model Years)

WIRING DIAGRAM COMPONENT LOCATIONS
When trying to locate a component in a wiring diagram and you don't know the specific system where it is located, use this handy component
locator to find the system wiring diagram in which the component is located. Then, go to that system and locate the component within the
wiring diagram.
For example, if you don't know the specific system in which the ignition switch is located, look up ignition switch in the wiring diagram
component location tables and go to the appropriate wiring diagram(s) which contain either full or partial views of the ignition switch. The full
view of the ignition switch is located in Power Distribution.
The first listing for the component will be the full or most complete view of the component. Additional listings will be partial views of the
component. Not all components are used on all models.
All components will have a partial view in Ground Distribution and Power Distribution. Data Link Connectors show connecting circuits
between modules. Alternate names for components may be listed in wiring diagram component locations tables.
WIRING DIAGRAM COMPONENT LOCATIONS
ComponentWiring Diagram
ABS Electronic Control UnitAnti-Lock Brakes; Data Link Connectors
ABS Hydraulic UnitAnti-Lock Brakes
Acceleration SensorAnti-Lock Brakes
Accessory Delay RelayPower Windows
A/C Compressor Clutch RelayEngine Performance
A/C SensorEngine Performance
A/C Pressure SwitchEngine Performance
Adaptive Lamp Control ModuleExterior Lights
Air Bag(s)Air Bag Restraint System
Air Bag ModuleAir Bag Restraint System
Air Bag Sensor(s)Air Bag Restraint System
Air Injection Pump RelayEngine Performance
Air Temperature SensorOverhead Console
Alternator (Generator)Generators & Regulators
Anti-Theft Control ModuleAnti-Theft System; Starters
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Height SensorElectronic Suspension
HornsSteering Column Switches
Horn RelaySteering Column Switches
Idle Air Control (IAC) Motor/ValveEngine Performance
Ignition Coil(s)Engine Performance
Ignition Key Lock CylinderAnti-Theft System
Ignition ModuleEngine Performance
Ignition SwitchPower Distribution; Engine Performance; Generators &
Regulators; Starters
Illuminated Entry ModuleIllumination/Interior Lights
Illumination LightsIllumination/Interior Lights
Impact SensorAir Bag Restraint System
Inertia Fuel Shutoff SwitchEngine Performance
In h ib it Rel ayStarters
Instrument ClusterAnalog Instrument Panels
Intake Air Temperature (IAT) SensorEngine Performance
Interior LightsIllumination/Interior Lights
In t erl o ck Swit chStarters
Junction BlockPower Distribution
Keyless Entry ReceiverRemote Keyless Entry
Key Reminder SwitchStarters
Knock SensorEngine Performance
Lamp Control ModuleExterior Lights
License Plate LampExterior Lights
Lighting Control ModuleLighting Control Modules; Anti-Theft System; Daytime Running
Lights; Headlight Systems
Lower RelayPower Convertible Top
Malfunction Indicator Light (MIL)Engine Performance; Instrument Panels
Manifold Absolute Pressure (MAP) SensorEngine Performance
Mass Airflow (MAF) SensorEngine Performance
Mega FuseGenerators & Regulators
Memory Seat/Mirror ModuleMemory Systems
M ir r o r De fo gge rRear Window Defogger
Moon Roof MotorPower Moon Roof
Moon Roof RelayPower Moon Roof
Multi-Function Control ModuleWarning Systems
Neutral Safety SwitchStarters
Oil Level SwitchEngine Performance
Oil Pressure Switch/Sending UnitAnalog Instrument Panels; Engine Performance
Overhead ConsoleOverhead Console
Oxygen Sensor(s) (O2S)Engine Performance
Parking Brake SwitchAnalog Instrument Panels
Park LightsExterior Lights
Park/Neutral Position SwitchStarters; Engine Performance; Anti-Theft System; Body Control
Module
Perimeter Lighting Control RelayExterior Lights
Power AmplifierPower Antennas
Power Antenna ModulePower Antennas
Power Antenna MotorPower Antennas
Power Distribution CenterPower Distribution; Generators & Regulators; Starters
Power Door Lock MotorsPower Door Locks
Power Mirror MotorsPower Mirrors; Memory Systems
Power Sliding Door ControllerPower Sliding Side Door
Power Seat MotorsPower Seats; Memory Systems
Power Steering Pressure SwitchEngine Performance
Power Top MotorPower Convertible Top
Power Top Relay(s)Power Convertible Top
Powertrain Control ModuleEngine Performance; Analog Instrument Panels; Cruise Control
Systems; Data Link Connectors; Generators & Regulators; Starters
Power Window MotorsPower Windows
Power Window Relay(s)Power Windows
Radiator Fan Motor(s)Electric Cooling Fans
Radiator Fan Relay(s)Engine Performance; Electric Cooling Fans;
Rainsense ModuleWiper/Washer Systems
Raise RelayPower Convertible Top
Remote Anti-Theft Personality (RAP) ModuleAnti-Theft System; Starters; Warning Systems
Seat Belt PretensionersAir Bag Restraint System
Seat Belt Retractor SolenoidPassive Restraints
Seat Belt SwitchAir Bag Restraint System; Passive Restraints
Shift Interlock SolenoidShift Interlock Systems
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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)
Page 1 of 4 MITCHELL 1 ARTICLE - F - BASIC TESTING 1991-92 ENGINE PERFORMANCE Ford Motor Co. Basic Diagnostic Proced
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GENERAL INFORMATION
Com m only Used Abbreviations
* PLEASE READ THIS FIRST *
"A"
A
Amperes
ABS
Anti-Lock Brakes
ABRS
Air Bag Restraint System
AC
Alternating Current
A/C
Air Conditioning
ACCS
A/C Cycling Switch
ACCUM
Accumulator
ACCY
Accessory
ACT
Air Charge Temperature Sensor
ADJ
Adjust or Adjustable
ADV
Advance
AFS
Airflow Sensor
AI
Air Injection
AIR or A.I.R.
Air Injection Reactor
AIS
Air Injection System
Alt.
Alternator or Altitude
Amp./amp/amps
Ampere NOTE:T his article is intended for general inform ation purposes only. T his inform ation m ay not apply to all
m akes and m odels. Not all abbreviations are covered as m anufacturers add new ones every day.
Page 1 of 15 MITCHELL 1 ARTICLE - GENERAL INFORMATION Commonly Used Abbreviations
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