1991 FORD FESTIVA washer fluid

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WIPER/WASHER SYST EM
1991 ACCESSORIES & SAFET Y EQUIPMENT Ford Motor Co. Wiper/Washer System s
DESCRIPTION & OPERATION
Capri and Festiva vehicles are equipped with a 2-speed wiper motor with an optional intermittent system. The Festiva rear wiper uses a single
speed wiper motor. Washer systems for both front and rear washers use pumps mounted near fluid reservoirs.
ADJUSTMENTS
W IPER ARM ADJUSTMENT
Remove wiper arm and blade assemblies from pivot shafts. Turn wiper switch on and allow wiper motor to cycle 2 to 3 times. Turn wiper
switch off to place pivot shafts in park position. Reinstall wiper arm and blade assemblies with tips of wiper blades at specified distance from
lower edge of windshield. See WIPER BLADE ADJUSTMENT SPECIFICATIONS
table. Tighten wiper arm retaining nut to 89-124
INCH Lbs. (10-14 N.m).
WIPER BLADE ADJUSTMENT SPECIFICATIONS
TESTING
FRONT WIPER MOTOR TEST
Capri
1. Check WIPER fuse in interior fuse block and replace if necessary. Perform FRONT INTERVAL WIPE MODULE TEST . If
wiper/washer switch and interval module are operating properly, disconnect wiper motor connector. Turn ignition on and place
wiper/washer switch in HIGH position. Measure voltage at Blue/Red and Blue wires at wiper motor vehicle harness connector.
2. If battery voltage is not present, check Blue/Red or Blue wire for open circuit. If battery voltage is present at Blue/Red and Blue wires,
check Black ground wire at wiper motor vehicle harness connector for an open circuit and repair as necessary. If Black ground wire is
okay, replace wiper motor.
Festiva
1. Place wiper in any position other than park. Remove WIPER fuse. Disconnect wiper motor electrical connector. Using an ohmmeter,
check for continuity to ground at motor case. Continuity should exist. If continuity does not exist, replace or repair wiper motor ground
strap or wire.
2. Check for continuity to ground at Blue/Black terminal of wiper motor. Continuity should exist. If continuity does not exist, replace
wiper motor.
FRONT INTERVAL WIPE MODULE TEST
Capri
1. Check WIPER fuse in interior fuse block and replace if necessary. Perform FRONT WIPER/WASHER SWITCH TEST . Access
interval wipe module connector. Interval wipe module is located below instrument panel near console. Ensure wiper switch is in OFF
position. Turn ignition on and measure voltage at Blue/White and Blue/Black wires of module connector. Battery voltage should not be
present. Turn wiper switch to LOW position. Measure voltage at Blue/White and Blue/Black wires of module connector. Battery voltage
should be present.
2. Turn wiper switch to HIGH position. Measure voltage at Blue/White, Blue/Black and Blue/Red wires of module connector. Battery
voltage should be present. Turn wiper switch to INT position. Measure voltage at Blue/White and Blue/Black wires of module
connector. Battery voltage should be present during each cycle. If module does not perform as specified, replace module.
Festiva
Information is not available from manufacturer.
FRONT WIPER/WASHER SWITCH TEST
Capri
Remove lower steering column cover to gain access to wiper switch electrical connector. Using an ohmmeter, ensure continuity exists between
terminals listed in table at specified switch positions. If switch does not test as specified, replace wiper/washer switch. See FRONT
WIPER/WASHER SWITCH CONTINUITY (CAPRI) table. See Fig. 1 .
FRONT WIPER/WASHER SWITCH CONTINUITY (CAPRI)
ApplicationIn. (mm)
Capri
Driver Side1.0 (25)
Passenger Side1.26 (32)
Festiva
Both Sides1.0 (25)
Rear(1) 3.15 (80)
(1)From left edge of liftgate window.
TerminalPositionContinuity
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Fig. 2: Identifying Front Wiper/Washer Switch Terminals (Festiva)

Courtesy of FORD MOTOR CO.
FRONT WASHER MOTOR TEST
Remove washer fluid reservoir. Remove washer motor from reservoir. Connect fused jumper wire between washer motor terminal that
corresponds with Blue/Orange wire (Capri) or Blue wire (Festiva) and battery positive terminal. Connect other washer motor terminal to
ground. Washer motor should run smoothly. If washer motor does not run smoothly or does not run, replace motor.
REAR WIPER MOTOR TEST
Festiva
1. Place wiper in any position other than park. Disconnect wiper motor electrical connector. Using an ohmmeter, check for continuity to
ground at motor case. Continuity should exist. If continuity does not exist, repair wiper motor housing ground wire.
2. Check for continuity to ground at Blue terminal of wiper motor. Continuity should exist. If continuity does not exist, replace wiper
mo t o r.
REAR WIPER/WASHER SWITCH TEST
Festiva
Remove rear wiper/wash switch. Using a self-powered test light or an ohmmeter, ensure continuity exists between terminals listed in table at
specified switch positions. If switch does not test as specified, replace wiper/washer switch. See Fig. 3
. Also, refer to the REAR
WIPER/WASHER SWITCH CONTINUITY (FESTIVA) table.
REAR WIPER/WASHER SWITCH CONTINUITY (FESTIVA)
TerminalPositionContinuity
BLU - BLKOffNo
"OnYes
GRN/BLK - BLKOffNo
"OnYes
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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
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lock nut. Discard axle lock nut. Separate tie rod end from knuckle.
2. Disconnect brake hose from strut (if necessary). Remove brake caliper assembly from knuckle and wire out of way. Remove nuts and
bolts holding ball joint and strut to knuckle assembly.
3. Remove knuckle assembly from ball joint and drive shaft. If binding occurs, use a dual-jawed puller to force knuckle/hub/rotor assembly
off drive axle shaft.
4. Using a puller, separate knuckle from wheel hub. Retain original outer bearing preload spacer to maintain bearing preload setting. If
replacing bearing, change spacer to maintain proper bearing preload (if necessary). See FRONT WHEEL BEARINGS under REMOVAL
& INSTALLATION. Scribe match marks between hub and rotor assembly. Remove rotor-to-hub bolts. Separate hub from rotor.
Installation
Align marks and install rotor on hub. Press knuckle and preload spacer into wheel hub assembly. To complete installation, reverse removal
procedure. Tighten axle shaft lock nut to 117-175 ft. lbs. (159-237 N.m).
REAR BRAKE CALIPER & PADS
Removal (Capri)
1. Raise and support vehicle. Remove tire and wheel assembly. Using needle-nose pliers, remove parking brake return spring. Loosen
parking brake cable housing adjusting nut. Remove cable housing from bracket on lower control arm. Loosen parking brake cable
bracket-to-caliper attaching bolt. Remove parking brake cable from caliper.
2. Remove lower caliper retaining bolt. Pivot caliper upward on upper caliper guide pin. Remove brake pad retaining spring, pads and
shims. If replacing rear brake pads only, reverse removal procedure to install. If removing caliper, proceed to next step.
3. Remove attaching clip from brake flex hose. Remove flex hose banjo bolt from caliper and discard copper washers. Remove lower
caliper retaining bolt. Using a cold chisel, remove upper caliper guide pin dust cap. Using an Allen wrench, remove upper caliper guide
pin. Lift caliper off rotor.
Installation
1. To install, fit brake pads and shims into caliper anchor plate. Remove upper guide pin and lower guide pin bushing from caliper.
Remove guide pin and guide pin bushing dust boots. Lubricate upper guide pin and lower guide pin bushing with Disc Brake Caliper
Slide Grease (D7AZ-19590-A).
2. To complete installation, reverse removal procedure. To fit caliper over new brake pads, it may be necessary to rotate caliper piston into
caliper bore. Use NEW copper washers on flex hose. Bleed brakes, and then pump brake pedal several times to seat pads.
REAR BRAKE ROTOR
Removal & Installation (Capri)
See REAR WHEEL BEARINGS under REMOVAL & INSTALLATION.
REAR BRAKE SHOES
Removal & Installation (Festiva)
Remove brake drum. Remove hold-down springs. Remove return springs. Remove self adjuster. See Fig. 8 . To install, reverse removal
procedure. Apply brake grease to all shoe contact points. See REAR BRAKE SHOES under ADJUSTMENTS.
REAR WHEEL CYLINDER
Removal & Installation (Festiva)
Remove rear brake shoes. Disconnect brake line from wheel cylinder. Remove wheel cylinder. To install, reverse removal procedure. Bleed
brake system.
MASTER BRAKE CYLINDER
Removal
Disconnect low fluid level sensor wiring (if equipped). Drain some brake fluid from reservoir. Disconnect brake lines from master cylinder.
Cap lines and master cylinder ports. Remove attaching nuts and master cylinder.
Installation
To install, reverse removal procedure. Fill master cylinder to proper level and bleed hydraulic system (if necessary).
POWER BRAKE UNIT
Removal & Installation
Remove master cylinder. Disconnect vacuum line. Remove clevis pin at brake pedal. Remove power brake unit. To install, reverse removal
procedure.
FRONT WHEEL BEARINGS NOTE:Hub and rotor are a m atched and balanced assem bly. Before rem oving rotor, locate paint or etch
m ark indicating proper hub-to-rotor alignm ent. If m arks are not present, m ark hub and rotor for
assem bly alignm ent. Failure to properly align hub and rotor can result in an im balance condition.
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AXLE SHAFT S - FRONT
1988-93 Drive Axles - FWD Axle Shafts
DESCRIPTION & OPERATION
Axle shafts transfer power from transaxle to driving wheels. All axle shafts consist of a shaft with a flexible Constant Velocity (CV) joint at
each end. Inner CV joint is coupled to transaxle by splines. Outer CV joint is splined to hub assembly and secured by axle shaft nut.
Three different types of axle shaft CV joints are used: Double Offset Joint (DOJ) or Rzeppa type, Birfield Joint (BJ) and the Tripot Joint (TJ).
CV joint boots protect CV joints by maintaining proper lubrication and preventing contaminants from entering joint. Boots must be replaced
when signs of leakage or cracks are present. Inner CV joint may be disassembled and serviced. Outer CV joint boot may be replaced, but outer
Birfield CV joint must NOT be disassembled. It must be replaced as an assembly, if faulty.
To prevent torsional vibration and torque steer on turbocharged Capri vehicles, an intermediate shaft and conventional axle shaft are used on
the right side. Both shafts are of similar length and are supported by a bearing, which is attached to engine.
CV JOINT IDENTIFICATION
TROUBLE SHOOTING
REMOVAL, DISASSEMBLY, REASSEMBLY & INSTALLATION
FWD AXLE SHAFTS
Removal
1. Raise and support vehicle. Remove lower underbody splash shields. Drain transaxle fluid. Remove front wheels and loosen axle shaft
lock nut. On Capri, remove stabilizer bar-to-control arm attaching nuts, bolt, washers and bushings. On Festiva, remove stabilizer bar
attaching nuts and bracket. On all models, remove joint clamp bolt from lower control arm. Pry downward and separate steering knuckle
from ball joint, taking care not to damage ball joint dust boot.
2. On Capri turbo, remove bolts securing intermediate shaft bearing bracket to engine. On all models, slowly pry axle shaft from transaxle
using a flat-tip screwdriver or pry bar. Axle is held into transaxle by a circlip fitted to the end of the axle. Remove axle shaft from wheel
hub. If difficult to remove, use axle puller to remove axle from drive hub. Remove axle shaft from transaxle. Plug transaxle openings
with Plugs (T87C-7025-C ). Remove axle shaft assembly from vehicle. See Fig. 1
.

Fig. 1: Removing & Installing Axle Shafts

Courtesy of FORD MOTOR CO.
ApplicationJoint Type
Outer JointBirfield (BJ)
In n er Jo in t
Automatic TransaxleTripot (TJ)
Manual TransaxleRzeppa (DOJ)
NOTE:See TROUBLE SHOOTING - BASIC PROCEDURES article in GENERAL INFORMATION.
CAUTION: Dam age to CV joint will occur if a ham mer is used to separate half-shaft from wheel hub.
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levels to proper level.
Removal (1.6L & 1.6L Turbo)
1. Relieve fuel pressure and discharge air conditioning system (if equipped). See FUEL PRESSURE RELEASE under REMOVAL &
INSTALLATION. Disconnect and remove battery, battery tray and battery tray support bracket.
2. Release wiring harness retaining straps from battery support tray. Disconnect windshield washer supply hose between fluid reservoir and
hood. Mark hinge locations and remove hood.
3. Disconnect intake air tube and wiring to ignition coil and vane airflow meter. Remove air cleaner/vane airflow meter assembly. Remove
air cleaner assembly support brackets. Disconnect intercooler hoses from turbocharger (if equipped).
4. Drain engine coolant and remove radiator. Disconnect accelerator cable, and remove retaining bracket from cam cover. Position cable to
one side.
5. Disconnect and plug fuel lines at fuel filter and pressure regulator. Disconnect power brake booster manifold vacuum hose from
manifold. Disconnect heater hoses at heater core tubes. Label and remove vacuum hoses located at throttle body.
6. For manual transaxle turbocharged vehicles, disconnect clutch cable and remove support bracket and cable from transmission. On non-
turbo vehicles, disconnect clutch slave hydraulic line. For automatic transaxle, remove transaxle cooler lines.
7. Disconnect starter wiring at starter. Remove harness from locating strap on bracket. Disconnect alternator wiring. Disconnect wiring
from engine coolant sensors located on rear of engine block. Remove ground connection at bracket on thermostat cover. Disconnect O2
sensor wire, main wiring harness connector, TPS connector (turbocharged only), knock sensor connector, distributor wiring and
transaxle wiring. Disconnect ground wire and strap at front of engine, and reinstall lifting eye.
8. Remove engine oil dipstick and retaining clip. Remove power steering pump from mounting bracket. Remove power steering pump
mounting bracket. With hoses attached, position pump aside. Remove upper air conditioning compressor retaining bolts (if equipped).
9. Raise vehicle on hoist. Drain engine oil and cooling system. On vehicles with air conditioning, remove lower air conditioning
compressor mounting bolts, and position compressor out of way.
10. Remove front wheels and tires. Remove front ball joints-to-ste e r in g kn u c kl e s r e t a in in g b o l t s. R e mo ve sp l a sh gu a r d s. Dr a in t ransmission
oil and remove half shafts from differential. Remove front exhaust pipe bracket located on lower side of engine. Disconnect front
exhaust pipe from exhaust manifold, or turbocharger (if equipped).
11. Remove frame support bar-to-engine support bolt. Loosen right control arm bolt and, pivot support bar downward. Disengage rubber
exhaust hangers located directly behind catalytic converter. Allow exhaust system to hang down 6 inches, and support system with
mechanic's wire. Unbolt shift linkage and stabilizer bar at transaxle. Remove nuts from front and rear engine mounts, and lower vehicle.
12. Attach chains onto lift eyes at ends of cylinder head, and support engine with hoist. Remove RH engine mount through bolt. Raise
engine off mounts and slightly pivot engine/transaxle assembly. Disconnect oil pressure sensor and route starter/alternator wiring
harness from engine. Carefully lift engine/transaxle assembly, turn assembly while raising to clear brake master cylinder, shift linkage
universal joint, radiator support and air conditioning lines (if equipped).
13. Remove intake manifold support bracket. Remove gusset plate(s) (if equipped). Remove starter. Remove transaxle-to-engine retaining
bolts. Identify bolts to ensure correct installation. Separate transaxle from engine. On manual transaxle, remove pressure plate, clutch
disc and flywheel. On automatic transaxle, remove flexplate.
Installation (1.6L & 1.6L Turbo)
1. Install transaxle to engine in reverse order of removal. Attach hoist to engine/transaxle assembly and position assembly in vehicle.
Before engine contacts mounts, route starter, alternator and oil pressure sensor wiring, and connect oil pressure sensor. Lower engine
until front mount seats on crossmember. Install through bolt on RH engine mount. DO NOT tighten bolt.
2. Remove hoist. Raise vehicle and support with jackstands. Align rear engine mount to crossmember, and install retaining nuts to front
and rear engine mounts. Tighten nuts to specification. See TORQUE SPECIFICATIONS
table at end of article.
3. On manual transaxles, connect shift coupling and stabilizer. Tighten to specification. On automatic transaxles, connect shift linkage and
oil cooler lines. Tighten linkage retaining bolt, shift cable pivot and oil cooler hose clamps to specification. Connect front exhaust pipe
to manifold (or turbocharger). Install exhaust pipe to support bracket. Tighten bolts to specification. Tighten manifold (or turbocharger)
to specification. Attach rubber exhaust hangers. Position cross brace. Tighten retaining nut and bolt and right control arm front bolt.
4. Install drive axles. Install ball joint retaining bolts and tighten to specification. Mount A/C Compressor to engine (if equipped). Tighten
lower retaining bolts to specification. Install splash guards. Install tire and wheel assemblies. Tighten retaining nuts to specification.
5. Lower vehicle. Install upper A/C compressor retaining bolts (if equipped). Tighten bolts to specification. Tighten RH engine mo u n t
through bolt to specification. Connect alternator wiring.
6. Position power steering pump bracket on stud. Lower pump into engine compartment. Install power steering pump bracket retaining
bolts and nut. Tighten to specification. Install power steering pump and belt. Tighten adjustment nut and pivot bolt to specification.
7. Install engine oil dipstick and retaining clip. Install ground strap and ground wire to cylinder head. Install clutch cable (if equipped).
Connect clutch hydraulic line if equipped with manual transaxle or naturally aspirated. Connect transmission electrical connectors.
Connect fuel lines to fuel filter and pressure regulator. Install intake air tube to throttle body.
8. Install intercooler hoses on turbocharged models. Install air cleaner assembly brackets. Install air cleaner assembly with airflow meter
attached. Install intake air tube. Install coil and airflow meter connectors. Connect coolant crankcase and air bypass hoses. Install
vacuum hoses as noted in disassembly.
9. Connect accelerator cable. Install retaining bracket. Install power brake booster hose. Remove speedometer cable from transaxle. Fill
transaxle to specification. See CAPACITIES in SERVICE & ADJUSTMENT SPECIFICATIONS article. Install speedometer cable.
Connect speedometer cable connector. Fill engine oil to capacity.
10. Install radiator/fan assembly. Tighten bracket retaining bolts to specification. Connect coolant hoses and fan electrical connector. Fill
coolant to specification.
11. Install hood and connect washer hose. Install battery tray support, battery tray, battery and battery hold-down. Connect battery
terminal. Evacuate and charge air conditioning system (if equipped). Road test vehicle and inspect for leaks.
INTAKE MANIFOLD
Removal (1.3L)
CAUT ION: DO NOT allow com pressor to hang by hoses. T ie up com pressor with m echanic's wire.
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Disconnect negative battery cable. Drain cooling system. Remove air cleaner. Remove intake manifold bracket. Disconnect throttle cable.
Mark and disconnect vacuum hoses, fuel hoses and wiring. Remove intake manifold bolts. Remove intake manifold and gasket.
Installation (1.3L)
Clean all gasket mating surfaces. Ensure surface is free of burrs, scratches and cracks. Replace all gaskets. Position gasket and manifold to
cylinder head. Install bolts and tighten to specification. To complete installation, reverse removal procedure.
Removal (1.6L)
1. Disconnect negative battery terminal. Relieve fuel pressure. See FUEL PRESSURE RELEASE under REMOVAL &
INSTALLATION. Drain cooling system. Disconnect intercooler tube and/or air intake tube. Disconnect air by-pass hoses. Disconnect
main engine harness electrical connection and TPS connector. Disconnect vacuum hoses from throttle body.
2. Disconnect fuel lines from fuel filter and pressure regulator. Disconnect throttle cable. Disconnect hoses from By-pass Air Control valve
( B AC ) . R e mo ve B AC va l ve r e t a in in g n u t a n d b o l t . R e mo ve in t a ke manifold retaining nuts and bolts from support bracket and cylinder
head. Remove intake manifold and throttle body assembly.
Installation (1.6L)
1. Install new intake manifold gasket, ensuring coolant passage openings align with openings in cylinder head and manifold. Install intake
manifold. Tighten retaining nut and bolts and support bracket bolts to specification. See TORQUE SPECIFICATIONS
table at end of
article.
2. Install BAC valve and connect air hoses. Connect throttle cable. Connect fuel lines to fuel filters and pressure regulator. Connect main
engine harness connector and TPS connector. Connect vacuum lines to throttle body. Install intake air tube. Connect intercooler tube
and/or intake air tube. Connect air by-pass hoses. Fill cooling system. Connect negative battery terminal. Start engine and check for
fluid leaks and correct operation.
EXHAUST MANIFOLD
Removal (1.3L)
1. Raise vehicle. Remove catalytic converter inlet pipe at exhaust manifold. Remove pulse air tube nuts at inlet pipe. Remove inlet pipe
support bracket bolts. Lower vehicle. Remove air intake duct. Remove exhaust manifold heat shroud bolts and remove shroud.
2. Disconnect oxygen sensor connector. Remove exhaust manifold nuts and remove exhaust manifold. Remove gasket from inlet pipe and
cylinder head.
Installation
Position new gasket on cylinder head and inlet pipe. Install exhaust manifold and nuts. Tighten nuts to specification. See, at end of article,
TORQUE SPECIFICATIONS
table. To complete installation, reverse removal procedure. Tighten all bolts and nuts to specification.
Removal (1.6L Non-Turbo)
Remove intake air tube. Remove front exhaust pipe to exhaust manifold retaining nuts. Remove exhaust support bracket (if equipped). Remove
heat shield. Disconnect O2 sensor electrical connector. Remove exhaust manifold.
Installation (1.6L Non-Turbo)
Install exhaust manifold gaskets. Install heavier gasket first. Install exhaust manifold and tighten retaining nuts to specification. See TORQUE
SPECIFICATIONS table at end of article. Connect O2 sensor electrical connector. Install manifold heat shield. Install intake air tube.
Connect front exhaust pipe to intake manifold and tighten retaining nuts to specification. Install exhaust support bracket, if removed, and
tighten engine mount bolt to specification. Start engine and check for leaks.
Removal (1.6L Turbo)
1. Disconnect negative battery cable. Drain cooling system. Remove throttle body air intake tube. Disconnect intercooler hose from
turbocharger assembly and position both intercooler hoses out of the way. Remove O2 sensor connector from its retaining clip, and
disconnect O2 sensor. Remove lower heat shield and then upper heat shield. Remove turbocharger side heat shield.
2. Remove power steering pump (leave hoses attached) and lay aside. Disconnect lower radiator hose from water pump. Position power
steering pump to access mounting bracket retaining bolts and nut. Remove both bolts and one nut, and remove bracket from engine.
Remove 2 screws retaining air cleaner duct tube, loosen clamp at turbocharger and position duct tube out of the way. Disconnect
coolant return hose at turbocharger. Remove bolt and brass sealing washers from oil supply line at engine block.
3. Raise vehicle. Remove retaining nuts and washers from exhaust pipe flange. Remove 2 bolts retaining exhaust hangers to engine block.
Slide off two rubber exhaust hangers at catalytic converter. Pull exhaust pipe downward and to LH side of vehicle. Disconnect oil return
hose at turbocharger. Disconnect coolant return hose at turbocharger. Remove 2 retaining bolts from turbocharger support bracket.
Remove 2 bolts retaining coolant by-pass tube outlet to water pump. Lower vehicle.
4. Loosen retaining clamp bolt on coolant by-pass tube at rear of cylinder head. Remove 11 retaining nuts from exhaust manifold. Pull
coolant by-pass tube bracket from exhaust stud, and position tube out of way. Grasp manifold, pull off studs and move assembly slightly
to RH side of engine compartment to clear cooling fan, and remove assembly from vehicle.
5. Working on bench, remove 4 nuts retaining turbocharger to exhaust manifold, separate assembly and discard gasket.
Installation (1.6L Turbo)
NOTE:Feed O2 sensor wire and guide through upper heat shield.
NOTE:When reinstalling turbocharger, thoroughly rem ove all gaskets and sealant. Use new gaskets. Add .85
oz. (25 cc) of engine oil in the oil passage of the turbocharger.
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1. Position new gasket on exhaust manifold, and install turbocharger onto studs. Install 4 retaining nuts and tighten to specification. See
TORQUE SPECIFICATIONS
table at end of article.
2. Remove oil supply line from turbocharger. Position new (2-piece) exhaust gasket on cylinder head with heavy gasket installed first .
Carefully position turbocharger assembly in engine compartment and slide exhaust manifold on studs. Position heater tube bracket onto
exhaust stud. Install 11 retaining nuts onto exhaust manifold and tighten to specification. See TORQUE SPECIFICATIONS
table at
end of article. Tighten heater tube clamp bolt securely.
3. Raise vehicle. Position new gasket and install 2 retaining bolts on heater tube outlet. Install 2 retaining bolts into turbocharger support
bracket and tighten bolts to specification.
4. Connect coolant return hose. Connect oil return hose and secure with clamp. Position exhaust pipe onto turbocharger, and start nuts
and washers. Install 2 retaining bolts on exhaust hanger at engine. Slide on 2 rubber exhaust hangers at catalytic converter. Tighten
exhaust pipe retaining nuts to specification. Lower vehicle.
5. Install retaining bolt and brass washers on oil supply line, carefully position oil line into vehicle and hand-start bolt into engine block.
Connect and finger tighten oil line to turbocharger. Tighten oil line bolt and oil supply line on turbocharger to specification.
6. Connect coolant supply hose. Position air cleaner duct tube on turbocharger and tighten clamp. Install 2 screws retaining air cleaner
duct tube. Position power steering pump bracket on engine, and install 2 retaining bolts and one retaining nut. Tighten to specification.
Position power steering pump on mounting bracket, and install though bolt and adjuster. Connect lower radiator hose. Install power
steering belt. Position upper heat shield and install 2 retaining bolts finger tight.
7. Position lower heat shield and install three retaining bolts finger tight. Tighten all heat shield bolts to specification. Connect O2 sensor
and install connector into its retaining clip. See TORQUE SPECIFICATIONS
table at end of article. Position intercooler hose on
turbocharger and secure with clamp. Install throttle body air intake tube. Connect negative battery cable. Refill cooling system.
CYLINDER HEAD
Removal (1.3L)
1. Disconnect battery ground cable. Mark and disconnect fuel lines at fuel pump. Remove accessory belts, water pump pulley, crankshaft
pulley, timing belt covers, timing belt tensioner, timing belt, valve cover and exhaust and intake manifolds. Drain cooling system.
2. Mark and remove electrical connectors and vacuum hoses. Remove spark plug wires from spark plugs, and remove spark plugs. Remove
distributor cap. Disconnect vacuum hoses and distributor wiring.
3. Index distributor-to-mount position and remove hold-down bolt. Remove distributor assembly. Remove engine ground strap. Remove
front and rear engine lifting hooks. Remove upper radiator hose, by-pass hose and bracket.
4. Remove bolts retaining rocker arm shaft. Remove rocker arm assemblies. Remove cylinder head bolts. Remove head and gasket.
Inspection (1.3L)
1. Thoroughly clean and check gasket mating surface of cylinder head and block. Check cylinder for cracks, nicks, burrs or damage. Using
a straightedge and feeler gauge, check warpage over entire gasket area. Ensure cylinder head and/or block warpage does not
exceed .006" (.15 mm).
2. If warpage exceeds .006" (.15 mm), machine cylinder head and/or block gasket surface. Maximum machining allowed is .008" (.20 mm).
If more machining is required, replace block and/or cylinder head.
Installation (1.3L)
1. Place new head gasket properly on block. Carefully place cylinder head in position on block. Install head bolts. Tighten bolts in
sequence and in 2 steps. See Fig. 1
.
2. While tightening rocker arm shaft, slide shaft springs away from retaining bolt to prevent pinching springs. Tighten rocker arm shaft bolts
in sequence and to specification. See Fig. 5
. To complete installation, reverse removal procedure. Tighten all bolts/nuts to
specification. Fill all fluids to proper levels. NOTE:T urbocharger-to-exhaust m anifold m ounting nuts are of special quality. Ensure correct nuts are
used.
NOTE:Ensure one brass washer is positioned on each side of oil line fitting.
NOTE:Feed O2 sensor wire through upper heat shield. Install wire retainer under LH bolt.
NOTE:If turbocharger was replaced: Disconnect ignition coil, crank engine for 20 seconds, connect ignition
coil, start engine and run at idle for 30 seconds and check for leaks.
NOTE:If original tim ing belt is being reused, m ark direction of rotation for installation reference.
Page 4 of 19 MITCHELL 1 ARTICLE - ENGINE OVERHAUL 1991-92 FORD MOTOR CO. ENGINES 1.3L & 1.6L 4-Cylinder
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