Ford Festiva. Instruction — part 37

Fig. 2: Exploded View of Distributor Assembly (Capri Non-Turbo)

Courtesy of FORD MOTOR CO.

Fig. 3: Exploded View of Distributor Assembly (Capri Turbo)

Courtesy of FORD MOTOR CO.

ELECTRONIC CONTROL ASSEMBLY (ECA)

REMOVAL & INSTALLATION

Disconnect negative battery cable. On Festiva, from under instrument panel, remove heater duct. On Capri, disengage push-pin retainers by
pulling back on front edges of both center carpet panels. Remove carpet panel retaining screws and panels. Disconnect ECA wire harness
connector. Remove ECA bolts and ECA. To install, reverse removal procedure. On Festiva, ensure mounting clip is inserted into bulkhead
recess.

FUEL SYSTEM

FUEL SYSTEM PRESSURE RELEASE

Remove rear seat assembly. With engine running, disconnect fuel pump connector. Run engine until it stalls to relieve fuel line pressure.

FUEL INJECTORS

Removal

Relieve fuel system pressure. On Capri, remove throttle body. On Festiva, remove intake plenum. See INTAKE PLENUM. Remove fuel inlet
and fuel return line from fuel rail. Remove electrical connectors from injectors. Remove pressure regulator. See

Fig. 4

. Remove fuel rail

attaching bolts and fuel rail. Remove fuel injectors.

Installation

Install NEW "O" rings on fuel injectors and lubricate with gasoline. Install fuel injectors into cylinder head. Install fuel rail onto fuel injectors.
Install fuel rail attaching bolts. To complete installation, reverse removal procedure. Check system for leaks.

Fig. 4: Exploded View of Fuel Control System

Courtesy of FORD MOTOR CO.

FUEL PUMP

Removal

Remove fuel tank sending unit. Remove fuel filter from pump. Remove fuel pump wires from sending unit. Remove retaining clamp screw and
clamp. Remove rubber retaining band (if equipped). Remove fuel pump from sending unit.

Installation

To install, reverse removal procedure. Check system for leaks.

INTAKE PLENUM

WARNING:

ALWAYS relieve fuel pressure before disconnecting any fuel injection-related component. DO NOT
allow fuel to contact engine or electrical components.

WARNING:

ALWAYS relieve fuel pressure before disconnecting any fuel-related component. DO NOT allow fuel to
contact engine or electrical components.

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 side

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 from
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. Remove oil

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:

To prevent dust and dirt from entering intake manifold ports, cover ports with clean cloth after
removing intake plenum.

WARNING:

DO NOT remove oxygen sensor when engine is hot.

NOTE:

Clean throttle body exterior before removal.

CAUTION:

Before installing turbocharger, put .8 oz. (25 ml) engine oil into turbocharger oil inlet.

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 meter.

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 adjustments not covered in this article, see ADJUSTMENTS article in the ENGINE
PERFORMANCE Section.

Application

Ft. Lbs. (N.m)

Coolant By-Pass Tube Outlet-To-Water Pump Bolts

14-19 (19-26)

Distributor Mounting Bolts

14-19 (19-26)

Exhaust Manifold Retaining Nuts

29-42 (39-57)

Exhaust Pipe Nuts

18-25 (24-34)

Fuel Line-To-Fuel Filter Bolt

18-25 (24-34)

Fuel Pressure Regulator Nut

(1)

Fuel Rail Retaining Bolt

14-19 (19-26)

Heat Shield Bolts

14-19 (19-26)

Intake Plenum Bolts/Nuts

11-16 (15-22)

Oil Supply Line-To-Turbocharger Bolt

12-17 (16-23)

Oxygen Sensor

(1)

Power Steering Pump Bracket-To-Engine Bolts/Nut

35-48 (47-65)

Throttle Body Bolt/Nuts

12-17 (16-23)

Turbocharger Support Bracket Bolts

32-45 (43-61)

Turbocharger-To-Exhaust Manifold Nuts

20-25 (27-34)

INCH Lbs. (N.m)

Barometric Pressure (BP) Sensor Nut

54-84 (6-9)

MAP Sensor Nuts

54-84 (6-9)

Oil Supply Line-To-Engine Block Bolt

104-156 (12-18)

Vane Airflow Meter Nuts

110-152 (12-18)

(1)

Information not available from manufacturer.

Copyright 2009 Mitchell Repair Information Company, LLC. All Rights Reserved.

Article GUID: A00022705