Index Ford Ford Orion - service and repair manual

Content .. 1 2 3 ..

Ford Orion. Manual - part 1

Engine

Direction of crankshaft rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clockwise (seen from right-hand side of vehicle)

Oil filter:

HCS and CVH engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion C104

Zetec engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion C148

Cooling system

Coolant protection at standard 40% antifreeze/water mixture ratio:

Slush point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-25ºC (-13ºF)

Solidifying point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

-30ºC (-22ºF)

Coolant specific gravity at standard 40% antifreeze/water
mixture ratio and 15ºC/59ºF - with no other additives in coolant . . . . .

1.061

Fuel system

Idle speed*:

1.3 litre HCS (carburettor) engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .

750 ± 50 rpm (cooling fan running)

1.4 litre CVH (carburettor) engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .

800 ± 50 rpm (cooling fan running)

1.6 litre CVH (carburettor) engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .

800 ± 50 rpm (cooling fan running)

1.6 litre CVH (fuel-injected) engine:

Idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

900 ± 50 rpm

Base idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

750 ± 50 rpm

Chapter 1
Routine maintenance and servicing

Air conditioning system check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Air cleaner element renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Automatic transmission fluid level check  . . . . . . . . . . . . . . . . . . . . .

Automatic transmission fluid renewal  . . . . . . . . . . . . . . . . . . . . . . . . 32
Auxiliary drivebelt check and renewal  . . . . . . . . . . . . . . . . . . . . . . . . 11
Battery check, maintenance and charging  . . . . . . . . . . . . . . . . . . . .

Brake check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Brake fluid renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Coolant renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Door and bonnet check and lubrication  . . . . . . . . . . . . . . . . . . . . . . 24
Driveshaft rubber gaiter and CV joint check  . . . . . . . . . . . . . . . . . . . 20
Electrical system check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine compartment wiring check  . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine oil and filter change  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Exhaust system check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Fluid level checks  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ford Escort and Orion maintenance schedule . . . . . . . . . . . . . . . . .

Fuel filter renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Handbrake adjustment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Idle speed and mixture check and adjustment   . . . . . . . . . . . . . . . . 17

Ignition timing check . . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 5

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual transmission oil level check . . . . . . . . . . . . . . . . . . . . . . . . . 18
Oil filler cap check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Positive Crankcase Ventilation (PCV) system check and

filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Power steering fluid level check . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Road test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Roadwheel nut tightness check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Routine maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Seat belt check  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Spark plug renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Steering, suspension and roadwheel check  . . . . . . . . . . . . . . . . . . . 19
Timing belt renewal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Tyre and tyre pressure checks  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Underbody and fuel/brake line check  . . . . . . . . . . . . . . . . . . . . . . . . 22
Underbonnet check for fluid leaks and hose condition  . . . . . . . . . . 12
Valve clearance adjustment  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Windscreen/tailgate washer system and wiper blade check  . . . . . .

1•1

Easy, suitable for
novice with little
experience

Fairly easy, suitable
for beginner with
some experience

Fairly difficult,
suitable for competent
DIY mechanic

Difficult, suitable for
experienced DIY
mechanic

Very difficult,
suitable for expert
DIY or professional

Degrees of difficulty

Specifications

Contents

Fuel system (continued)

Idle mixture CO content*:

1.3 litre HCS (carburettor) engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.0 ± 0.5%

1.4 litre CVH (carburettor) engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.0 ± 0.5%

1.6 litre CVH (carburettor) engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 ± 0.5%

1.6 litre CVH (fuel-injected) engine . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.8 ± 0.25%

*Note: The idle speed and mixture CO content is only adjustable on the engines shown above. On all other engines, it is controlled by the engine
management system, and cannot be checked or adjusted without specialised test equipment.
Air filter element:

1.3 litre HCS engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion W225

1.4 litre CVH engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion W226

1.6 litre CVH (carburettor) engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion W226

1.6 litre CVH (fuel-injected) engine . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion U612

1.6 and 1.8 litre Zetec engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion U612

Fuel filter:

1.3 litre HCS (CFi fuel-injected) engine . . . . . . . . . . . . . . . . . . . . . . . .

Champion type not available

1.4 litre CVH (CFi fuel-injected) engine . . . . . . . . . . . . . . . . . . . . . . . .

Champion type not available

1.6 litre CVH (fuel-injected) engine . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion L204

1.6 and 1.8 litre Zetec engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion L218

Ignition system

Firing order:

HCS engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2-4-3 (No 1 cylinder at timing chain end of engine)

All other engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3-4-2 (No 1 cylinder at timing belt end of engine)

Spark plugs*:

1.3 litre HCS (carburettor) engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion RS9YCC or RS9YC

1.4 litre CVH engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion RC7YCC or RC7YC

1.6 litre CVH (carburettor) engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion RC7YCC or RC7YC

1.6 litre CVH (EFi fuel-injected) engine . . . . . . . . . . . . . . . . . . . . . . . .

Champion RC6YCC or RC6YC

1.6 and 1.8 litre Zetec engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion RE7YCC

Electrode gap*:

1.3 litre HCS engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.0 mm

1.4 litre CVH (carburettor) engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.8 mm

1.4 litre CVH (CFi fuel-injected) engine . . . . . . . . . . . . . . . . . . . . . . . .

1.0 mm

1.6 litre CVH engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.8 mm

1.6 and 1.8 litre Zetec engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.0 mm

Spark plug (HT) leads:

HCS engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion LS-28

1.4 litre CVH engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion LS-27

1.6 litre CVH (carburettor) engine . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion LS-27

1.6 litre CVH (fuel-injected) engine . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion LS-26

1.6 and 1.8 litre Zetec engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion type not available

Maximum resistance per lead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30 000 ohms

* Information on spark plug types and electrode gaps is as recommended by Champion Spark Plug. Where alternative types are used, refer to their
manufacturer’s recommendations.

Braking system

Minimum front or rear brake pad lining thickness . . . . . . . . . . . . . . . . .

1.5 mm

Minimum rear brake shoe lining thickness . . . . . . . . . . . . . . . . . . . . . . .

1.0 mm

Tyre pressures (cold)

Front

Rear

Saloon, Hatchback and Estate models:

Normally-laden* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.0 bars (29 psi)

1.8 bars (26 psi)

Fully-laden* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 bars (34 psi)

2.8 bars (40 psi)

Van models:

Normally-laden* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.0 bars (29 psi)

1.8 bars (26 psi)

Fully-laden*
With 165 R 13 tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 bars (34 psi)

3.0 bars (44 psi)

With 165 R 13 reinforced tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 bars (34 psi)

3.5 bars (51 psi)

Note: Normally-laden means up to 3 persons. For sustained high speeds above 100 mph (160 km/h), increased pressures are necessary. Consult
the driver’s handbook supplied with the vehicle.

Wiper blades

Windscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion X-5103

Tailgate/rear window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Champion X-5103

1•2

Servicing Specifications

Torque wrench settings

lbf ft

Auxiliary drivebelt cover fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 to 10

4 to 7

Auxiliary drivebelt adjustment:

Adjusting bolt (sliding arm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 to 25

13 to 18

Central (locking) bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18 to 25

13 to 18

Pinion (adjuster) nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 to 15

7 to 11

Alternator mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 to 27

15 to 19

Engine oil drain plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21 to 28

15 to 21

Manual transmission filler/level plug . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23 to 30

17 to 22

Spark plugs:

HCS engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 to 20

12 to 15

CVH engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 to 33

13 to 24

Zetec engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 to 20

12 to 15

Roadwheel nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

70 to 100

52 to 74

Seat belt mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29 to 45

22 to 331

Windscreen wiper arm nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 to 18

12.5 to 13

Lubricants and fluids

Servicing Specifications

1•3

Component or system

Lubricant type/specification

1 Engine

Multigrade engine oil to specification
API SG/CD or better, viscosity range
5W/50 to 10W/30

2 BC type manual

SAE 80 high pressure gear oil to Ford

transmission

specification SQM2C-9008-A

2 MTX-75 type manual

Gear oil to Ford specification

transmission

ESD-M2C-186-A

3 Automatic transmission

Transmission fluid to Ford
specification ESP-M2C-166-H

4 Power steering

Transmission fluid to Ford
specification ESP-M2C-166-H

5 Cooling system

Soft water, and antifreeze (ethylene
glycol-based, suitable for use in
mixed-metal cooling systems) to Ford
specification ESD-M97B-49-A

6 Braking system

Hydraulic fluid to Ford specification
ESD-M6C-57-A, Super DOT 4 or
equivalent

Wheel hub bearing grease

Grease to Ford specification

(front and rear)

SAM-1C-9111A

Capacities

Engine oil

At oil and filter change:

HCS engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.25 litres

CVH engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.50 litres

Zetec engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.25 litres

Difference between dipstick minimum and maximum
level notches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5 to 1.0 litre

Cooling system

1.3 litre HCS engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 litres

1.4 litre CVH engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.6 litres

1.6 litre CVH engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8 litres

1.6 and 1.8 Zetec engine . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4 litres

Fuel tank

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55.0 litres

Manual transmission

BC type (four-speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8 litres

BC type (five-speed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 litres

MTX-75 type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4 litres

Automatic transmission

Without fluid cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 litres

With fluid cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 litres

Washer system reservoir

Excluding headlight washer system . . . . . . . . . . . . . . . . .

4.0 litres

Including headlight washer system . . . . . . . . . . . . . . . . . .

8.0 litres

The manufacturer’s recommended maintenance schedule for these

vehicles is as described below - note that the schedule starts from the
vehicle’s date of registration. These are the minimum maintenance
intervals recommended by the factory for Escorts and Orions driven
daily, but subjected only to “normal” use. If you wish to keep your
vehicle in peak condition at all times, you may wish to perform some of
these procedures even more often. Because frequent maintenance
enhances the efficiency, performance and resale value of your vehicle,
we encourage you to do so. If your usage is not “normal”, shorter
intervals are also recommended - the most important examples of
these are noted in the schedule. These shorter intervals apply
particularly if you drive in dusty areas, tow a caravan or trailer, sit with
the engine idling or drive at low speeds for extended periods (ie, in
heavy traffic), or drive for short distances (less than four miles) in
below-freezing temperatures.

When your vehicle is new, it should be serviced by a Ford dealer

service department to protect the factory warranty. In many cases, the
initial maintenance check is done at no cost to the owner. Note that
this first free service (carried out by the selling dealer 1500 miles or
3 months after delivery), although an important check for a new
vehicle, is not part of the regular maintenance schedule, and is
therefore not mentioned here.

It should be noted that for the 1992 model year, the service

time/mileage intervals were extended by the manufacturer to the
periods shown in this schedule. Although these intervals can be
applied retrospectively, owners of earlier vehicles may notice a
discrepancy between this schedule and the one shown in the Service
Guide supplied with the vehicle.

1•4

Maintenance Schedule

Ford Escort and Orion maintenance schedule

General

Weekly, when refuelling, or before
any long journey

Check the engine oil level, and top-up if necessary
(Section 3)

Check the brake fluid level, and top-up if necessary
(Section 3). If repeated topping-up is required, check the
system for leaks or damage at the earliest possible
opportunity (Sections 12 and 22)

Check the windscreen/tailgate washer fluid level, and
top-up if necessary (Section 3)

Check the tyre pressures, including the spare (Section 4)

Check the tyres for excessive tread wear, or damage
(Section 4)

Check the operation of all (exterior and interior) lights
and the horn, wipers and windscreen/tailgate washer
system (Sections 6 and 8). Renew any blown bulbs
(Chapter 12), and clean the lenses of all exterior lights

Check the coolant level, and top-up if necessary (Sec-
tion 3)

Check the battery electrolyte level, where applicable
(Section 3)

Check the power steering fluid level, and top-up if
necessary (Section 5)

Check all reservoirs, hoses and pipes for leakage
(Section 12)

Check the operation of the air conditioning system
(Section 14)

Check the operation of the handbrake (Section 26 and
Section 33 for adjustment)

Check the aim of the windscreen/tailgate/headlight
washer jets, correcting them if required (Section 6)

Check the condition of the wiper blades, renewing them
if worn or no longer effective - note that the
manufacturer recommends renewing the blades as a
safety precaution, irrespective of their apparent
condition, at least once a year (Section 6)

Check the automatic transmission fluid level with the
engine still hot (Section 7)

Every 20 000 miles

Carry out all operations listed above, plus the following:

Renew the spark plugs - HCS and CVH engines only
(Section 27)

Standard service - every
10 000 miles or 12 months,
whichever occurs first

Check the electrical system (Section 8)

Check the battery (Section 9)

Check the seat belts (Section 10)

Check the auxiliary drivebelt (Section 11)

Check under the bonnet for fluid leaks and hose
condition (Section 12)

Check the condition of all engine compartment wiring
(Section 13)

Check the condition of all air conditioning system
components (Section 14)

Check the valve clearance adjustment - HCS engines
only (Section 15)

Change the engine oil and filter (Section 16)

Check the engine idle speed and mixture - HCS and
CVH engines only, where possible (Section 17)

Check the manual transmission oil level (Section 18)

Check the steering, suspension and roadwheels (Sec-
tion 19)

Check the driveshaft rubber gaiters and CV joints
(Section 20)

Check the exhaust system (Section 21)

Check the underbody, and all fuel/brake lines (Sec-
tion 22)

Check the brake system (Section 23)

Check the doors and bonnet, and lubricate their hinges
and locks (Section 24)

Check the security of all roadwheel nuts (Section 25)

Road test (Section 26).

Note: If the vehicle is used regularly for very short (less than 10
miles), stop/go journeys, the oil and filter should be renewed
between services (ie, every 5000 miles/6 months). Seek the advice of
a Ford dealer if in doubt on this point.

Content .. 1 2 3 ..