Ford Orion. Manual - part 36

starter to ensure that all pressure is released,
then switch off the ignition; do not forget to
refit the fuse (or depress the red button, as
appropriate) when work is complete.

Warning: This procedure will
merely relieve the increased
pressure necessary for the
engine to run. Remember that

fuel will still be present in the system
components, and take precautions
accordingly before disconnecting any of
them.
4 Note that, once the fuel system has been
depressurised and drained (even partially), it
will take significantly longer to restart the
engine - perhaps several seconds of cranking
- before the system is refilled and pressure
restored.

Fuel lines and fittings -
general information

Warning: The fuel system
pressure must be released before
any part of the system is
disturbed - see Section 2. Petrol

is extremely flammable, so take extra
precautions when you work on any part of
the fuel system. Don’t smoke, or allow
open flames or bare light bulbs, in or near
the work area. Don’t work in a garage
where a natural-gas appliance (such as a
water heater or clothes dryer) with a pilot
light is present. If you spill any fuel on your
skin, rinse it off immediately with soap and
water. When you perform any kind of work
on the fuel system, wear safety glasses,
and have a Class B type fire extinguisher
on hand.

Disconnecting and connecting
quick-release couplings

1 Quick-release couplings are employed at
many of the unions in the fuel feed and return
lines.
2 Before disconnecting any fuel system
component, relieve the residual pressure in
the system (see Section 2), and equalise tank
pressure by removing the fuel filler cap.

Warning: This procedure will
merely relieve the increased
pressure necessary for the
engine to run - remember that

fuel will still be present in the system
components, and take precautions
accordingly before disconnecting any of
them.
3 Release the protruding locking lugs on each
union, by squeezing them together and
carefully pulling the coupling apart. Use rag to
soak up any spilt fuel. Where the unions are
colour-coded, the pipes cannot be confused.
Where both unions are the same colour, note
carefully which pipe is connected to which,
and ensure that they are correctly
reconnected on refitting.

4 To reconnect one of these couplings, press
them together until the locking lugs snap into
their groove. Switch the ignition on and off
five times to pressurise the system, and check
for any sign of fuel leakage around the
disturbed coupling before attempting to start
the engine.

Checking

5 Checking procedures for the fuel lines are
included in Chapter 1.

Component renewal

6 If you must renew any damaged sections,
use original-equipment replacement hoses or
pipes, constructed from exactly the same
material as the section you are replacing. Do
not install substitutes constructed from
inferior or inappropriate material, or you could
cause a fuel leak or a fire.
7 Before detaching or disconnecting any part
of the fuel system, note the routing of all
hoses and pipes, and the orientation of all
clamps and clips. Replacement sections must
be installed in exactly the same manner.
8 Before disconnecting any part of the fuel
system, be sure to relieve the fuel system
pressure (see Section 2), and equalise tank
pressure by removing the fuel filler cap. Also
disconnect the battery negative (earth) lead -
see Chapter 5, Section 1. Cover the fitting
being disconnected with a rag, to absorb any
fuel that may spray out.

Air cleaner assembly and air
inlet components - removal
and refitting

Note: Air cleaner element renewal and air
cleaner temperature control system checks
(where applicable) are described in Chapter 1.

Air cleaner assembly

CFi system

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Undo the retaining bolts and partially lift the
air cleaner from the CFi unit, so that the hose
and wiring connections to the underside of
the air cleaner body are accessible.
3 Note their connections and routings, then

detach the wiring and hoses from the
underside of the air cleaner.
4 Lift the air cleaner clear from the CFi unit.
5 Refit in the reverse order of removal.
6 Renew any hoses that are perished or
cracked, and ensure that all fittings are
securely and correctly reconnected.

EFi system

7 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
8 Undo the retaining nut at the front, then
loosen off the air duct-to-filter housing clip
screw, and detach the air duct from the
housing (see illustration).
9 Unscrew and remove the two retaining nuts
on the underside of the housing (that secure it
to the location studs).
10 Disconnect the hose at the base of the
unit (to the inlet manifold) and lift the air
cleaner clear.
11 Refit in the reverse order of removal.
Ensure that the air hose and duct are securely
located.

SEFi system

12 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
13 Detach the crankcase breather hose from
the air cleaner housing (see illustration).
14 Disconnect the air mass meter wiring
multi-plug, then release the two clips and
withdraw the air mass meter, complete with
inlet hose, from the air cleaner cover (see
illustration). Carefully position the air mass
meter and hose assembly to one side.

Fuel and exhaust systems – fuel-injected engines 4B•3

4.13 Detach the crankcase breather hose

from the air cleaner housing

4.8 General view of the air filter (A) and air

duct (B) fitted to the 1.6 litre EFi engine

4.14 Disconnect the air mass meter wiring

multi-plug, then release the two clips and

withdraw the air mass meter, complete

with inlet hose

15 Detach the air inlet duct from the air
cleaner housing.
16 Unscrew the air cleaner housing front
retaining nut, then pull the housing sharply
upwards to release the two lower locating
pegs from their rubber grommets. Remove
the assembly from the car.
17 Refitting is the reverse of the removal
procedure. Ensure that the housing pegs seat
fully in their grommets, and that the air inlet
duct is correctly located.

Air inlet components

CFi system

18 The air cleaner inlet spout and related
components are removed with the air cleaner
assembly as described above.

EFi system

19 Disconnect the HT leads from the spark
plugs, labelling them if necessary to avoid
confusion on refitting.
20 Slacken the retaining clips, and detach
the air inlet hose and breather hose from the
air inlet duct.
21 Undo the two retaining bolts, and remove
the air inlet duct from the rocker cover (see
illustration).
22 Slacken the retaining clip, and remove the
air inlet hose from the air cleaner assembly.
23 Refitting is the reverse of the removal
procedure.

SEFi system

24 Slacken the hose clips at each end, and
detach the air inlet hose from the inlet duct
and air mass meter. Note the small projection
on the end of the hose, which engages with a
cut-out in the inlet duct to ensure correct
orientation when refitting (see illustration).
25 Undo the two nuts, and lift off the air inlet
duct retaining strap (see illustration).
26 Withdraw the inlet duct from the throttle
housing.
27 Refer to Chapter 6, Section 4 for further
information on the air mass meter.
28 Refitting is the reverse of the removal
procedure, but ensure correct orientation of
the inlet hose by aligning the projections and
cut-outs.

Accelerator cable - removal,
refitting and adjustment

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Fold back the carpet and insulation in the
driver’s footwell to gain access to the
accelerator pedal.
3 Detach the accelerator cable from the
pedal.
4 On CFi systems, remove the air cleaner
assembly as described in Section 4.
5 Working at the throttle housing end of the
cable, pivot the throttle quadrant by hand to
release the tension from the cable, then
detach the inner cable nipple from the throttle
lever (see illustration).
6 Detach the outer cable from the
adjuster/support bracket, then remove the
cable (see illustration).

Refitting and adjustment

7 Refit in the reverse order of removal. When
the cable is reconnected at each end, have an
assistant depress the accelerator, and check
that the throttle fully opens and shuts without
binding. Ensure that there is a small amount of
slack in the inner cable when the throttle is
fully released. If adjustment is required,

release the outer cable retaining clip from the
cable at the adjustment/support bracket, slide
the cable through the adjuster grommet to the
point required, then refit the retaining clip to
secure it in the set position.

Accelerator pedal -
removal and refitting

Refer to Section 5 in Part A of this Chapter.

Fuel pump/fuel pressure -
checking

Warning: Petrol is extremely
flammable, so take extra
precautions when you work on
any part of the fuel system. Don’t

4B•4 Fuel and exhaust systems – fuel-injected engines

5.6 Accelerator outer cable location at the

adjuster/support bracket

5.5 Disconnecting the accelerator inner

cable from the throttle quadrant

4.25 Undo the two nuts (arrowed) and lift

off the air inlet duct retaining strap

4.24 Detach the air inlet hose from the

inlet duct. Note the small projection on the

end of the hose which engages with a cut-

out in the inlet duct

4.21 Undo the two retaining bolts

(arrowed) and remove the air inlet duct

from the rocker cover

Fuel pump operation check

1 Switch on the ignition, and listen for the fuel
pump (the sound of an electric motor running,
audible from beneath the rear seats).
Assuming there is sufficient fuel in the tank,
the pump should start and run for
approximately one or two seconds, then stop,
each time the ignition is switched on. Note: If
the pump runs continuously all the time the
ignition is switched on, the electronic control
system is running in the backup (or “limp-
home”) mode referred to by Ford as “Limited
Operation Strategy” (LOS). This almost
certainly indicates a fault in the ECU itself, and
the vehicle should therefore be taken to a Ford
dealer for a full test of the complete system,
using the correct diagnostic equipment; do
not waste time or risk damaging the
components by trying to test the system
without such facilities.
2 Listen for fuel return noises from the fuel
pressure regulator. It should be possible to
feel the fuel pulsing in the regulator and in the
feed hose from the fuel filter.
3 If the pump does not run at all, check the
fuse, relay and wiring (see Chapter 6). Check
also that the fuel cut-off switch has not been
activated and if so, reset it.

Fuel pressure check

4 A fuel pressure gauge will be required for
this check. On CFi and EFi systems, the
gauge should be connected in the fuel line
between the fuel filter and the CFI unit or fuel
rail, in accordance with the gauge maker’s
manuals. On SEFi systems, a pressure
gauge equipped with an adapter to suit the
Schrader-type valve on the fuel rail pressure
test/release fitting (identifiable by its blue
plastic cap, and located on the union of the
fuel feed line and the fuel rail) will be required.
If the Ford special tool 29-033 is available, the
tool can be attached to the valve, and a
conventional-type pressure gauge attached to
the tool.
5 If using the service tool, ensure that its tap
is turned fully anti-clockwise, then attach it to
the valve. Connect the pressure gauge to the
service tool. If using a fuel pressure gauge
with its own adapter, connect it in accordance
with its maker’s instructions (see illustration).

6 With the gauge connected proceed as
follows according to engine type.

CFi system

7 Start the engine and allow it to idle. Note
the gauge reading as soon as the pressure
stabilises, and compare it with the figures
given for regulated fuel pressure in this
Chapter’s Specifications. If the pressure is
high, check for a restricted fuel return line. If
the pressure is low, renew the fuel pressure
regulator.
8 Switch off the engine, and check that after
one minute, the hold pressure has not fallen
below that specified. If it has, check the seals
on the fuel injector (see Section 15) and renew
them if they appear in any way suspect. If the
seals are okay, then the fuel pressure
regulator or CFi unit are suspect.
9 Carefully disconnect the fuel pressure
gauge, depressurising the system first as
described in Section 2.
10 Run the engine, and check that there are
no fuel leaks.

EFi system

11 Disconnect the wiring from the E-DIS
ignition coil and the fuel injectors.
12 Switch the ignition on and off twice, and
check that the pump pressure is as listed in
this Chapter’s Specifications.
13 If the pressure is not as specified, check
the fuel system for leaks or damage. If the
system appears okay, renew the fuel pump.
14 Reconnect the wiring to the ignition coil
and fuel injectors.
15 If the pump pressure was satisfactory,
start the engine and allow it to idle.
Disconnect the vacuum hose at the fuel
pressure regulator, and plug the hose. Note
the gauge reading as soon as the pressure
stabilises, and compare it with the figures
given for regulated fuel pressure in this
Chapter’s Specifications.
16 If the regulated fuel pressure is not as
specified, remove the plug from the top of the
fuel pressure regulator, and using a suitable
Allen key, adjust the pressure regulator as
necessary.
17 Switch off the engine, and check that the
fuel pressure stays at the specified hold
pressure for two minutes after the engine is
turned off.
18 Carefully disconnect the fuel pressure
gauge, depressurising the system first as
described in Section 2. Reconnect the ignition
coil and fuel injector wiring.
19 Run the engine, and check that there are
no fuel leaks.

SEFi system

20 Start the engine and allow it to idle. Note
the gauge reading as soon as the pressure
stabilises, and compare it with the regulated
fuel pressure figures listed in this Chapter’s
Specifications.
a)

If the pressure is high, check for a
restricted fuel return line. If the line is
clear, renew the fuel pressure regulator.

If the pressure is low, pinch the fuel return
line. If the pressure now goes up, renew
the fuel pressure regulator. If the pressure
does not increase, check the fuel feed
line, the fuel pump and the fuel filter.

21 Detach the vacuum hose from the fuel
pressure regulator; the pressure shown on the
gauge should increase. Note the increase in
pressure, and compare it with that listed in
this Chapter’s Specifications. If the pressure
increase is not as specified, check the
vacuum hose and pressure regulator.
22 Reconnect the regulator vacuum hose,
and switch off the engine. Verify that the hold
pressure stays at the specified level for five
minutes after the engine is turned off.
23 Carefully disconnect the fuel pressure
gauge, depressurising the system first as
described in Section 2. Be sure to cover the
fitting with a rag before slackening it. Mop up
any spilt petrol.
24 Run the engine, and check that there are
no fuel leaks.

Fuel tank -
removal and refitting

Warning: Petrol is extremely
flammable, so take extra
precautions when you work on
any part of the fuel system. Don’t

Removal

1 Run the fuel level as low as possible prior to
removing the tank.
2 Relieve the residual pressure in the fuel
system (see Section 2), and equalise tank
pressure by removing the fuel filler cap.

Warning: This procedure will
merely relieve the increased
pressure necessary for the
engine to run - remember that

fuel will still be present in the system
components, and take precautions
accordingly before disconnecting any of
them.

3 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
4 Remove the fuel filler cap, then syphon or
pump out the remaining fuel from the fuel tank
(there is no drain plug). The fuel must be
emptied into a suitable container for storage.
5 Chock the front wheels, then raise and
support the vehicle on axle stands at the rear.
6 Disconnect the fuel filler pipe from the fuel
tank. Drain any remaining fuel into the

Fuel and exhaust systems – fuel-injected engines 4B•5

7.5 Fuel pressure gauge connected to the

fuel line

container for safe storage, and plug the hose
and tank connections. Disconnect the
handbrake cable locating strap from the fuel
filler pipe on the tank.
7 Disconnect the filler neck pipe sensing hose
from the rear of the tank.
8 Support the underside of the fuel tank to
hold it in position, then remove the four tank
retaining bolts.
9 Partially lower the fuel tank, and detach the
ventilation tube from the tank top surface.
Also disconnect the fuel pump/fuel gauge
sender unit wiring multi-plug and the fuel
hoses. Where quick-release couplings are
used on the fuel hoses, release the protruding
locking lugs on each union, by squeezing
them together and carefully pulling the
coupling apart.
10 Slowly lower the tank; as it is withdrawn,
detach the filler pipe.

Inspection

11 When removed, the fuel tank can be
inspected for damage or deterioration.
Removal of the pump/sender unit (see Sec-
tion 9) will allow a partial inspection of the
interior. If the tank is contaminated with
sediment or water, swill it out with clean
petrol. Do not under any circumstances
undertake any repairs on a leaking or
damaged fuel tank; this work must be carried
out by a professional who has experience in
this critical and potentially-dangerous work.
12 Whilst the fuel tank is removed from the
vehicle, it should not be placed in an area
where sparks or open flames could ignite the

fumes coming out of the tank. Be especially
careful inside garages where a natural-gas
appliance is located, because the pilot light
could cause an explosion.
13 Check the condition of the filler pipe seal
in the fuel tank, and renew it if necessary.

Refitting

14 Refitting is a reversal of the removal
procedure. Apply a light smear of grease to
the filler pipe seal, to ease fitting. Ensure that
all connections are securely fitted. Where
quick-release fuel couplings are fitted, press
them together until the locking lugs snap into
their groove. If evidence of contamination was
found, do not return any previously-drained
fuel to the tank unless it is carefully filtered
first.

Fuel pump/fuel gauge
sender unit - removal and
refitting

Warning: Petrol is extremely
flammable, so take extra
precautions when you work on
any part of the fuel system. Don’t

smoke, or allow open flames or bare light
bulbs, in or near the work area. Don’t work
in a garage where a natural-gas appliance
(such as a water heater or clothes dryer)
with a pilot light is present. If you spill any
fuel on your skin, rinse it off immediately
with soap and water. When you perform
any kind of work on the fuel system, wear
safety glasses, and have a Class B type
fire extinguisher on hand.
Note: Ford specify the use of their service tool
23-014 or 23-026 (a large box spanner with
projecting teeth to engage the fuel
pump/sender unit retaining ring’s slots) for this
task. While alternatives are possible, in view of
the difficulty experienced in removing and
refitting the pump/sender unit, owners are
strongly advised to obtain the correct tool
before starting work.

Removal

1 A combined fuel pump and fuel gauge
sender unit are located in the top face of the

fuel tank. The combined unit can only be
detached and withdrawn from the tank after
the tank is released and lowered from under
the vehicle. Refer to Section 8 and remove the
fuel tank, then proceed as follows.
2 With the fuel tank removed, the
pump/sender unit can be unscrewed using
the special tool (see illustration).
3 Withdraw the unit upwards from the tank
(see illustration), and detach the seal ring.
The seal ring must be renewed whenever
the pump/sender unit is withdrawn from the
tank.

Refitting

4 Refit in the reverse order of removal. Lightly
coat the new unit seal ring with grease to ease
fitting, and ensure that the seal is not distorted
as the unit is fitted into position. Insert the unit
so that the lug of the unit is in engagement with
the slot in the tank aperture, then turn the unit
to lock and secure (see illustration).

10 Roll-over valve -

removal and refitting

Refer to Section 10 in Part A of this

Chapter.

11 Fuel cut-off switch -

removal and refitting

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Remove the front footwell side cowl trim
panel on the driver’s side as described in
Chapter 11.
3 Undo the retaining screws and withdraw
the cut-off (inertia) switch unit from the body
(see illustration). As it is with-
drawn, disconnect the wiring connector to the
switch.

4B•6 Fuel and exhaust systems – fuel-injected engines

9.4 Fuel pump/sender unit refitting to the

tank, showing position of the locating

lug (A)

9.3 In-tank fuel pump (B) and sender

unit (A)

9.2 Fuel pump/sender unit removal from

the fuel tank using Ford special tool 23-026

11.3 Fuel cut-off switch location in the

driver’s footwell

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