Ford Orion. Manual — part 23

23 Locate a jack under the transmission, and
raise it to take the weight of the transmission.
24 Unscrew and remove the remaining
engine-to-transmission retaining bolts on the
upper flange.
25 Check around the engine to ensure that all of
the relevant fixings and attachments are
disconnected and out of the way for the removal.
26 Enlist the aid of an assistant, then move
the engine forwards and away from the
transmission, whilst simultaneously raising the
transmission. When the engine is separated
from the transmission, carefully guide it up
and out of the engine compartment. Do not
allow the weight of the engine to hang on the
transmission input shaft at any point during
the removal (or refitting) of the engine. When
the engine sump is clear of the vehicle, swing
the power unit out of the way, and lower it
onto a trolley (if available). Unless a mobile
hoist is being used, it will be necessary to
move the vehicle rearwards and out of the
way in order to allow the engine to be lowered
for removal. In this instance, ensure that the
weight of the transmission is well supported
as the vehicle is moved.
27 While the engine is removed, check the
mountings; renew them if they are worn or
damaged. Similarly, check the condition of all
coolant and vacuum hoses and pipes (see
Chapter 1); components that are normally
hidden can now be checked properly, and
should be renewed if there is any doubt at all
about their condition. Also, take the
opportunity to overhaul the clutch components
(see Chapter 8). It is regarded by many as good
working practice to renew the clutch assembly
as a matter of course, whenever major engine
overhaul work is carried out. Check also the
condition of all components (such as the
transmission oil seals) disturbed on removal,
and renew any that are damaged or worn.

Refitting

28 Refitting is in general, a reversal of the
removal procedure, but the following special
points should be noted.
29 Before coupling the engine to the
transmission, apply a thin smear of high-
melting-point grease onto the transmission input
shaft splines. If the clutch has been removed,
ensure that the clutch disc is centralised, and

disconnect the clutch cable from the release
lever on the transmission casing.
30 Tighten all fixings to their recommended
torque wrench settings.
31 Check that the mating faces are clean,
and fit a new exhaust downpipe-to-manifold
gasket and self-locking nuts when
reconnecting this joint.
32 Ensure that all wiring connections are
correctly and securely made.
33 Remove the plugs from the fuel lines before
reconnecting them correctly and securely.
34 Reconnect and adjust the accelerator and
choke cables as described in Chapter 4. The
refitting details for the air cleaner unit are also
given in that Chapter.
35 Renew any coolant hoses (and/or
retaining clips) that are not in good condition.
36 Refer to Chapter 8 for details on
reconnecting the clutch cable.
37 When the engine is fully refitted, check
that the various hoses are connected, and
then top-up the engine oil and coolant levels
as described in Chapter 1.
38 When engine refitting is completed, refer to
Section 22 for the engine start-up procedures.

5

Engine/transmission -
removal and refitting
(CVH engine)

3

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

smoke, or allow naked flames or bare light
bulbs, in or near the work area, and don’t
work in a garage where a natural-gas
appliance (such as a clothes dryer or water
heater) is installed. If you spill petrol on
your skin, rinse it off immediately. Have a
fire extinguisher rated for petrol fires
handy, and know how to use it.
Note: Read through the entire Section, as well
as reading the advice in the preceding Section,
before beginning this procedure. The engine
and transmission are removed as a unit,
lowered to the ground and removed from
underneath, then separated outside the vehicle.

Removal

1 On all fuel-injected engines, refer to

Chapter 4B and depressurise the fuel system.
2 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Referring to Chapter 1 for details, drain the
coolant and the engine oil. Refit the drain plug
to the sump on completion.
4 Refer to Chapter 11 for details, and remove
the bonnet. Store it in a safe area where it will
not get damaged.
5 Remove the air cleaner unit as described in
Chapter 4. On 1.6 litre EFi fuel-injected
models, remove the air inlet components and
the complete air cleaner unit.
6 Release the retaining clips and detach the
coolant top hose, the heater hose and the
radiator overflow hose from the thermostat
housing. Disconnect the coolant hose from the
inlet manifold, and the bottom hose from the
water pump and/or the radiator (see
illustrations). On 1.4 litre CFi fuel-injected
models, also disconnect the coolant hose from
the injection unit. On 1.6 EFi models, detach
the heater hose Y-connector. Allow for coolant
spillage as the hoses are detached, note their
routing, and position them out of the way.
7 Refer to Chapter 4 for details, and
disconnect the accelerator cable from the
throttle linkage and support/adjuster bracket.
Where applicable, also disconnect the choke
cable. Position the cable(s) out of the way.
8 On carburettor models, disconnect the fuel
supply hose from the fuel pump, and the
return hose from the carburettor.
9 On CFi models, detach the fuel hose at the
injector/pressure regulator unit, and the return
line, by compressing the couplings whilst
pulling the hoses free from their connections.
On EFi models, unscrew the union nut to
detach the fuel line from the fuel rail; release
the retaining clip to detach the return pipe
from the pressure regulator. Plug the exposed
ends of the hoses and connections, to
prevent fuel spillage and the ingress of dirt.
Position the hoses out of the way.
10 Press the clamp ring inwards, and simul-
taneously pull free the brake servo hose from
the inlet manifold. Position it out of the way.
11 On CFi and EFi models, detach the
vacuum hose from the MAP sensor, and the
hose between the carbon canister and the fuel
injection unit (see illustration).

Engine removal and general engine overhaul procedures 2D•9

5.11 Vacuum hose to MAP sensor (A) and

brake servo (B)

5.6B Heater coolant hoses and Y-

connector on 1.6 litre EFi fuel-injected

models

5.6A Coolant hose connections to the

thermostat (arrowed)

2D

12 Note their connections and routings, and
detach the following wiring connections,
according to model:
a)

Coolant temperature sender unit (see
illustration).

b)

Oil pressure switch (see illustration).

c)

DIS ignition coil unit.

d)

Coolant temperature sensor.

e)

Cooling fan thermostatic switch.

f)

Carburettor.

g)

Earth lead (radio).

h)

Reversing light switch (from transmission).

i)

Crankshaft speed/position sensor (see
illustration).

j)

Earth leads from the transmission and
engine.

Additional items specific to CFi and EFi

models only (see illustrations).
a)

Inlet air temperature sensor.

b)

Vehicle speed sensor.

c)

Throttle plate control motor (CFi models).

d)

Throttle position sensor.

e)

Injector harness connector.

f)

Idle speed control valve (EFi models).

13 Unscrew the retaining bolt and detach the
bracket locating the wiring and coolant hoses
above the transmission.
14 Disconnect the speedometer drive cable
from the transmission.
15 On manual transmission models,
disconnect the clutch cable from the release
lever at the transmission (see Chapter 8 for
details). Position the cable out of the way.

16 Unscrew the two retaining bolts, and
detach the engine/transmission mounting
from the mounting bracket (see illustration).
17 Apply the handbrake, then raise and
support the vehicle at the front end on axle
stands. Allow sufficient clearance under the
vehicle to withdraw the engine and
transmission units from under the front end.
18 Where applicable on catalytic converter-
equipped vehicles, release the multi-plug from
the bracket and disconnect the wiring
connector from the oxygen sensor in the
exhaust downpipe (see illustration).
19 Undo the three retaining bolts, detach the
exhaust downpipe from the manifold, and
collect the gasket from the flange joint (see
illustration). Now disconnect the exhaust
downpipe from the rest of the system, and
remove it from the vehicle. Where applicable,
disconnect the pulse-air supply hose from the
check valve. Noting their connections (to
ensure correct reassembly), detach the
appropriate system vacuum hoses at the PVS
(three-port vacuum switch) under the inlet
manifold.
20 Where fitted, undo the four retaining nuts
and two bolts securing the front part of the
exhaust heat shield to the floor, then remove
the heat shield (see illustration).
21 Note their connections, and detach the
wiring from the starter motor and the
alternator. Unbolt and remove the starter
motor.

2D•10 Engine removal and general engine overhaul procedures

5.18 Wiring connections to the oxygen

sensor (A) and starter motor (B)

5.16 Engine/transmission mounting

bracket bolts (arrowed)

5.12E Wiring connections to the CFi unit

on the 1.4 litre engine

A Coolant temperature sensor
B Throttle plate control motor
C Throttle position sensor
D Injector

5.12D Engine and associated component

wiring plug connections

A Main wiring loom
B Road speed sensor unit
C DIS ignition coil
D Reversing light switch
E Cooling fan temperature sensor

F Temperature gauge sender

G Engine speed/crankshaft position sensor
H Throttle position sensor

I

Idle speed control valve

J

Coolant temperature sensor

K Intake air temperature sensor

L Oil pressure switch

5.12C . . . and the crankshaft

speed/position sensor

5.12B . . . the oil pressure switch . . .

5.12A Disconnect the wiring at the

temperature gauge sender unit . . .

Manual transmission models

22 Select fourth gear, to assist in correct
adjustment of the gearchange during
reassembly. If it is likely that the gear lever will
be moved from this position before refitting,
mark the relative position of the transmission
shift rod and the selector shaft before
separating them. Undo the clamp bolt, and
then pull free and detach the shift rod from the
selector shaft (see illustration).
23 Unscrew the retaining bolt, and detach
the shift rod stabiliser from the transmission.
As it is detached, note the washer located
between the stabiliser and the transmission.
Tie the stabiliser and the shift rod up out of
the way.

Automatic transmission models

24 Unclip and detach the wiring connector
from the starter inhibitor switch (on the
transmission housing).
25 Referring to Chapter 4 for details, unhook
the accelerator (cam plate) cable from the
carburettor or fuel injection unit (as applicable)
at the transmission end of the cable. Undo the
retaining bolt and detach the cable sheath
bracket from the transmission. Detach the
cam plate cable from the link.
26 Undo the two nuts from the selector cable
bracket which connects it to the lever on the
selector shaft. Disconnect the yoke from the
lever on the selector shaft and the cable from
the lever.

27 Unscrew the union nuts, and disconnect
the oil cooler feed and return pipes from the
transmission. Allow for a certain amount of
spillage, and plug the connections to prevent
the ingress of dirt.

All models

28 Note the direction of fitting, unscrew the
retaining nut and withdraw the Torx-type
clamp bolt securing the lower suspension arm
to the spindle carrier on each side.
29 Refer to Chapter 10 for details, and
detach the right-hand track rod end balljoint
from the spindle carrier.
30 Insert a suitable lever between the right-
hand driveshaft inner joint and the
transmission housing, and prise free the
driveshaft from the transmission; be prepared
for oil spillage from the transmission case
through the vacated driveshaft aperture. As it
is being prised free, simultaneously pull the
roadwheel outwards on that side, to enable
the driveshaft inboard end to separate from
the transmission. Once it is free, suspend and
support the driveshaft from the steering gear,
to prevent unnecessary strain being placed on
the driveshaft joints. The outer joint must not
be angled in excess of 45º, the inner joint no
more than 20º, or the joints may be damaged.
Refer to Chapter 8 for further details if
necessary.
31 Insert a suitable plastic plug (or if
available, an old driveshaft joint), into the

transmission driveshaft aperture, to
immobilise the gears of the differential unit.
32 Proceed as described above in
paragraphs 29 to 31, and disconnect the left-
hand driveshaft from the transmission.
33 Unscrew the retaining bolts, and remove
the brace between the transmission left front
mounting bracket and the transmission flange
(see illustration).
34 Connect a suitable lift hoist and sling to
the engine, connecting to the lifting eyes (see
illustration). When securely connected, take
the weight of the engine/transmission unit so
that the tension is relieved from the
mountings.
35 Unscrew the two retaining bolts, and
detach the transmission front mounting from
the side member.
36 Unscrew the three retaining bolts, and
remove the auxiliary drivebelt cover from
under the crankshaft pulley.
37 Unscrew the two retaining nuts, and
detach the right-hand engine mounting from
the suspension strut mounting. On EFi
engines, remove the MAP sensor (see
illustration).
38 The engine/transmission unit should now
be ready for removal from the vehicle. Check
that all of the associated connections and
fittings are disconnected from the engine and
transmission, and positioned out of the way.
39 Enlist the aid of an assistant to help
steady and guide the power unit down

Engine removal and general engine overhaul procedures 2D•11

5.22 Manual transmission shift rod clamp
bolt (A), stabiliser-to-transmission bolt (B)

and washer (C)

5.20 Exhaust system heat shield, showing

securing nut and bolt locations

5.37 Right-hand engine mounting bracket

and MAP sensor on EFi models

5.34 Connect a suitable lift hoist and sling

to the engine, connecting to the lifting

eyes

5.33 Remove the brace between the

transmission left front mounting bracket

and the transmission flange

2D

5.19 Exhaust downpipe-to-manifold flange

and securing bolts

through the engine compartment as it is
removed. If available, position a suitable
engine trolley or crawler board under the
engine/transmission so that when lowered,
the power unit can be withdrawn from the
front end of the vehicle, and then moved to
the area where it is to be cleaned and
dismantled. On automatic transmission
models, particular care must be taken not to
damage the transmission fluid pan (sump)
during the removal and subsequent refitting
processes.
40 Carefully lower the engine and
transmission unit, ensuring that no fittings
become snagged. Detach the hoist and
remove the power unit from under the vehicle
(see illustration).
41 Referring to the relevant Part of Chap-
ter 7, separate the transmission from the
engine.
42 While the engine/transmission is removed,
check the mountings; renew them if they are
worn or damaged. Similarly, check the
condition of all coolant and vacuum hoses
and pipes (see Chapter 1). Components that
are normally hidden can now be checked
properly, and should be renewed if there is
any doubt at all about their condition. Where
the vehicle is fitted with manual transmission,
take the opportunity to inspect the clutch
components (see Chapter 8). It is regarded by
many as good working practice to renew the
clutch assembly as a matter of course,
whenever major engine overhaul work is
carried out. Check also the condition of all
components (such as the transmission oil
seals) disturbed on removal, and renew any
that are damaged or worn.

Refitting

43 Refitting is a reversal of removal, however
note the following additional points:
a)

Refer to the applicable Chapters and
Sections as for removal.

b)

Fit new spring clips to the grooves in the
inboard end of the right- and left-hand
driveshaft joints. Lubricate the splines
with transmission oil prior to fitting.

c)

Renew the exhaust flange gasket when
reconnecting the exhaust. Ensure that all
wires are routed clear of the exhaust
system and, on catalytic converter

models, ensure that the heat shields are
securely and correctly fitted.

d)

Ensure that all earth lead connections are
clean and securely made.

e)

Tighten all nuts and bolts to the specified
torque.

f)

Fit a new oil filter, and refill the engine and
transmission with oil, with reference to
Chapter 1.

g)

Refill the cooling system with reference to
Chapter 1.

44 When engine and transmission refitting is
complete, refer to the procedures described
in Section 22 before restarting the engine.

6

Engine/transmission -
removal and refitting

(Zetec engine)

3

Warning: Petrol is extremely
flammable, so take extra
precautions when disconnecting

any part of the fuel system. Don’t smoke,
or allow naked flames or bare light bulbs,
in or near the work area, and don’t work in
a garage where a natural-gas appliance
(such as a clothes dryer or water heater) is
installed. If you spill petrol on your skin,
rinse it off immediately. Have a fire
extinguisher rated for petrol fires handy,
and know how to use it.
Note: Read through the entire Section, as well
as reading the advice in the preceding
Section, before beginning this procedure. The
engine and transmission are removed as a
unit, lowered to the ground and removed from
underneath, then separated outside the
vehicle.

Removal

1 Park the vehicle on firm, level ground, apply
the handbrake firmly, and slacken the nuts
securing both front roadwheels.
2 Depressurise the fuel system as described
in Chapter 4B.
3 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
4 Place protective covers on the wings, then
remove the bonnet (see Chapter 11).
5 Drain the cooling system and the engine oil

(see Chapter 1). Also drain the transmission
(MTX-75 type only) as described in the
relevant Part of Chapter 7.
6 Whenever you disconnect any vacuum
lines, coolant and emissions hoses, wiring
loom connectors, earth straps and fuel lines
as part of the following procedure, always
label them clearly, so that they can be
correctly reassembled. Take instant photos,
or sketch the locations of components and
brackets.

7 Remove the air inlet components and the
complete air cleaner unit as described in
Chapter 4B.
8 Equalise the pressure in the fuel tank by
removing the filler cap, then release the fuel
feed and return quick-release couplings, and
pull the hoses off the fuel pipes. Plug or cap
all open fittings.
9 Disconnect the accelerator cable from the
throttle linkage as described in Chapter 4B.
Secure the cable clear of the engine/
transmission.
10 Releasing its wire clip, unplug the power
steering pressure switch electrical connector,
then disconnect the earth cable from the
engine lifting eye. Refit the bolt after
disconnecting the cable.
11 Marking or labelling all components as they
are disconnected (see paragraph 6 above),
disconnect the vacuum hoses as follows:
a)

From the rear of the inlet manifold.

b)

The braking system vacuum servo unit
hose - from the inlet manifold (see
Chapter 9 for details).

c)

While you are there, trace the vacuum line
from the pulse-air filter housing, and
disconnect it from the pulse-air solenoid
valve.

d)

Secure all these hoses so that they won’t
get damaged as the engine/transmission
is removed.

12 Unbolt the engine/transmission-to-body
earth lead from the transmission (see
illustration). Disconnect the speedometer
drive cable (see Chapter 12) and secure it
clear of the engine/transmission.
13 Disconnect the earth strap at the top of
the engine/transmission flange, and the
adjacent bolt securing the wiring harness clip.

2D•12 Engine removal and general engine overhaul procedures

6.12 Unbolt the engine/transmission-to-

body earth lead from the transmission

5.40 Removing the engine/transmission

from under the vehicle

Masking tape and/or a touch-up paint
applicator work well for marking items.