Ford Orion. Manual — part 38

34 Refer to Section 4 and remove the air
cleaner.
35 Detach the wiring multi-plugs from the
throttle position sensor and the throttle plate
control motor, and release the retaining clips
on the bracket (see illustrations).
36 Undo and remove the motor support
bracket screws, and remove the bracket
complete with the motor from the CFi unit
(see illustration).
37 Undo the motor retaining screws and
remove it from the support bracket.
38 Refit in the reverse order of removal, but
note the following points:
a)

When refitting the motor and its support
bracket to the injector unit, the throttle
position sensor must locate on the
accelerator linkage, and the bracket must
align with the pegs.

b)

On completion, the idle speed should be
checked by a Ford garage or fuel injection
specialist who has the required
equipment to link up with the engine
management ECU.

Fuel trap

Check

39 A fuel trap is fitted to the Manifold
Absolute Pressure (MAP) sensor hose (see
illustration).
40 Disconnect the vacuum hose between the
MAP sensor and the inlet manifold, and check
carefully for any sign that fuel may be present
in the hose. Remove both hoses from the fuel
trap, and blow out both with compressed air.
Ensure that when in its fitted position there
are no dips in the hose, and that it does not
chafe against any components or wiring. Note
that if fuel was found to be present in the
vacuum hose, it is possible that the MAP
sensor may have been contaminated; this
component should be tested by a Ford dealer
using specialist equipment.

Renewal

41 To renew the fuel trap, first disconnect the
battery negative (earth) lead (refer to Chap-
ter 5, Section 1), then disconnect the vacuum
hoses from the fuel trap and withdraw it.
42 Refit in the reverse order of removal. It is
important to ensure that the trap is correctly
orientated, with the “CARB” mark on one end

face towards the inlet manifold, and the
“DIST” mark towards the MAP sensor (see
illustration).

16 Fuel injection system

components (1.6 litre EFi) -
checking and renewal

3

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.

Fuel rail and injectors

Check

1 Refer to the procedure in the fuel injection
system check (see Section 14).

Renewal

Note: For simplicity, and to ensure the
necessary absolute cleanliness on reassembly,
the following procedure describes the removal
of the fuel rail assembly, complete with the

injectors and pressure regulator, so that the
injectors can be serviced individually on a
clean work surface. It is also possible to
remove and refit an individual injector, once
the fuel system has been depressurised and
the battery has been disconnected. If this
approach is followed, read through the
complete procedure, and work as described in
the relevant paragraphs, depending on the
amount of preliminary dismantling required. Be
careful not to allow any dirt to enter the
system.
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 Loosen off the retaining clip, and detach
the hot-air hose duct from the exhaust
manifold (see illustration).
5 Disconnect the ignition HT lead connectors
from the spark plugs, and release the leads
from their locating grooves in the air inlet
duct. Position them out of the way.
6 Unscrew the retaining nuts and the bolt,
and detach the accelerator cable support
bracket at the throttle housing.
7 Disconnect the wiring connector from the
throttle position sensor.
8 Unscrew the four retaining bolts, and
remove the throttle housing and its mating
face gasket (see illustration).
9 Disconnect the wiring multi-plug from the

Fuel and exhaust systems – fuel-injected engines 4B•11

15.42 Fuel trap orientation markings

15.39 Fuel trap location (arrowed) in MAP

sensor vacuum hose

15.36 Throttle plate control motor

retaining screws (arrowed)

16.4 Disconnecting the hot-air duct from

the exhaust manifold

4B

16.8 Throttle housing retaining bolt

locations (arrowed)

engine coolant temperature sensor and the air
inlet temperature sensor.
10 Disconnect the wiring connectors from
the fuel injectors, then undo the two retaining
bolts and detach the wiring harness from the
fuel rail (see illustrations).
11 Unscrew the fuel supply pipe at the fuel
rail. Plug the rail and pipe, to prevent further
fuel spillage and the possible ingress of dirt.
12 Disconnect the fuel return and vacuum
pipes from the pressure regulator, and catch
any fuel spillage in a clean cloth.
13 Unscrew the fuel rail securing bolts, and
carefully withdraw the rail (complete with
injectors) from the engine (see illustrations).
14 Detach the fuel injectors from the fuel rail,
then remove the upper and lower seal from

each injector. All seals must be renewed (even
if only one injector is to be renewed).
15 Prior to refitting the injectors, ensure that
all mating surfaces are perfectly clean.
Lubricate the new injector seals with clean
engine oil to ease their assembly to the
injectors (see illustration).
16 Refitting is a reversal of the removal
procedure. Refer to the Specifications at the
start of this Chapter for the tightening torques.
When refitting the fuel rail, ensure that the
injectors are correctly located. Ensure that the
mating surfaces of the throttle housing are
perfectly clean before assembling.
17 On completion, restart the engine and
check the various fuel connections for any
signs of leaks.

Fuel pressure regulator

Check

18 Refer to the fuel pump/fuel pressure
check procedure (see Section 7).

Renewal

19 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.
20 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
21 Release the fuel return pipe securing clip,
and detach the pipe from the regulator.
22 Pull free the vacuum pipe from the
regulator connector (see illustration).
23 Unscrew the two retaining bolts and
remove the regulator. Remove the old sealing
ring for renewal.
24 Refit in the reverse order of removal.
Lubricate the new seal ring with clean engine
oil to ease assembly. When the regulator is
refitted and the fuel and vacuum lines are
reconnected, turn the ignition on and off five
times (without cranking the engine) and check
for any sign of fuel leaks before restarting the
engine.

4B•12 Fuel and exhaust systems – fuel-injected engines

16.22 Fuel pressure regulator showing

vacuum pipe (A) and return pipe

connections (B)

16.15 Fuel injector with new seals fitted

16.13C . . . and withdraw the fuel rail and

injectors

16.13B . . . release each injector . . .

16.13A Remove the injector rail retaining

bolts . . .

16.10C . . . and remove the injector wiring

harness

16.10B . . . unbolt the wiring harness . . .

16.10A Disconnect the wiring connector

from each injector . . .

Idle speed control valve

Check

25 Disconnect the battery negative (earth)
lead - see Chapter 5, Section 1.
26 Unplug the valve’s electrical connector
(see illustration).
27 Connect a 12-volt battery across the
valve’s terminals - positive (+) to terminal 37,
and negative (-) to terminal 21.

Caution: It is essential that the
correct polarity is observed, or
the diode incorporated in the
valve may be damaged.

28 A distinct click should be heard each time
contact is made and broken. If not, measure
the resistance between the terminals. If the
resistance is as specified, the valve is okay
(but there may be a problem with the wiring or
the ECU). If the resistance is not as specified,
renew the valve (see below).
29 Plug in the valve’s electrical connector.

Renewal

30 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
31 Unplug the valve’s electrical connector.
32 Undo the four retaining screws, and
remove the idle speed control valve.
33 Refitting is a reversal of the removal
procedure. Ensure that the mating faces of
the valve and inlet manifold are clean before
reassembling.
34 When the valve is refitted, restart the
engine and check that there are no induction
leaks. Run the engine until its normal
operating temperature is reached, and check
that the idle speed is stable. Stop the engine,
connect up a tachometer in accordance with
its maker’s manuals, then restart the
engine and check that the idle speed is as
specified with all electrical items (lights, heater
blower motor, etc) switched off, then on. The
idle speed should remain the same. Switch off
the electrical items, turn the engine off and
detach the tachometer to complete the test.

Throttle housing

Check

35 Remove the air inlet duct (see Section 4),
and verify that the throttle linkage operates
smoothly.

36 If the housing bore and valve are dirty
enough for you to think that this might be the
cause of a fault, seek the advice of a Ford
dealer. Do not clean the housing (see the
notes in the checking procedure given in
Section 14).

Renewal

37 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.
38 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
39 Loosen off the retaining clip, and detach
the hot-air duct from the exhaust manifold
(see illustration 16.4).
40 Disconnect the ignition HT lead
connectors from the spark plugs, and release
the leads from their locating grooves in the air
inlet duct. Position them out of the way.
41 Unscrew the retaining nuts and the bolt,
and detach the accelerator cable support
bracket at the throttle housing.
42 Disconnect the vacuum hoses from the
inlet manifold and the fuel pressure regulator.
43 Detach the wiring connections from the
idle speed control valve, the temperature
sensor and the harness connector.
44 Disconnect the fuel return hose from the
pressure regulator unit.
45 Unscrew the throttle housing-to-manifold
retaining bolts, and unbolt the throttle housing
support bracket bolts (see illustration 16.8).
Remove the throttle housing and gasket.
46 Refit in the reverse order of removal.
Check that the mating faces are clean, and fit
a new gasket.

17 Fuel injection system

components (1.6 and 1.8 litre
SEFi) - checking and renewal

3

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.

Throttle housing

Check

1 Refer to Section 16, paragraphs 35 and 36.

Renewal

2 Disconnect the battery negative (earth) lead
- see Chapter 5, Section 1.
3 Remove the air inlet duct as described in
Section 4.
4 Disconnect the accelerator cable from the
throttle linkage (see Section 5).
5 Disconnect the throttle position sensor
multi-plug.
6 Remove the throttle housing mounting
screws, then detach the throttle housing and
gasket from the inlet manifold (see
illustration). Discard the gasket - this must be
renewed whenever it is disturbed.
7 Using a soft brush and carburettor cleaner,
thoroughly clean the exterior of the throttle
housing, then blow out all passages with
compressed air.

Caution: Do not clean the throttle
housing’s bore, the throttle valve,
or the throttle position sensor,
either by scraping or with a

solvent. Just wipe them over carefully with
a clean soft cloth.
8 Refitting is the reverse of the removal
procedure. Fit a new gasket, and tighten the
housing screws to the specified torque.

Fuel rail and injectors

Check

9 Refer to the procedure in the fuel system
check (see Section 14).

Renewal

10 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.
11 Disconnect the battery negative (earth)
lead - see Chapter 5, Section 1.

Fuel and exhaust systems – fuel-injected engines 4B•13

16.26 Idle speed control valve and wiring

connector

17.6 Throttle housing mounting screw

locations (arrowed)

4B

12 Remove the air inlet duct as described in
Section 4.
13 Disconnect the accelerator cable from the
throttle linkage (see Section 5).
14 Disconnect the throttle position sensor
multi-plug.
15 Remove the throttle housing mounting
screws, then detach the throttle housing and
gasket from the inlet manifold. Discard the
gasket - this must be renewed whenever it is
disturbed.
16 Detach the crankcase breather hose from
the cylinder head cover, and the fuel pressure
regulator vacuum hose from the inlet
manifold.
17 Releasing the wire clips, unplug the four
fuel injector multi-plugs and the inlet air
temperature sensor multi-plug.
18 Refer to Section 3 and disconnect the fuel
feed and return lines at the quick-release
couplings next to the braking system vacuum
servo unit, then unclip the fuel hoses from the
inlet manifold; use rag to soak up any spilt
fuel. Note: Do not disturb the threaded
couplings at the fuel rail unions unless
absolutely necessary; these are sealed at the
factory. The quick-release couplings will
suffice for all normal service operations.
19 Unscrew the three bolts securing the fuel
rail (see illustration). Withdraw the rail,
carefully prising it out of the inlet manifold,
and draining any remaining fuel into a suitable
clean container. Note the seals between the
rail noses and the manifold; these must be
renewed whenever the rail is removed.
20 Clamping the rail carefully in a vice fitted
with soft jaws, unscrew the two bolts securing
each injector, and withdraw the injectors.
Place each in a clean, clearly-labelled storage
container.
21 If you are renewing the injector(s), discard
the old injector, the nose seal and the O-rings.
If you are simply renewing leaking injector
O-rings, and intend to re-use the same
injectors, remove the old nose seal and
O-rings, and discard them.
22 Further testing of the injector(s) is beyond
the scope of the home mechanic. If you are in
doubt as to the status of any injector(s), these
can be tested at a dealer service department.

23 Refitting is the reverse of the removal
procedure, noting the following points:
a)

Lubricate each nose seal and O-ring with
clean engine oil on installation.

b)

Locate each injector carefully in the fuel
rail recess, ensuring that the locating tab
on the injector head fits into the slot
provided in the rail. Tighten the bolts to
the specified torque.

c)

Fit a new seal to each fuel rail nose, and
ensure the seals are not displaced as the
rail is refitted. Ensure that the fuel rail is
settled fully in the manifold before
tightening the three bolts evenly and to
the torque wrench setting specified.

d)

Fasten the fuel feed and return quick-
release couplings as described in Section
3.

e)

Ensure that the breather hose, vacuum
hose and wiring are routed correctly, and
secured on reconnection by any clips or
ties provided.

f)

On completion, switch the ignition on and
off five times, to activate the fuel pump
and pressurise the system, without
cranking the engine. Check for signs of
fuel leaks around all disturbed unions and
joints before attempting to start the
engine.

Fuel pressure regulator

Check

24 Refer to the fuel pump/fuel pressure
check procedure (see Section 7).

Renewal

25 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.
26 Disconnect the battery negative (earth)
lead - see Chapter 5, Section 1.
27 Disconnect the vacuum hose from the
regulator.
28 Unscrew the two regulator retaining bolts

(see illustration) then use a wad of clean rag
to soak up any spilt fuel, and withdraw the
regulator.
29 Refitting is the reverse of the removal
procedure, noting the following points:
a)

Renew the regulator sealing O-ring
whenever the regulator is disturbed.
Lubricate the new O-ring with clean
engine oil on installation.

b)

Locate the regulator carefully in the fuel
rail recess, and tighten the bolts to the
specified torque wrench setting.

c)

On completion, switch the ignition on and
off five times, to activate the fuel pump and
pressurise the system, without cranking
the engine. Check for signs of fuel leaks
around all disturbed unions and joints
before attempting to start the engine.

Idle speed control valve

Check

30 Refer to the procedures given in Sec-
tion 16, paragraphs 25 to 29, noting that on
the SEFi system, the valve is located on the
right-hand side of the inlet manifold, just
below the throttle position sensor.

Renewal

31 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
32 Disconnect the valve’s wiring multi-plug.
33 Unscrew the three retaining bolts, and
withdraw the valve from the inlet manifold
(see illustration).
34 Refitting is the reverse of the removal
procedure, noting the following points:
a)

Clean the mating surfaces carefully, and
always fit a new gasket whenever the
valve is disturbed.

b)

Tighten the bolts evenly and to the
specified torque wrench setting.

c)

Once the wiring and battery are
reconnected, start the engine and allow it
to idle. When it has reached normal
operating temperature, check that the idle
speed is stable, and that no induction (air)
leaks are evident. Switch on all electrical
loads headlights, heated rear window,
etc), and check that the idle speed is still
correct.

4B•14 Fuel and exhaust systems – fuel-injected engines

17.33 Unscrew the three retaining bolts

(arrowed) and withdraw the idle speed

control valve from the inlet manifold

17.28 Disconnect the vacuum hose and

undo the bolts (arrowed) to withdraw the

fuel pressure regulator

17.19 Undo the three bolts (arrowed) to

release the fuel rail from the manifold