Ford Orion. Manual — part 28

13 Compare the width of the crushed
Plastigage to the scale printed on the
Plastigage envelope, to obtain the running
clearance (see illustration 20.15). Compare it
to the Specifications, to make sure the
clearance is correct.
14 If the clearance is not as specified, seek
the advice of a Ford dealer or similar engine
reconditioning specialist - if the crankshaft
journals are in good condition (see Section
16), it may be possible simply to renew the
shells to achieve the correct clearance. If this
is not possible, the crankshaft must be
reground by a specialist, who can also supply
the necessary undersized shells. First though,
make sure that no dirt or oil was trapped
between the bearing shells and the
connecting rod or cap when the clearance
was measured. Also, recheck the crankpin
diameter. If the Plastigage was wider at one
end than the other, the crankpin journal may
be tapered (see Section 16).
15 Carefully scrape all traces of the
Plastigage material off the journal and the
bearing surface. Be very careful not to scratch
the bearing - use your fingernail or the edge of
a credit card.

Final piston/connecting rod
refitting

16 Make sure the bearing surfaces are
perfectly clean, then apply a uniform layer of
clean molybdenum disulphide-based grease,
engine assembly lubricant, or clean engine oil,
to both of them. You’ll have to push the piston
into the cylinder to expose the bearing surface
of the shell in the connecting rod.
17 Slide the connecting rod back into place
on the crankpin (big-end) journal, refit the big-
end bearing cap, and then tighten the bolts as
described above.
18 Repeat the entire procedure for the
remaining piston/connecting rod assemblies.
19 The important points to remember are:

a)

Keep the backs of the bearing shells and
the recesses of the connecting rods and
caps perfectly clean when assembling
them.

b)

Make sure you have the correct
piston/rod assembly for each cylinder -
use the etched cylinder numbers to
identify the front-facing side of both the
rod and its cap.

c)

The arrow on the piston crown must face
the timing belt/chain end of the engine.

d)

Lubricate the cylinder bores with clean
engine oil.

e)

Lubricate the bearing surfaces when
refitting the big-end bearing caps after the
running clearance has been checked.

20 After all the piston/connecting rod
assemblies have been properly installed,
rotate the crankshaft a number of times by
hand, to check for any obvious binding.
21 On the HCS engine, if the oil pick-up pipe
and strainer was removed, this is a good time
to refit it. First clean the joint area, then coat
the area indicated with the specified activator
(available from Ford dealers) (see
illustration). Wait for a period of ten minutes,
then smear the shaded area with the specified
adhesive and immediately press the inlet pipe
into position in the crankcase.

22 Engine -

initial start-up after overhaul

1

1 With the engine refitted in the vehicle,
double-check the engine oil and coolant
levels. Make a final check that everything has
been reconnected, and that there are no tools
or rags left in the engine compartment.
2 With the spark plugs removed and the
ignition system disabled by unplugging the
ignition coil’s electrical connector, remove
fuse 5 (fuel-injected engines) to disconnect

the fuel pump. Turn the engine on the starter
until the oil pressure warning light goes out.
3 Refit the spark plugs, and connect all the
spark plug (HT) leads (Chapter 1). Reconnect the
ignition coil. On fuel-injected engines, refit the
fuel pump fuse, switch on the ignition and listen
for the fuel pump; it will run for a little longer than
usual, due to the lack of pressure in the system.
4 Start the engine, noting that this also may
take a little longer than usual, due to the fuel
system components being empty.
5 While the engine is idling, check for fuel,
coolant and oil leaks. Don’t be alarmed if
there are some odd smells and smoke from
parts getting hot and burning off oil deposits.
If the hydraulic tappets (where applicable)
have been disturbed, some valve gear noise
may be heard at first; this should disappear as
the oil circulates fully around the engine, and
normal pressure is restored in the tappets.
6 Keep the engine idling until hot water is felt
circulating through the top hose, check that it
idles reasonably smoothly and at the usual
speed, then switch it off.
7 After a few minutes, recheck the oil and
coolant levels, and top-up as necessary
(Chapter 1).
8 If they were tightened as described, there is
no need to re-tighten the cylinder head bolts
once the engine has first run after reassembly
- in fact, Ford state that the bolts must not be
re-tightened.
9 If new components such as pistons, rings
or crankshaft bearings have been fitted, the
engine must be run-in for the first 500 miles
(800 km). Do not operate the engine at full-
throttle, or allow it to labour in any gear during
this period. It is recommended that the oil and
filter be changed at the end of this period.

Engine removal and general engine overhaul procedures 2D•29

21.21 Oil inlet pipe refitting details on the

HCS engine

A Area of sealant application -

dimensions in mm

B Edge must be parallel with engine

longitudinal axis

21.11B . . . or a fabricated type as shown

21.11A Angle-tightening the big-end bolts

using the correct tool . . .

2D

3

Coolant

Mixture type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 1

Cooling system capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 1

System pressure

Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 bars - should hold this pressure for at least 10 seconds

Expansion tank filler cap

Pressure rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 bars approximately - see cap for actual value

Thermostat

Starts to open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

85ºC to 89ºC

Coolant temperature sensor

Resistance:

At 0ºC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

89 to 102 kilohms

At 20ºC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 to 40 kilohms

At 100ºC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.9 to 2.5 kilohms

At 120ºC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.0 to 1.4 kilohms

Air conditioning system

Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

R12 or R134a

Chapter 3
Cooling, heating and air conditioning systems

Air conditioning system check . . . . . . . . . . . . . . . . . .

See Chapter 1

Air conditioning system - general information and precautions . . . . 13
Air conditioning system components - removal and refitting . . . . . . 14
Antifreeze - general information . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Auxiliary drivebelt check and renewal . . . . . . . . . . . . . . See Chapter 1
Coolant level check . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Coolant renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Cooling system checks (coolant leaks, hose

condition) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1

Cooling system electrical switches and sensors - testing,

removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

Cooling system hoses - disconnection and renewal . . . . . . . . . . . .

3

Cooling system servicing (draining, flushing and

refilling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 1

Heater/air conditioning controls - removal and refitting . . . . . . . . . . 12
Heater/ventilation components - removal and refitting . . . . . . . . . . . 11
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

Radiator and expansion tank - removal, inspection and refitting . . .

7

Radiator electric cooling fan assembly - testing, removal

and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Thermostat - removal, testing and refitting . . . . . . . . . . . . . . . . . . . .

4

Water pump (CVH engine) - removal and refitting . . . . . . . . . . . . . .

9

Water pump (HCS engine) - removal and refitting . . . . . . . . . . . . . .

8

Water pump (Zetec engine) - removal and refitting . . . . . . . . . . . . . . 10

3•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

Torque wrench settings

Nm

lbf ft

Thermostat housing/water outlet:

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

18 to 22

13 to 16

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

9 to 12

7 to 9

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

18 to 22

13 to 16

Water pump pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 to 12

6 to 9

Water pump retaining bolts:

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

7 to 10

5 to 7

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

7 to 10

5 to 7

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

16 to 20

12 to 15

Coolant temperature gauge sender:

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

5 to 7

3.5 to 5

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

5 to 7

3.5 to 5

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

6 to 10

4 to 7

Coolant temperature sensor:

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

20 to 25

15 to 18

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

18 to 20

13 to 15

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

12 to 18

9 to 13

Radiator retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 to 27

15 to 20

Cooling fan motor-to-shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 to 12

7 to 9

Cooling fan shroud-to-radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 to 5

2 to 3.5

Heater housing to body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 to 11

5 to 8

Air conditioning system components:

Condenser to side member . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 to 9

5 to 7

Shroud to radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 to 5

2 to 3.5

Dehydrator to radiator bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 to 8

3.5 to 6

High pressure switch to dehydrator . . . . . . . . . . . . . . . . . . . . . . . . . .

12 to 15

9 to 11

Expansion valve to evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 to 5

3 to 3.5

Air conditioner housing to cowl panel . . . . . . . . . . . . . . . . . . . . . . . .

6 to 8

4 to 6

Low and high pressure pipes to compressor . . . . . . . . . . . . . . . . . . .

20 to 26

15 to 19

Low pressure liquid pipe to expansion valve . . . . . . . . . . . . . . . . . . .

6 to 8

4 to 6

Dehydrator connecting pipe to condenser . . . . . . . . . . . . . . . . . . . . .

14 to 19

10 to 14

Pipes to dehydrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14 to 19

10 to 14

Compressor to bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 to 27

15 to 20

Compressor driveplate to compressor . . . . . . . . . . . . . . . . . . . . . . . .

11 to 16

8 to 12

3•2 Cooling, heating and air conditioning systems

1

General information

Engine cooling system

The cooling system is of the pressurised

type consisting of a belt-driven pump,
aluminium crossflow radiator, expansion tank,
electric cooling fan and a thermostat. The
system functions as follows. Cold coolant in
the bottom of the radiator passes through the
bottom hose to the water pump, where it is
pumped around the cylinder block and head
passages. After cooling the cylinder bores,
combustion surfaces and valve seats, the
coolant reaches the underside of the
thermostat, which is initially closed. The
coolant passes through the heater and inlet
manifold and is returned to the water pump.

When the engine is cold, the coolant

circulates through the cylinder block, cylinder
head, heater and inlet manifold. When the
coolant reaches a predetermined
temperature, the thermostat opens, and the
coolant then passes through the top hose to
the radiator. As the coolant circulates through
the radiator, it is cooled by the inrush of air
when the car is in forward motion. Airflow is

supplemented by the action of the electric
cooling fan when necessary. Upon reaching
the bottom of the radiator, the coolant is now
cooled, and the cycle is repeated.

When the engine is at normal operating

temperature, the coolant expands, and some
of it is displaced into the expansion tank. This
coolant collects in the tank, and is returned to
the radiator when the system cools.

The electric cooling fan, mounted behind

the radiator, is controlled by a thermostatic
switch. At a predetermined coolant
temperature, the switch contacts close, thus
actuating the fan.

Warning: DO NOT attempt to
remove the expansion tank filler
cap, or to disturb any part of the
cooling system, while it or the

engine is hot, as there is a very great risk
of scalding. If the expansion tank filler cap
must be removed before the engine and
radiator have fully cooled down (even
though this is not recommended) the
pressure in the cooling system must first
be released. Cover the cap with a thick
layer of cloth, to avoid scalding, and slowly
unscrew the filler cap until a hissing sound
can be heard. When the hissing has
stopped, showing that pressure is
released, slowly unscrew the filler cap

further until it can be removed; if more
hissing sounds are heard, wait until they
have stopped before unscrewing the cap
completely. At all times, keep well away
from the filler opening.
Warning: Do not allow antifreeze to come
in contact with your skin, or with the
painted surfaces of the vehicle. Rinse off
spills immediately with plenty of water.
Never leave antifreeze lying around in an
open container, or in a puddle in the
driveway or on the garage floor. Children
and pets are attracted by its sweet smell,
but antifreeze can be fatal if ingested.
Warning: If the engine is hot, the electric
cooling fan may start rotating even if the
engine is not running, so be careful to
keep hands, hair and loose clothing well
clear when working in the engine
compartment.

Heating system

The heating system consists of a blower fan

and heater matrix (radiator) located in the
heater unit, with hoses connecting the heater
matrix to the engine cooling system. Hot
engine coolant is circulated through the
heater matrix. When the heater temperature
control on the facia is operated, a flap door
opens to expose the heater matrix to the

passenger compartment. Air entering the
vehicle passes over the matrix and is thus
heated - the supply of air can be supplemen-
ted by operating the blower fan as required.

Air conditioning system

See Section 13.

2

Antifreeze -
general information

Warning: Do not allow antifreeze
to come in contact with your
skin, or with the painted surfaces
of the vehicle. Rinse off spills

immediately with plenty of water.
Antifreeze is highly toxic if ingested. Never
leave antifreeze lying around in an open
container, or in puddles on the floor;
children and pets are attracted by its
sweet smell, and may drink it. Check with
local authorities about disposing of used
antifreeze - many have collection centres
which will see that antifreeze is disposed
of safely.

The cooling system should be filled with a

water/ethylene glycol-based antifreeze
solution, of a strength which will prevent
freezing down to at least -25ºC, or lower if the
local climate requires it. Antifreeze also
provides protection against corrosion, and
increases the coolant boiling point.

The cooling system should be maintained

according to the schedule described in
Chapter 1. If antifreeze is used that is not to
Ford’s specification, old or contaminated
coolant mixtures are likely to cause damage,
and encourage the formation of corrosion and
scale in the system. Use distilled water with
the antifreeze, if available - if not, be sure to
use only soft water. Clean rainwater is
suitable.

Before adding antifreeze, check all hoses

and hose connections, because antifreeze
tends to leak through very small openings.
Engines don’t normally consume coolant, so if
the level falls regularly, find the cause and
correct it.

The exact mixture of antifreeze-to-water

which you should use depends on the relative
weather conditions. The mixture should
contain at least 40% antifreeze, but not more
than 70%. Consult the mixture ratio chart on
the antifreeze container before adding
coolant. Hydrometers are available at most
automotive accessory shops to test the
coolant. Use only good-quality ethylene-
glycol-based antifreeze which meets the
vehicle manufacturer’s specifications.

3

Cooling system hoses -
disconnection and renewal

1

Note: Refer to the warnings given in Section 1
of this Chapter before starting work.
1 If the checks described in Chapter 1 reveal
a faulty hose, it must be renewed as follows.
2 First drain the cooling system (see Chapter
1); if the antifreeze is not due for renewal, the
drained coolant may be re-used, if it is
collected in a clean container.
3 To disconnect any hose, use a pair of pliers
to release the spring clamps (or a screwdriver
to slacken screw-type clamps), then move
them along the hose clear of the union.
Carefully work the hose off its stubs. The
hoses can be removed with relative ease
when new - on an older car, they may have
stuck.
4 If a hose proves stubborn, try to release it
by rotating it on its unions before attempting
to work it off. Gently prise the end of the hose
with a blunt instrument (such as a flat-bladed
screwdriver), but do not apply too much force,
and take care not to damage the pipe stubs or
hoses. Note in particular that the radiator hose
unions are fragile; do not use excessive force
when attempting to remove the hoses. If all
else fails, cut the hose with a sharp knife, then
slit it so that it can be peeled off in two pieces.
While expensive, this is preferable to buying a
new radiator. Check first, however, that a new
hose is readily available.
5 When refitting a hose, first slide the clamps
onto the hose, then work the hose onto its
unions. If the hose is stiff, use soap (or

washing-up liquid) as a lubricant, or soften it
by soaking it in boiling water, but take care to
avoid scalding.
6 Work each hose end fully onto its union,
then check that the hose is settled correctly
and is properly routed. Slide each clip along
the hose until it is behind the union flared end,
before tightening it securely.
7 Refill the system with coolant (see Chap-
ter 1).
8 Check carefully for leaks as soon as
possible after disturbing any part of the
cooling system.

4

Thermostat -
removal, testing and refitting

1

Note: Refer to the warnings given in Section 1
of this Chapter before starting work.

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Drain the cooling system (see Chapter 1).

HCS and CVH engines

3 Loosen the clips, and disconnect the
radiator top hose and expansion tank hose
(HCS engines) or the radiator top hose,
expansion tank hose and heater hose (CVH
engines) from the thermostat housing (see
illustrations).
4 Disconnect the thermostatic switch wire
multi-plug from the thermostat housing.
5 Unscrew the retaining bolts, and remove
the thermostat housing (see illustration).
6 Remove the gasket from the mating face of
the thermostat housing, then using suitable
pliers, compress the thermostat retaining clip
and remove it from the housing. Extract the
thermostat from the housing (noting its
direction of fitting) and where applicable,
remove the O-ring seal (see illustrations).

Zetec engines

7 Disconnect the expansion tank hose and
the radiator top hose from the thermostat
housing’s water outlet.

Cooling, heating and air conditioning systems 3•3

4.5 Removing the thermostat housing

(CVH engine)

4.3B Detaching the heater hose from the

thermostat housing (CVH engine)

4.3A Detaching the expansion tank top

hose from the thermostat housing on the

HCS engine. Thermostatic switch is also

shown (arrowed)

3