Ford Orion. Manual — part 8

flap inside the air cleaner inlet. When the
ambient air temperature is below a
predetermined level, the flap admits air
heated from the exhaust manifold shroud; as
the ambient temperature rises, the flap opens
to admit more cool air from the engine
compartment until eventually it is fully open. A
similar system is used on CVH engines,
except that a vacuum actuator modifies any
opening or closing action of the temperature
sensor on the flap valve, according to the level
of the inlet manifold vacuum under running
conditions.

HCS engines

8 This check must be made when the engine
is cold. Detach and remove the air cleaner
inlet trunking. Examine the position of the
check valve within the duct. When the
underbonnet air temperature is below 28ºC,
the valve must be open to allow hot air to
enter the filter (see illustration).
9 Refit the inlet trunking. Start the engine and
run it until it reaches its normal operating
temperature, then stop the engine, remove
the inlet trunking and check that the valve has
closed off the air passage from the exhaust
and opened the main (cool) air inlet.
10 If the flap does not operate correctly,
check that it is not seized. Apart from this
there is no adjustment possible, and the unit
should be renewed if faulty. Refit the air inlet
trunking on completion.

CVH engines

11 This check must be made when the
engine is cold. Disconnect the main air inlet
duct, and visibly check that the flap to the
hot-air inlet is closed (i.e. open to the passage
of cold air).
12 Start the engine, and check that with the
engine idling, the hot-air inlet is open to allow
warm air from the exhaust manifold area to
enter the air cleaner. If the flap operates as
described, it is functioning correctly (see
illustration).
13 If the flap fails to operate as described,
check the condition of the vacuum pipe and
its connections, and check that the flap valve
has not seized. If these are in order, either the

temperature sensor or vacuum actuator is
faulty, and a new air cleaner assembly must
be obtained. Refit the main air duct on
completion.

30 Positive Crankcase

Ventilation (PCV) system
check and filter cleaning

1

1 The function of the crankcase ventilation
system is to reduce the emission of unburned
hydrocarbons from the crankcase, and to
minimise the formation of oil sludge. By
ensuring that a depression is created in the
crankcase under most operating conditions,
particularly at idle, and by positively inducing
fresh air into the system, the oil vapours and
“blow-by” gases collected in the crankcase
are drawn from the crankcase, through the air
cleaner or oil separator, into the inlet tract, to
be burned by the engine during normal
combustion.
2 On HCS engines, the system consists of a
vented oil filler cap (with an integral mesh
filter) and a hose connecting it to the oil
separator/engine breather valve connector on
the underside of the air cleaner housing. A
further hose leads from the adapter/filter to
the inlet manifold.
3 On CVH engines, a closed-circuit type
crankcase ventilation system is used, the
function of which is basically the same as that
described for the HCS engine type, but the
breather hose connects directly to the rocker
cover. The oil filler cap incorporates a
separate filter in certain applications.
4 On Zetec engines, the crankcase ventilation
system main components are the oil
separator mounted on the front (radiator) side
of the cylinder block/crankcase, and the
Positive Crankcase Ventilation (PCV) valve set
in a rubber grommet in the separator’s left-
hand upper end. The associated pipework
consists of a crankcase breather pipe and two
flexible hoses connecting the PCV valve to a
union on the left-hand end of the inlet
manifold, and a crankcase breather hose
connecting the cylinder head cover to the air

cleaner assembly. A small foam filter in the air
cleaner prevents dirt from being drawn
directly into the engine.
5 Check that all components of the system
are securely fastened, correctly routed (with
no kinks or sharp bends to restrict flow) and in
sound condition; renew any worn or damaged
components.
6 If oil leakage is noted, disconnect the
various hoses and pipes, and check that all
are clear and unblocked. Remove the air
cleaner assembly cover, and check that the
hose from the cylinder head cover to the air
cleaner housing is clear and undamaged.
7 Where fitted, the PCV valve is designed to
allow gases to flow out of the crankcase only,
so that a depression is created in the
crankcase under most operating conditions,
particularly at idle. Therefore, if either the oil
separator or the PCV valve are thought to be
blocked, they must be renewed (see Chapter
6). In such a case, however, there is nothing to
be lost by attempting to flush out the
blockage using a suitable solvent. The PCV
valve should rattle when shaken.
8 While the air filter element is removed (see
Section 29), wipe out the housing, and on
Zetec engines, withdraw the small foam filter
from its location in the rear right-hand corner
of the housing (see illustration). If the foam is
badly clogged with dirt or oil, it must be
cleaned by soaking it in a suitable solvent,
and allowed to dry before being refitted.

31 Oil filler cap check

1

1 On HCS engines, remove and inspect the
cap to ensure that it is in good condition, and
not blocked up with sludge.
2 Disconnect the hoses at the cap, and clean
the cap if necessary by brushing the inner
mesh filter with petrol, and blowing through
with light pressure from an air line. Renew the
cap if it is badly congested.

Every 30 000 miles

1•29

30.8 The PCV system foam filter is located

in the rear right-hand corner of the air

cleaner housing on Zetec engines

29.12 Air cleaner inlet and flap valve on

the CVH engine

A Flap open (cool air inlet closed)
B Warm air inlet

29.8 Air cleaner inlet and flap valve on the

HCS engine

A Main air cleaner inlet (cool air)
B Warm air duct (flap open)

1

32 Automatic transmission fluid

renewal

1

1 The automatic transmission fluid should
only be changed when the transmission is
cold.
2 Position the vehicle over an inspection pit,
on vehicle ramps, or jack it up, but make sure
that it is level.
3 Place a suitable container beneath the drain
plug on the transmission sump pan. Remove
the transmission fluid dipstick to speed up the
draining operation.
4 Thoroughly clean the area around the drain
plug in the transmission sump pan, then
unscrew the plug and allow the fluid to drain
into the container.
5 When all the fluid has drained (this may take
quite some time) clean the drain plug, then
refit it together with a new seal and tighten it
securely.
6 Place a funnel with a fine mesh screen in
the dipstick tube, and fill the transmission with
the specified type of fluid. It is essential that
no dirt is introduced into the transmission
during this operation.
7 Depending on the extent to which the fluid
was allowed to drain, it is possible that the
amount of fluid required when filling the
transmission may be more than the specified
amount (see “Lubricants, fluids and
capacities”). However, due to fluid remaining

in the system, it is more likely that less than
the specified amount will be required. Add
about half the specified amount, then run the
engine up to its normal operating temperature
and check the level on the dipstick. When the
level approaches the maximum mark,
proceed as detailed in Section 7 to check the
level and complete the final topping-up as
described.

33 Handbrake adjustment

2

1 Chock the front roadwheels and fully
release the handbrake.
2 Raise the vehicle at the rear, and support it
on axle stands.
3 Check that the handbrake cables are
correctly routed and secured by the retaining
clips at the appropriate points under the
vehicle.

Drum brake models

4 The handbrake is checked for adjustment
by measuring the amount of movement
possible in the handbrake adjuster plungers.
These are located on the inside face of each
rear brake backplate (see illustration). The
total movement of the two plungers combined
should be between 0.5 and 2.0 mm. If the
movement measured is outside of this
tolerance, the handbrake is in need of

adjustment. Adjustment is made altering the
position of the in-line cable adjuster sleeve
(see illustration).
5 When adjustment to the handbrake is
necessary, a new adjustment sleeve locking
pin will be required, and this must therefore
be obtained before making the adjustment.
6 To adjust the handbrake, first ensure that it
is fully released, then firmly apply the
footbrake a few times to ensure that the rear
brake adjustment is taken up by the automatic
adjusters. Extract the locking pin from the
adjuster sleeve, then turn the sleeve to set the
combined movement of the plungers within
the tolerance range specified (0.5 to 2.0 mm).
Turn the locking nut by hand as tight as is
possible (two clicks) against the adjustment
sleeve. Now grip the locknut with a suitable
wrench, and turn it a further two clicks
(maximum).
7 Secure the adjustment by inserting the new
lock pin.
8 Check that the operation of the handbrake
is satisfactory, then lower the vehicle to the
ground, apply the handbrake and remove the
chocks from the front wheels.

Disc brake models

9 Remove the blanking plug from the rear of
the brake carrier plate, just below and to the
rear of the brake caliper.
10 With the handbrake released, insert a
screwdriver through the blanking plug hole
and engage the end of the screwdriver in the
teeth of the adjuster wheel. Move the
screwdriver up and down to turn the adjuster
wheel as necessary, until the wheel is just
locked.
11 Now back off the adjuster wheel until the
wheel can be turned freely without binding.
12 Repeat this procedure on the other brake
assembly, then check the operation of the
handbrake. Ensure that both wheels are
locked when the handbrake lever is applied,
and that both are released, with no trace of
binding when the lever is fully released.
13 When all is satisfactory, refit the blanking
plugs, and lower the vehicle to the ground.
Reapply the handbrake and remove the
chocks from the front wheels.

1•30

Every 30 000 miles

33.4B Handbrake cable adjuster nut (A)

locknut (B) and lockpin (C)

33.4A Handbrake adjustment plunger on

drum brake models

34 Timing belt renewal

4

Refer to Chapter 2, Part B or C as

appropriate.

35 Fuel filter renewal

1

Warning: Petrol is extremely
flammable, so extra precautions
must be taken when working on
any part of the fuel system. Do

not smoke, or allow open flames or bare
light bulbs, near the work area. Also, do not
work in a garage if a natural gas-type
appliance with a pilot light is present. While
performing any work on the fuel system,
wear safety glasses, and have a suitable
(Class B) fire extinguisher on hand. If you
spill any fuel on your skin, rinse it off
immediately with soap and water.
1 On fuel-injected engines, an in-line fuel filter
is provided in the fuel pump outlet line, and is
located below and to the rear of the engine,
above the driveshafts. The filter performs a
vital role in keeping dirt and other foreign
matter out of the fuel system, and so must be
renewed at regular intervals, or whenever you
have reason to suspect that it may be
clogged. It is always unpleasant working
under a vehicle - pressure-washing or hosing

clean the underbody in the filter’s vicinity will
make working conditions more tolerable, and
will reduce the risk of getting dirt into the fuel
system.
2 Relieve any residual pressure in the system
by removing the fuel pump fuse (No 5) and
starting the engine; allow the engine to idle
until it dies. Turn the engine over once or twice
on the starter, to ensure that all pressure is
released, then switch off the ignition.

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 Noting the comments made in Section 1 of
Chapter 5, disconnect the battery earth
terminal.
4 Jack up the front of the vehicle, and
securely support it on axle stands.
5 Using rag to soak up any spilt fuel, release
the fuel feed and outlet pipe unions from the
filter, by squeezing together the protruding
locking lugs on each union, and carefully
pulling the union off the filter stub. Where the
unions are colour-coded, the feed and outlet
pipes cannot be confused; where both unions
are the same colour, note carefully which pipe
is connected to which filter stub, and ensure
that they are correctly reconnected on
refitting.
6 Noting the arrows and/or other markings on
the filter showing the direction of fuel flow
(towards the engine), slacken the filter clamp

screw and withdraw the filter. Note that the
filter will still contain fuel; care should be
taken, to avoid spillage and to minimise the
risk of fire.
7 On installation, slide the filter into its clamp
so that the arrow marked on it faces the
correct way (see illustration), then slide each
pipe union on to its (correct) respective filter
stub, and press it down until the locking lugs
click into their groove. Tighten the clamp
screw carefully, until the filter is just prevented
from moving; do not overtighten the clamp
screw, or the filter casing may be crushed.
8 Refit the fuel pump fuse and reconnect the
battery earth terminal, then switch the ignition
on and off five times, to pressurise the
system. Check for any sign of fuel leakage
around the filter unions before lowering the
vehicle to the ground and starting the engine.

Every 60 000 miles

1•31

35.7 Fuel filter as fitted to 1.6 litre EFi

engines showing direction of flow arrow

1

Every 60 000 miles

Every 3 years

36 Brake fluid renewal

3

The procedure is similar to that for the

bleeding of the hydraulic system as described
in Chapter 9, except that the brake fluid
reservoir should be emptied by syphoning,

and allowance should be made for the old
fluid to be removed from the circuit when
bleeding a section of the circuit.

2A

General

Engine type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four-cylinder, in-line overhead valve

Engine code:

Carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

JBD

CFi fuel-injected models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

J6A

Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1297 cc

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73.96 mm

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

75.48 mm

Compression ratio:

Carburettor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.5:1

CFi fuel-injected models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.8:1

Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

Clockwise (seen from right-hand side of vehicle)

Valves

Valve clearance (cold):

Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.20 mm

Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.30 mm

Lubrication

Engine oil type/specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 1

Engine oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 1

Oil pressure:

At idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.60 bars

At 2000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.50 bars

Oil pump clearances:

Outer rotor-to-body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.14 to 0.26 mm

Inner rotor-to-outer rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.051 to 0.127 mm

Rotor endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.025 to 0.06 mm

Chapter 2 Part A:
HCS engine - in-car engine repair procedures

Auxiliary drivebelt check and renewal . . . . . . . . . . . . .

See Chapter 1

Compression test - description and interpretation . . . . . . . . . . . . . .

3

Crankshaft oil seals - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Crankshaft pulley - removal and refitting . . . . . . . . . . . . . . . . . . . . . 11
Cylinder head - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 10
Cylinder head and valve components - cleaning and

inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 2D

Cylinder head rocker cover - removal and refitting . . . . . . . . . . . . . .

5

Cylinder head rocker gear - removal, inspection and refitting . . . . .

9

Engine oil and filter change . . . . . . . . . . . . . . . . . . . . .

See Chapter 1

Engine oil level check . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 1

Engine overhaul - general information . . . . . . . . . . . . See Chapter 2D
Engine/transmission - removal and refitting . . . . . . . . See Chapter 2D
Engine/transmission mountings - inspection and renewal . . . . . . . . 18
Exhaust manifold - removal, inspection and refitting . . . . . . . . . . . .

8

Flywheel - removal, inspection and refitting . . . . . . . . . . . . . . . . . . . 19
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

Inlet manifold - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .

7

Oil pump - dismantling, inspection and reassembly . . . . . . . . . . . . . 16
Oil pump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Repair operations possible with the engine in the vehicle . . . . . . . .

2

Spark plug renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . See Chapter 1
Sump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Timing chain cover - removal and refitting . . . . . . . . . . . . . . . . . . . . 12
Timing chain, sprockets and tensioner - removal, inspection

and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Top Dead Centre (TDC) for No 1 piston - locating . . . . . . . . . . . . . .

4

Valve clearances - checking and adjustment . . . . . . . . . . . . . . . . . .

6

Water pump - removal and refitting . . . . . . . . . . . . . . .

See Chapter 3

2A•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