Ford Orion. Manual — part 15

belt, crankshaft sprocket and thrustwasher
(Sections 10 and 11), and the sump (Sec-
tion 15).
4 Unscrew the retaining nut/bolts and remove
the oil pick-up pipe (see illustration).
5 Unbolt and withdraw the oil pump from the
front face of the engine. Clean the oil pump
for inspection. Refer to Section 17 for the
inspection procedures. The oil seal in the oil
pump housing should always be renewed
(Section 18).

Refitting

6 Before refitting the oil pump and the
associated fittings, clean off the respective
mating faces. A new oil pump gasket must be
obtained, as well as the seals and gaskets for

the other associated components to be
refitted.
7 When refitting the oil pump, precautionary
measures must be taken to avoid the
possibility of damaging the new oil seal as it is
engaged over the shoulder and onto its
journal on the crankshaft. Extract the
Woodruff key from the groove in the
crankshaft, then cut a plastic guide which will
furl over and protrude beyond the shoulder of
the seal journal on the crankshaft. This will
allow the seal to ride over the step, and avoid
damaging the seal lip as it is pushed into
position on the crankshaft.
8 If a new oil pump is being fitted or the old
pump is to be re-used after cleaning and
inspection, first prime the pump by squirting
clean engine oil into it, and simultaneously
rotating the drivegear a few times (see
illustration).
9 Align the pump gear flats with those on the
crankshaft, then fit the oil pump. Check that
the sump mating faces of the oil pump and
the base of the crankcase are flush each side,
then tighten the retaining bolts to the
specified torque setting. Remove the
protective guide (see illustrations).
10 Refit the oil pick-up tube to the oil pump,
using a new gasket. Refer to the Specifi-
cations for the tightening torque details.
11 Slide the thrustwasher onto the front end
of the crankshaft, then insert the Woodruff key
into position in the groove in the crankshaft
(see illustration). The key must be located
with its flat edge parallel with the line of the

crankshaft, to ensure that the crankshaft
sprocket slides fully into position as it is being
refitted.
12 Refit the sump, crankshaft sprocket, the
timing belt, timing belt cover and drivebelt
pulley (as described in the appropriate earlier
Sections of this Chapter). Refit and adjust the
drivebelt as described in Chapter 1.
13 On completion, lower the vehicle and
reconnect the battery.

17 Oil pump - dismantling,

inspection and reassembly

3

1 The oil pump fitted is a low-friction rotor-
type, driven from the front end of the
crankshaft. Where a high-mileage engine is
being reconditioned, it is recommended that a
new oil pump is fitted.
2 To inspect the rotor assembly, first remove
the pump from the engine (Section 16), then
undo the retaining screws and remove the
cover plate (see illustration). Remove the O-
ring seal.
3 Clean the rotors and the inside of the pump
housing, then visually inspect the various
components for signs of excessive wear and
scoring. Check the pump components for
wear using feeler gauges in the same manner
as that described in Part A of this Chapter,
Section 16. Refer to the accompanying
illustrations, and to the Specifications Section
at the start of Part B (see illustrations).

2B•14 CVH engine – in-car engine repair procedures

17.3A Outer rotor-to-oil pump body

clearance check

17.2 Oil pump cover plate retaining

screws (arrowed)

16.11 Locating the Woodruff key into the

groove in the crankshaft

16.9B With the oil pump refitted, remove

the protective guide (arrowed)

16.9A Refit the oil pump

16.8 Prime the oil pump prior to fitting

16.4 Removing the oil inlet pipe

4 When reassembling the pump, ensure that
the inner (driving) and outer (driven) rotors are
located with the corresponding indented
matchmarks facing the same way (see
illustration).

18 Crankshaft oil seals -

renewal

4

Front oil seal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Apply the handbrake, then raise the vehicle
at the front end, and support it on axle stands.
3 Remove the auxiliary drivebelt as described
in Chapter 1.
4 Remove the crankshaft pulley (Section 8),
the timing belt covers (Section 9), the timing
belt (Section 10) and crankshaft sprocket,
Woodruff key and thrustwasher (Section 11).
5 The oil seal is now accessible for removal
from the front face of the oil pump housing
(see illustration). To withdraw the seal, a
hooked tool will be required; if available, use
Ford special tool No 21-096. Take care not to
damage the oil pump housing during removal.
As it is removed, note the fitted orientation of
the seal in its housing.
6 Clean the oil pump housing and the
crankshaft stub, then lubricate the lips of the
new seal and the crankshaft front stub with
clean engine oil.

7 The oil seal should be drawn into position
using the Ford special tool No 21-093A.
Failing this, use a tube of suitable diameter,
with the crankshaft pulley bolt and washers.
Do not hammer the seal into position. To
protect the seal lips as it is fitted onto the
crankshaft, cut a thin sheet of plastic to suit
and furl it round the front of the crankshaft,
over the journal shoulder (see illus-
tration 17.18 in Part C of this Chapter).
8 When the seal is fully fitted, remove the
special tool (or fabricated tool) and withdraw
the plastic protector. Check that the
crankshaft is still at the TDC position and refit
the Woodruff key, thrustwasher and sprocket.
Refit and tension the timing belt, then refit the
timing belt cover and crankshaft pulley as
described in the appropriate Sections earlier
in this Chapter.
9 Refit and adjust the auxiliary drivebelt as
described in Chapter 1.
10 On completion, lower the vehicle and
reconnect the battery.

Rear oil seal

11 With the engine or transmission removed
from the vehicle for access, remove the clutch
as described in Chapter 8.
12 Remove the flywheel/driveplate as
described in Section 20.
13 If available, use Ford tool No 21-151 or a
suitable clawed tool to extract the seal from
its housing. If the seal housing is removed
from the rear face of the engine, the seal can

be removed as described in paragraph 18. As
it is removed, note the direction of fitting, and
take care not to damage the seal housing as
the seal is extracted.
14 Clean the seal housing, the crankshaft
rear flange face, and the flywheel/driveplate
mating surfaces.
15 One of two possible methods may be
used to insert the new oil seal, depending on
the tools available.
16 If Ford special service tool No 21-095 is
available, lubricate the seal lips of the seal and
its running face on the crankshaft with clean
engine oil. Position the seal (correctly
orientated) into the special tool, then draw the
seal into the housing using two
flywheel/driveplate securing bolts so that the
seal is against the stop.
17 If the correct Ford service tool is not
available, it will be necessary to remove the oil
seal carrier housing. To do this, first remove
the sump as described in Section 15, then
unscrew the seal housing retaining bolts and
remove the housing from the rear face of the
crankcase.
18 Drive the old seal from the housing by
carefully tapping it from its aperture using a
suitable punch as shown (see illustration). As
it is removed, note the direction of fitting, and
take care not to damage the seal housing as
the seal is extracted.
19 New gaskets will be required for the seal
housing and sump during reassembly. Clean
the mating faces of the seal housing, the
crankcase and sump. Insert the new seal

CVH engine – in-car engine repair procedures 2B•15

17.4 Inner and outer rotor matchmarks

(arrowed)

17.3C Rotor endfloat check

17.3B Outer-to-inner rotor clearance

check

18.19 Rear oil seal installation - housing

mounted in a vice with protected jaws

18.18 Rear oil seal removal

18.5 Crankshaft front oil seal - seen from

below (arrowed)

2B

squarely into its housing. To avoid damaging
the seal or the housing, place a flat piece of
wood across the face of the seal, and
carefully tap or draw the seal into place (see
illustration). Do not allow the seal to tilt in the
housing as it is being fitted.
20 Lubricate the running surface on the
crankshaft and the oil seal lip with clean
engine oil. Locate a new gasket onto the rear
face of the crankcase, and refit the oil seal
housing and seal. To avoid damaging the lips
of the seal as it is passed over the end of the
crankshaft, cut a thin sheet of plastic to suit
and furl it round the rear flange of the
crankshaft so that it protrudes, and press the
seal over it. With the seal in position, withdraw
the plastic protector. Centralise the seal on
the shaft, check that the housing-to-sump
flange faces are flush to the sump face on the

base of the crankcase, then insert and tighten
the housing retaining bolts to the specified
torque.
21 Refit the sump with reference to Sec-
tion 15.
22 Refit the flywheel/driveplate as described
in Section 20.
23 Refit the clutch as described in Chapter 8.
24 Refit the engine or transmission, as
applicable.

19 Engine/transmission

mountings - renewal

1

The procedures for renewing the

engine/transmission mountings on the CVH
engine are much the same as those described
for the HCS engine in Part A of this Chapter.
Refer to Part A for details.

20 Flywheel/driveplate -

removal, inspection and
refitting

3

Removal

1 Access to the flywheel (manual
transmission) or driveplate (automatic
transmission) is gained by first removing the
transmission (Chapter 7). On manual
transmission models, remove the clutch
(Chapter 8).

2 Unscrew and remove the six
flywheel/driveplate retaining bolts (see
illustration), and carefully withdraw the
flywheel/driveplate from the rear face of the
crankshaft. Take care not to drop the
flywheel, as it is heavy. Note that the retaining
bolts must be renewed when refitting.

Inspection

3 The inspection procedures for the
flywheel/driveplate are the same as those
described for the HCS engine in Part A of this
Chapter, but note that the grinding
procedures do not apply to automatic
transmission models (the driveplate cannot be
reground).

Refitting

4 Check that the mating faces of the
flywheel/driveplate and crankshaft are clean
before refitting.
5 Smear the new retaining bolt threads with
thread-locking compound. Fit the
flywheel/driveplate into position on the rear
end face of the crankshaft. Check that all of
the bolt holes in the flywheel/driveplate are in
exact alignment with the corresponding bolt
holes in the crankshaft, then insert the bolts
and tighten them in a progressive sequence to
the specified torque wrench setting.
6 Refit the clutch (manual transmission
models) as described in Chapter 8.
7 Refit the transmission (according to type) as
described in Chapter 7.

2B•16 CVH engine – in-car engine repair procedures

20.2 Flywheel retaining bolts

2C

General

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

Four-cylinder, in-line, double overhead camshafts

Engine code:

1.6 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIE

1.8 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RDA, RQB

Capacity:

1.6 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1597 cc

1.8 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1796 cc

Bore:

1.6 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

76.0 mm

1.8 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

80.6 mm

Stroke - all models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

88.0 mm

Compression ratio:

1.6 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.3:1

1.8 litre models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.0:1

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

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

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

Clockwise (seen from right-hand side of vehicle)

Cylinder head

Hydraulic tappet bore inside diameter . . . . . . . . . . . . . . . . . . . . . . . . . .

28.395 to 28.425 mm

Camshafts and hydraulic tappets

Camshaft bearing journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25.960 to 25.980 mm

Camshaft bearing journal-to-cylinder head running clearance . . . . . . .

0.020 to 0.070 mm

Camshaft endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.080 to 0.220 mm

Lubrication

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

See Chapter 1

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

See Chapter 1

Oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

No information available at time of writing

Oil pump clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

No information available at time of writing

Chapter 2 Part C:
Zetec engine - in-car engine repair procedures

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

See Chapter 1

Camshaft oil seals - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Camshafts and hydraulic tappets - removal, inspection

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

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

3

Crankshaft oil seals - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Crankshaft pulley - removal and refitting . . . . . . . . . . . . . . . . . . . . .

8

Cylinder head - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . 14
Cylinder head and valve components - cleaning and

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

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

5

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 . . . . . . . . 19
Exhaust manifold - removal, inspection and refitting . . . . . . . . . . . .

7

Flywheel/driveplate - removal, inspection and refitting . . . . . . . . . . 18
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

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

6

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

2

Spark plug renewal . . . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 1

Sump - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Timing belt - removal, refitting and adjustment . . . . . . . . . . . . . . . . 10
Timing belt covers - removal and refitting . . . . . . . . . . . . . . . . . . . . .

9

Timing belt tensioner and toothed pulleys - removal, inspection

and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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

4

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

See Chapter 3

2C•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