Ford Orion. Manual — part 31

frostbite. They must also not be
discharged in an enclosed space, as there
is a risk of suffocation. The refrigerant is
heavier than air, and so must never be
discharged over a pit.

b)

The refrigerant must not be allowed to
come in contact with a naked flame,
otherwise a poisonous gas will be created
- under certain circumstances, this can
form an explosive mixture with air. For
similar reasons, smoking in the presence
of refrigerant is highly dangerous,
particularly if the vapour is inhaled
through a lighted cigarette.

c)

Never discharge the system to the
atmosphere - R134a is not an ozone-
depleting ChloroFluoroCarbon (CFC) as is
R12, but is instead a hydrofluorocarbon,
which causes environmental damage by
contributing to the “greenhouse effect” if
released into the atmosphere.

d)

R134a refrigerant must not be mixed with
R12; the system uses different seals (now
green-coloured, previously black) and has
different fittings requiring different tools,
so that there is no chance of the two
types of refrigerant becoming mixed
accidentally.

e)

If for any reason the system must be
disconnected, entrust this task to your
Ford dealer or a refrigeration engineer.

f)

It is essential that the system be profes-
sionally discharged prior to using any
form of heat - welding, soldering, brazing,
etc - in the vicinity of the system, before
having the vehicle oven-dried at a
temperature exceeding 70ºC after
repainting, and before disconnecting any
part of the system.

14 Air conditioning system

components -
removal and refitting

2

Warning: Refer to the
precautions given in the previous
Section before proceeding.

Note: This Section refers to the components
of the air conditioning system itself - refer to
Sections 11 and 12 for details of components
common to the heating/ventilation system.

Condenser

1 Have the refrigerant discharged at a dealer
service department or an automotive air
conditioning repair facility.
2 Disconnect the battery negative (earth) lead
(see Chapter 5, Section 1).
3 Secure the radiator to the front body panel
using string or wire to prevent it dropping
when the mounting bracket is removed in a
subsequent operation.
4 Apply the handbrake, then raise the front of
the vehicle and securely support it on axle
stands.
5 Undo the six plastic screws, and remove
the cover from under the condenser/radiator
mounting bracket.

6 Using the Ford service tool 34-001,
disconnect the refrigerant lines from the
condenser. Immediately cap the open fittings,
to prevent the entry of dirt and moisture.
7 Undo the two bolts and one nut securing
the dehydrator to the condenser/radiator
mounting bracket, and move the dehydrator
to one side.
8 Undo the two bolts each side securing the
condenser/radiator mounting bracket to the
body side members.
9 Detach the condenser and mounting
bracket from the right-hand then the left-hand
upper radiator mountings, and withdraw the
assembly from under the car.
10 Release the clips and remove the air
deflector from the condenser, then undo the
two nuts and remove the mounting bracket. If
required, unscrew the two mountings.
11 Refitting is the reversal of removal.
12 Have the system evacuated, charged and
leak-tested by the specialist who discharged
it.

Evaporator and blower motor

13 Have the refrigerant discharged at a
dealer service department or an automotive
air conditioning repair facility.
14 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1), followed
by the positive lead, then remove the battery
from its location.
15 For improved access, refer to Chapter 4
for details, and remove the air cleaner (where
applicable).
16 Peel back the seal strip from the top edge
of the bulkhead.
17 Cut the ties and detach the hose and
wiring loom from the bulkhead.
18 Undo the three bolts, and detach the air
conditioning pipe gasket retaining plate
complete with gasket, from the bulkhead.
19 Undo the six retaining bolts, and remove
the cover from the air chamber.
20 Release the evaporator housing cover
from its guides and remove it.
21 Undo the retaining bolt, and disconnect
the compressor low-pressure pipe and the
dehydrator liquid pipe from the front of the
expansion valve.
22 Disconnect the blower motor resistor
multi-plug, and disconnect the blower motor
earth lead at the connection on the body.
23 At the vacuum reservoir, disconnect the
multi-plugs for the vacuum motor switch and
de-ice switch, and detach the two vacuum
hoses. Undo the screw and remove the
vacuum reservoir assembly from the
evaporator housing.
24 Disconnect the two condensation hoses
from the front of the evaporator housing.
25 Undo the two bolts and two nuts, and
remove the evaporator housing from the
vehicle.
26 From the side of the evaporator housing,
release the vacuum motor linkage clamp
screw, then undo the two nuts and remove
the vacuum motor. Undo the two screws

securing the de-ice switch, and withdraw the
switch sensor.
27 Disconnect the blower motor resistor
wiring plug, then undo the three screws and
withdraw the evaporator housing cover.
28 Undo the two screws, release all the
retaining clips securing the upper and lower
halves of the evaporator housing, and lift off
the upper half.
29 Undo the two screws, and detach the
expansion valve from the side of the
evaporator. Recover the valve seals.
30 Lift the evaporator out of the lower half of
the housing.
31 To remove the blower motor, undo the
securing bolt from the motor retaining strap,
and lift out the motor.
32 Refitting is a reversal of the removal
procedure, but use new seals where
applicable, and tighten all fastenings to the
specified torque wrench settings (where
given).
33 Have the system evacuated, charged and
leak-tested by the specialist who discharged
it.

Compressor

34 Have the refrigerant discharged at a
dealer service department or an automotive
air conditioning repair facility.
35 Disconnect the battery negative (earth)
lead (see Chapter 5, Section 1).
36 Apply the handbrake, then raise the front
of the vehicle and securely support it on axle
stands.
37 Remove the auxiliary drivebelt (see
Chapter 1).
38 Undo the six plastic screws, and remove
the cover from under the condenser/radiator
mounting bracket.
39 Disconnect the compressor clutch wiring
multi-plug, then undo the retaining bolt to
detach the compressor high- and low-
pressure pipes.
40 Undo the four bolts, and remove the
compressor from its mounting bracket. Note:
Keep the compressor level during handling
and storage. If the compressor has seized, or
if you find metal particles in the refrigerant
lines, the system must be flushed out by an air
conditioning technician, and the dehydrator
must be renewed.
41 Refit the compressor in the reverse order
of removal; renew all seals disturbed.
42 Have the system evacuated, charged and
leak-tested by the specialist that discharged
it.

Dehydrator

43 Have the refrigerant discharged at a
dealer service department or an automotive
air conditioning repair facility.
44 Disconnect the battery negative (earth)
lead (see Chapter 5, Section 1).
45 Unscrew the pipe to the expansion valve
and the compressor connecting pipe at the
dehydrator.
46 Disconnect the high-pressure switch

3•12 Cooling, heating and air conditioning systems

multi-plug, then remove the high-pressure
switch.
47 Apply the handbrake, then raise the front
of the vehicle and securely support it on axle
stands.
48 Undo the six plastic screws, and remove
the cover from under the condenser/radiator
mounting bracket.
49 Undo the two bolts and one nut securing
the dehydrator to the condenser/radiator
mounting bracket, and remove the dehydrator
from under the vehicle.
50 Refit the dehydrator in the reverse order
of removal; renew all seals disturbed.
51 Have the system evacuated, charged and
leak-tested by the specialist that discharged
it.

Electric cooling fan motor

52 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
53 Detach the wiring multi-plugs from the air
conditioning fan motor and the motor resistor.
Cut free the cable ties securing the wires to
the bracket.
54 Working from above, unscrew the left-
hand retaining nut from the fan motor support
frame. Apply the handbrake, then raise and
support the vehicle, then working from
underneath, unscrew and remove the right-
hand retaining nut from the support frame.
55 Undo the four retaining bolts, and detach
the transmission brace (where fitted) from the
bearer and transmission flange.
56 Remove the starter motor (Chapter 5).
57 Detach and remove the exhaust
downpipe (Chapter 4).
58 Lift the support frame and fan motor from
the mounting each side, and withdraw it from
underneath the vehicle. If required, undo the
three retaining nuts and detach the fan unit
from the support frame (see illustration).
59 Refit in the reverse order of removal.
Tighten all fastenings to their specified torque
wrench settings (where given). Ensure that all
wiring connections are securely made and,
where applicable, relocate the wiring using
new cable ties.

De-ice switch

60 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1), followed
by the positive lead, then remove the battery
from its location.
61 For improved access, refer to Chapter 4
for details, and remove the air cleaner (where
applicable).
62 Peel back the seal strip from the top edge
of the bulkhead.
63 Cut the ties and detach the hose and
wiring loom from the bulkhead.
64 Undo the three bolts, and detach the air
conditioning pipe gasket retaining plate
complete with gasket, from the bulkhead.

65 Undo the six retaining bolts, and remove
the cover from the air chamber.
66 Release the evaporator housing cover
from its guides and remove it.
67 At the vacuum reservoir, disconnect the
multi-plugs for the vacuum motor switch and
de-ice switch, and detach the two vacuum
hoses. Undo the screw, and remove the
vacuum reservoir assembly from the
evaporator housing.
68 Undo the two bolts and two nuts, and
remove the evaporator housing from the
vehicle.
69 Undo the two screws securing the de-ice
switch, and withdraw the switch from the
housing.
70 Refitting is a reversal of the removal
procedure.

Air conditioning control switch

71 The switch is located in the main heating
and ventilation control panel. Remove the
control panel from the facia as described in
Section 12, then unclip the air
conditioning/blower motor switch from the
control unit.
72 Disconnect the wiring multi-plug and the
light lead from the switch.
73 Refit in the reverse order of removal.

Vacuum motor switch

74 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1), followed
by the positive lead, then remove the battery
from its location.
75 Detach the wiring multi-plug from the
vacuum motor switch, then undo the two
retaining screws and remove the switch from
the vacuum reservoir.
76 Refit in the reverse order of removal, but
ensure that the seal is seated correctly.

Vacuum motor

77 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1), followed
by the positive lead, then remove the battery
from its location.

78 For improved access, refer to Chapter 4
for details, and remove the air cleaner (where
applicable).
79 Peel back the seal strip from the top edge
of the bulkhead.
80 Cut the ties and detach the hose and
wiring loom from the bulkhead.
81 Undo the three bolts, and detach the air
conditioning pipe gasket retaining plate
complete with gasket, from the bulkhead.
82 Undo the six retaining bolts and remove
the cover from the air chamber.
83 Release the evaporator housing cover
from its guides and remove it.
84 From the side of the evaporator housing,
release the vacuum motor linkage clamp
screw, then undo the two nuts and remove
the vacuum motor. As it is withdrawn, detach
the vacuum hose (see illustration).
85 Refit in the reverse order of the removal.
Ensure that the vacuum hose and wiring
connections are securely made. Renew the
cable ties to relocate the wiring to the
bulkhead cover.

Vacuum reservoir

86 Proceed as described in paragraphs 77 to
83 inclusive above, then continue as follows.
87 Detach the two vacuum hoses from the
vacuum reservoir. Detach the wiring multi-
plug from the vacuum motor switch, then
undo the retaining screw and remove the
vacuum reservoir from the evaporator
housing.
88 Undo the two retaining screws and
remove the vacuum motor switch from the
reservoir.
89 Refit in the reverse order of the removal.
Ensure that the vacuum hose and wiring
connections are securely made. Renew the
cable ties to relocate the wiring to the
bulkhead cover.

Cooling, heating and air conditioning systems 3•13

14.84 Vacuum motor assembly

A Vacuum motor linkage clamp screw
B Vacuum motor
C Vacuum hoses
D Vacuum motor switch
E De-ice switch

14.58 Left-hand (A) and right-hand (B) fan

motor-to-support frame retaining nuts

(arrowed)

3

4A

Fuel grade

Fuel octane requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

95 RON unleaded

Fuel pump

Delivery pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.24 to 0.38 bars

Carburettor (general)

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Twin choke, downdraught

Application/identification:

1.3 HCS engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weber 2V TLDM

1.4 and 1.6 CVH engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weber 2V TLD

Choke type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual or automatic

Weber TLDM carburettor

Idle speed and mixture settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 1 Specifications

Fast idle speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2500 rpm

Float height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28 to 30 mm

Throttle kicker operating speed (automatic transmission) . . . . . . . . . . .

1800 to 2000 rpm
Primary

Secondary

Venturi diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19

20

Main jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90

122

Emulsion jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F113

F75

Air correction jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

185

130

Chapter 4 Part A:
Fuel and exhaust systems - carburettor engines

Accelerator (cam plate) cable (CTX automatic transmission

models) - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Accelerator cable (manual transmission models) - removal,

refitting and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Accelerator pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . .

5

Air cleaner - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Air cleaner element renewal . . . . . . . . . . . . . . . . . . . .

See Chapter 1

Automatic choke (Weber TLD carburettor) - adjustment . . . . . . . . . 21
Automatic choke (Weber TLD carburettor) - removal,

inspection and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Carburettor (Weber TLD) - fast idle speed adjustment . . . . . . . . . . . 19
Carburettor (Weber TLD) - description . . . . . . . . . . . . . . . . . . . . . . . 18
Carburettor (Weber TLD) - dismantling, cleaning/inspection

and reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Carburettor (Weber TLD) - removal and refitting . . . . . . . . . . . . . . . . 23
Carburettor (Weber TLDM) - description . . . . . . . . . . . . . . . . . . . . . . 12
Carburettor (Weber TLDM) - dismantling, cleaning, inspection

and reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Carburettor (Weber TLDM) - fast idle speed adjustment . . . . . . . . . 13
Carburettor (Weber TLDM) - removal and refitting . . . . . . . . . . . . . . 16
Catalytic converter . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 6

Choke cable - removal, refitting and adjustment . . . . . . . . . . . . . . .

6

Exhaust manifold - removal and refitting . . . . . . . . . .

See Chapter 2

Exhaust system - general information and component renewal . . . . 25
Exhaust system check . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 1

Fuel gauge sender unit - removal and refitting . . . . . . . . . . . . . . . . .

9

Fuel pump - testing, removal and refitting . . . . . . . . . . . . . . . . . . . .

7

Fuel tank - removal, inspection and refitting . . . . . . . . . . . . . . . . . . .

8

Fuel tank filler pipe - removal and refitting . . . . . . . . . . . . . . . . . . . . 11
General information and precautions . . . . . . . . . . . . . . . . . . . . . . . .

1

General fuel system checks . . . . . . . . . . . . . . . . . . . .

See Chapter 1

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

See Chapter 2

Needle valve and float (Weber TLD carburettor) -

removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 20

Needle valve and float (Weber TLDM carburettor) -

removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 14

Oxygen sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 6

Throttle kicker unit (Weber TLDM carburettor) -

removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 15

Roll-over valve - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . 10
Underbody fuel/brake line check . . . . . . . . . . . . . . . .

See Chapter 1

Underbonnet hose check . . . . . . . . . . . . . . . . . . . . . .

See Chapter 1

4A•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

Weber TLD carburettor

Idle speed and mixture settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See Chapter 1 Specifications

Float height:

1.4 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31.0 ± 0.5 mm

1.6 litre (without air conditioning) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31.0 ± 0.5 mm

1.6 litre (with air conditioning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29.0 ± 0.5 mm

Choke vacuum pull-down:

1.4 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 ± 0.5 mm

1.6 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7 ± 0.5 mm

Choke fast idle (on kickdown step):

1.4 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1900 ± 50 rpm

1.6 litre (with manual steering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1750 ± 50 rpm

1.6 litre (with power steering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Module-controlled

Venturi diameter:

Primary

Secondary

1.4 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

22

1.6 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

23

Main jet:

1.4 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

107

140

1.6 litre (without air conditioning) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115

140

1.6 litre (with air conditioning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115

127

Emulsion tube

1.4 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F105

F75

1.6 litre (without air conditioning) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F105

157

1.6 litre (with air conditioning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

F105

171

Air correction jet:

1.4 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

195

170

1.6 litre (without air conditioning) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180

150

1.6 litre (with air conditioning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

185

125

Throttle kicker speed:

1.4 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1400 rpm

1.6 litre . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1300 rpm

4A•2 Fuel and exhaust systems – carburettor engines

1

General information and
precautions

The fuel system on all models with

carburettor induction comprises a rear-
mounted fuel tank, a mechanical diaphragm
fuel pump, a carburettor and an air cleaner.

The fuel tank is mounted at the rear, under

the floorpan behind the rear seats. The tank
has a “ventilation-to-atmosphere system”
through a combined roll-over/anti-trickle fill
valve assembly, located in the left-hand rear
wheel arch. A filler neck sensing pipe, integral
with the fuel tank filler pipe, will shut off the
fuel pump filler gun when the predetermined
maximum level of fuel is reached in the tank,
so preventing spillage and wastage. A
conventional fuel level sender unit is mounted
in the top face of the fuel tank.

One of two fuel pump types will be fitted,

depending on the engine type. On HCS
engines, the fuel pump is operated by a
pivoting rocker arm; one end rests on an
eccentric lobe on the engine camshaft, and
the other end is attached to the fuel pump
diaphragm. The pump fitted to the CVH
engine is operated by a separate pushrod,
one end rests on an eccentric lobe on the
engine camshaft, and the other rests on the
pump actuating rod which operates the
diaphragm. Both types of mechanical pump
incorporate a nylon filter, and are of sealed
type (they cannot be serviced or overhauled).

A twin-venturi Weber carburettor is fitted,

further details being given in later Sections of
this Chapter.

The air cleaner incorporates a “waxstat”

controlled air intake, supplying either hot air
from a shroud mounted around the exhaust
manifold, or cool air from a duct in the front of
the vehicle.

Precautions

Warning: Many of the procedures
in this Chapter require the
removal of fuel lines and
connections, which may result in

some fuel spillage. 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. Before carrying out any operation
on the fuel system, refer also to the
precautions given in “Safety first!” at the
beginning of this manual, and follow them
implicitly. Petrol is a highly-dangerous and
volatile liquid, and the precautions
necessary when handling it cannot be
overstressed.

Reference must also be made to Chapter 5,

Section 1 for precautionary notes concerning
the ignition system and battery disconnection,
and to any further safety-related text
contained within the appropriate Section,
before working on the vehicle. When
disconnecting the automatic choke or other
coolant hoses, ensure that the cooling system
is not pressurised (refer to Chapter 2). Do not
work on or near a hot cooling system.

Certain adjustment points in the fuel system

are protected by tamperproof caps, plugs or
seals. In some territories, it is an offence to
drive a vehicle with broken or missing
tamperproof seals. Before disturbing a
tamperproof seal, first check that no local or
national laws will be broken by doing so, and
fit a new tamperproof seal after adjustment is
complete, where required by law. Do not
break tamperproof seals on any vehicle whilst
it is still under warranty.

When working on fuel system components,

scrupulous cleanliness must be observed,
and care must be taken not to introduce any
foreign matter into the fuel lines or
components. Carburettors in particular are
delicate instruments, and care must be taken
not to disturb any components unnecessarily.
Before attempting work on a carburettor,
ensure that the relevant spares are available;
it should be noted that a complete strip down
of a carburettor is unlikely to cure a fault
which is not immediately obvious, without
introducing new problems. If persistent
problems occur, it is recommended that the