Ford Orion. Manual — part 32

services of a Ford dealer or a carburettor
specialist are sought. Most dealers will be
able to provide carburettor rejetting and
servicing facilities. Where necessary, it may
be possible to purchase a reconditioned
carburettor.

Air cleaner -
removal and refitting

Note: Air cleaner element renewal and air
cleaner temperature control system checks
are described in Chapter 1.

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 On CVH engine models, pull free and
release the accelerator cable from the locating
clip on the side of the air cleaner.
3 Undo the three retaining bolts, and partially
lift the air cleaner from the carburettor so that
the hose and wiring connections to the
underside of the air cleaner body are
accessible.
4 Note their connections and routings, then
detach the wiring and hoses from the
underside of the air cleaner. On CVH engines,
also disconnect the vacuum hose from the
inlet manifold (see illustrations).
5 Lift the air cleaner clear from the carburettor.
6 If required, the intake air temperature

sensor can be unscrewed and removed from
the base of the air cleaner (where fitted).

Refitting

7 Refit in the reverse order of removal. Renew
any hoses that are perished or cracked, and
ensure that all fittings are securely and
correctly reconnected.

Accelerator cable (manual
transmission models) -
removal, refitting and adjustment

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Working inside the vehicle, disconnect the
cable from the top of the accelerator pedal,
release the grommet and pull the cable free
from the pedal (see illustration). Withdraw
the cable through the engine side of the
bulkhead.
3 Refer to Section 2 and remove the air
cleaner.
4 Detach the inner cable from the carburettor
linkage (see illustrations).
5 Prise free the retaining clip, detach the
outer cable from the support bracket, and
remove the cable.

Refitting and adjustment

6 To refit the cable, feed the inner cable

through the bulkhead, and reconnect the inner
cable to the accelerator pedal.
7 Locate the grommet in the bulkhead, then
push the outer cable into it to secure it in the
bulkhead.
8 Lubricate the cable grommet at the
carburettor end with a mild soapy solution,
then reconnect the cable to the carburettor.
Locate the outer cable by pulling it towards
the rocker cover.
9 Have an assistant depress the accelerator
pedal fully, and hold it in this position. The
outer cable should be seen to move in its
grommet. Refit the securing clip to the
bracket, then release the accelerator pedal.
10 Depress the accelerator pedal, then
release it and check that the throttle opens
and shuts fully. Further adjust if necessary
before refitting the air cleaner and
reconnecting the battery.

Accelerator (cam plate) cable
(CTX automatic transmission
models) - adjustment

1 Refer to Section 2 and remove the air
cleaner.
2 Release the cable by pressing the orange
(or red) button on the cable auto adjuster
mechanism. As the cable is released, it will be

Fuel and exhaust systems – carburettor engines 4A•3

2.4C Disconnecting the intake air

temperature sensor connector

(CVH engine)

2.4B Disconnecting the vacuum hose from

the inlet manifold (CVH engine)

2.4A Disconnecting the oil

separator/crankcase ventilation hose from

the air cleaner (CVH engine)

3.4B Cable connections to the carburettor

on the HCS engine

A Choke cable
B Accelerator cable
C Choke cable inner cable connection
D Choke cable support bracket connection

3.4A Accelerator inner (A) and outer (B)

cable connection to the CVH engine

3.2 Disconnecting the accelerator cable

from the pedal

heard to click. The cable shoulder will now be
seen to protrude from the adjuster
mechanism by approximately 20 mm (see
illustration).
3 Turn the cam plate by hand so that the
throttle moves to the fully-open position. Now
release the cam plate and close the throttle.
The cable will automatically adjust as
required, and the adjuster will be heard to
click as it makes the adjustment. The cable
shoulder will now be seen to protrude from
the auto adjuster mechanism by
approximately 10 mm.
4 Remove the clip from the cable adjusting
sleeve at the carburettor bracket, and pull the
adjusting sleeve right out (see illustration).
5 Have an assistant fully depress the
accelerator pedal, then refit the clip to the
cable adjusting sleeve. Release the pedal.
6 Depress the accelerator pedal once or
twice, to check that the throttle opens fully. If
necessary, repeat paragraphs 4 and 5.
7 Refit the air cleaner as described in Sec-
tion 2, and reconnect the battery earth lead.

Accelerator pedal -
removal and refitting

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Peel back the carpet and insulation from
the driver’s footwell to allow access to the
accelerator pedal.
3 Detach the accelerator cable from the pedal
(see Section 3), then release the circlip from
the pivot shaft and remove the accelerator
pedal.

Refitting

4 Refit in the reverse order of removal. On
completion, check the action of the pedal and
the cable to ensure that the throttle has full
unrestricted movement, and fully returns
when released.
5 Reconnect the battery earth lead.

Choke cable - removal,
refitting and adjustment

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Refer to Section 2 and remove the air
cleaner.
3 Carefully prise free the choke inner cable
from its linkage connection on the carburettor,
then release the outer cable from the support
bracket.
4 Release the choke control knob from the
cable by depressing the retaining pin on the
underside of the knob.
5 Undo the choke control-to-trim retaining
collar.
6 Undo and remove the screw securing the
choke control recessed trim, and remove the
trim and cable control. Detach the “choke on”
warning light lead from the control, then
withdraw the choke cable from the facia trim
(passing it through the bulkhead) (see
illustration).

Refitting

7 To refit the cable, first pass it through the
bulkhead and trim panel, then refit the
retaining collar and attach the wiring
connector. Fit the trim recess to the main trim

panel, and tighten the retaining screw to
secure. Push the knob into position on the
choke cable control so that it is felt to lock
into engagement.
8 Reconnect the inner choke cable to the
carburettor linkage.
9 Pull the choke control knob fully out (to the
full-on position). Return to the carburettor
end, and move the choke lever by hand to its
full-on position; hold it there whilst simultane-
ously reconnecting the outer cable to its
support bracket.

Adjustment

10 To check that the choke cable is correctly
adjusted, the control knob must be pulled out
to the full-on position and the choke lever
must be in contact with its stop (see
illustration). Adjust as required if necessary.
11 Press the choke knob fully in (to the off
position), then check that the choke linkage at
the carburettor has fully returned to its off
position and the choke valve plate in the
carburettor is at a right angle (90

∞

) to the

venturi.
12 Refit the air cleaner.
13 Reconnect the battery, turn the ignition
on, operate the choke and check that the
choke warning light operates correctly.

Fuel pump -
testing, removal and refitting

Warning: 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.

4A•4 Fuel and exhaust systems – carburettor engines

6.10 Choke cable adjustment

A Choke lever B Full choke stop
C Cable in “full-on” position

6.6 Disconnecting the wiring connector

from the choke control (control unit

removed for clarity)

4.4 Remove the clip from the cable

adjusting sleeve at the carburettor

bracket, and pull the adjusting sleeve right

out

4.2 Cam plate cable release showing

cable taut (A) and released (B). Also shown

are the release button (C) and 20 mm pre-

adjustment/10 mm post-adjustment

minimum protrusion (D)

Testing

1 Access to the fuel pump on HCS engine
models is best gained from underneath the
vehicle (see illustrations). Apply the
handbrake, then raise and support it on axle
stands at the front end.
2 The fuel pump may be tested by
disconnecting the fuel feed pipe from the
carburettor, and placing the pipe’s open end
in a suitable container.
3 Detach the multi-plug from the DIS ignition
coil, to prevent the engine from firing.
4 Actuate the starter motor. If the fuel pump
is in good working order, regular well-defined
spurts of fuel should eject from the open end
of the disconnected fuel pipe.
5 If this does not occur, and there is fuel in
the tank, the pump is defective and must be
renewed. The fuel pump is a sealed unit, and
cannot be repaired.

Removal

6 Two types of mechanical fuel pump are
fitted, the application depending on the
engine type. Some models may also be fitted
with a fuel vapour separator; if this is
removed, its hoses should be labelled to
avoid the possibility of confusion and
incorrect attachment on refitting.
7 To remove the fuel pump, first disconnect
the battery negative (earth) lead (refer to
Chapter 5, Section 1).
8 Where applicable, remove the air cleaner to
improve access to the fuel pump (see Sec-
tion 2).

9 Disconnect the fuel hoses from the fuel
pump, noting their respective connections for
refitting. Where quick-release couplings are
used on the fuel hoses, release the protruding
locking lugs on each union, by squeezing
them together and carefully pulling the
coupling apart. Use rag to soak up any spilt
fuel. Where the unions are colour-coded, the
pipes cannot be confused. Where both unions
are the same colour, note carefully which pipe
is connected to which, and ensure that they
are correctly reconnected on refitting. Plug
the hoses to prevent fuel spillage and the
ingress of dirt.
10 Unscrew and remove the retaining bolts
or nuts (as applicable) and remove the fuel
pump (see illustration).
11 Recover the gasket/spacer and if
required, withdraw the pump operating
pushrod (CVH engines only) (see illustration).
12 Thoroughly clean the mating faces on the
pump and engine.

Refitting

13 Refit in the reverse order of removal. Be
sure to use a new gasket, and tighten the
securing bolts/nuts securely. Ensure that the
hoses are correctly and securely reconnected.
If they were originally secured with crimped
type hose clips, discard them and fit screw
clamp type clips. Where quick-release
couplings are fitted, press them together until
the locking lugs snap into their groove.
14 When the engine is restarted, check the
pump connections for any signs of fuel leaks.

Fuel tank - removal,
inspection and refitting

Warning: Petrol is extremely
flammable, so take extra
precautions when you work on
any part of the fuel system. Don’t

Removal

1 Run the fuel level as low as possible prior to
removing the tank.
2 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
3 Remove the fuel filler cap, then syphon or
pump out the remaining fuel from the fuel tank
(there is no drain plug). The fuel must be
emptied into a suitable container for storage.
4 Chock the front wheels, then raise and
support the vehicle on axle stands at the rear.
5 Disconnect the fuel filler pipe from the fuel
tank (see illustration). Drain any remaining
fuel into the container for safe storage, and
plug the hose and tank connections.

Fuel and exhaust systems – carburettor engines 4A•5

7.10 Fuel pump removal from the

CVH engine

7.1B Fuel pump location on the

CVH engine

7.1A Underside view of the fuel pump

fitted to the HCS engine

8.6 Fuel tank sensing hose-to-pipe

connection (arrowed)

8.5 Fuel filler pipe connection to the fuel

tank. Note the handbrake cable locating

strap

7.11 Withdrawing the fuel pump pushrod

from the CVH engine

Disconnect the handbrake cable locating
strap from the fuel filler pipe on the tank.
6 Disconnect the filler neck sensing hose
from the rear of the tank (see illustration).
7 Support the underside of the fuel tank to
hold it in position, then remove the four tank
retaining bolts (see illustrations).
8 Partially lower the fuel tank, and detach the
ventilation tube from the tank top surface.
Also disconnect the fuel gauge sender unit
wiring multi-plug and the fuel hoses. Where
quick-release couplings are used on the fuel
hoses, release the protruding locking lugs on
each union, by squeezing them together and
carefully pulling the coupling apart.
9 Slowly lower the tank, and as it is
withdrawn, detach the filler pipe.

Inspection

10 Whilst removed, the fuel tank can be
inspected for damage or deterioration.
Removal of the sender unit (see Section 9) will
allow a partial inspection of the interior. If the
tank is contaminated with sediment or water,
swill it out with clean petrol. Do not under any
circumstances undertake any repairs on a
leaking or damaged fuel tank; this work must
be carried out by a professional who has
experience in this critical and potentially-
dangerous work.
11 Whilst the fuel tank is removed from the
vehicle, it should not be placed in an area
where sparks or open flames could ignite the
fumes coming out of the tank. Be especially
careful inside garages where a natural-gas
type appliance is located, because the pilot
light could cause an explosion.
12 Check the condition of the filler pipe seal
in the fuel tank, and renew it if necessary.

Refitting

13 Refitting is a reversal of the removal
procedure. Apply a light smear of grease to
the filler pipe seal, to ease fitting. Ensure that
all connections are securely fitted. Where
quick-release fuel couplings are fitted, press
them together until the locking lugs snap into
their groove. If evidence of contamination was
found, do not return any previously-drained
fuel to the tank unless it is carefully filtered
first.

Fuel gauge sender unit -
removal and refitting

Warning: 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 type
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.
Note: Ford specify the use of their service tool
23-014 or 23-026 (a large box spanner with
projecting teeth to engage the fuel gauge
sender unit retaining ring’s slots) for this task.
While alternatives are possible, in view of the
difficulty experienced in removing and refitting
the sender unit, owners are strongly advised
to obtain the correct tool before starting work.
The help of an assistant will be required.

Removal

1 Remove the fuel tank as described in
Section 8.
2 Engage the special tool into the sender unit
then carefully turn the sender unit and release
it from the tank (see illustration).

Refitting

3 Refit the sender unit in the reverse order of
removal. Be sure to fit a new seal, and
lubricate it with a smear of grease to prevent it
from distorting when fitting the sender unit.

10 Roll-over valve -

removal and refitting

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Chock the front wheels, then raise and
support the vehicle at the rear on axle stands.
Remove the rear wheel on the fuel filler cap
side to improve the access under the wheel
arch.
3 Undo the retaining screw, withdraw the roll-
over valve from the filler pipe, detach the vent
hoses and remove the valve (see illustration).

Refitting

4 Refit in the reverse order of removal.

11 Fuel tank filler pipe -

removal and refitting

Warning: Petrol is extremely
flammable, so take extra
precautions when you work on
any part of the fuel system. Don’t

Removal

1 Refer to Section 8 and remove the fuel tank.
2 Detach the roll-over valve clamp, undo the
filler pipe securing screws, then lower the pipe
from the vehicle.

4A•6 Fuel and exhaust systems – carburettor engines

10.3 Roll-over valve location on fuel filler

pipe

9.2 Sender unit removal from the fuel tank

using special tool No 23-014

8.7B Fuel tank securing bolt at the front

edge

8.7A Fuel tank retaining bolt locations

(arrowed)

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Ford Orion. Manual — part 32

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