Ford Orion. Manual - part 3

Maintenance & Servicing  

1•9

1

Underside view at rear end showing

component locations on a 1.3 litre

Hatchback model

1  Fuel filler pipe
2  Handbrake cable adjuster
3  Fuel tank
4  Suspension mounting
5  Rear axle beam
6  Exhaust rear silencer
7  Exhaust system support/insulator

Underside view at rear end showing

component locations on a 1.6 litre Estate

model

1  Fuel filler pipe
2  Shock absorber
3  Handbrake cable
4  Fuel tank
5  Suspension mounting
6  Rear axle beam
7  Rear coil spring
8  Exhaust system rear silencer

3

Fluid level checks

2

General

1 Fluids are an essential part of the
lubrication, cooling, braking and other
systems. Because these fluids gradually
become depleted and/or contaminated during
normal operation of the vehicle, they must be
periodically replenished. See “Lubricants and
fluids and capacities” at the beginning of this
Chapter before adding fluid to any of the
following components. Note: The vehicle
must be on level ground before fluid levels are
checked, to ensure accuracy.

Engine oil

2 The engine oil level is checked with a
dipstick located at the front of the engine; it
can be identified by its yellow/black plastic
grip (see illustration). The dipstick extends
through a metal tube, from which it protrudes
down into the sump at the bottom of the
engine.

3 The oil level should be checked before the
vehicle is driven, or about 5 minutes after the
engine has been switched off.

4 Pull the dipstick from the tube, and wipe all
the oil from the end with a clean rag or paper
towel; note the dipstick’s maximum and
minimum levels, indicated by notches (see
illustration). Insert the clean dipstick all the
way back into its metal tube, and pull it out
again. Observe the oil on the end of the
dipstick; its level should be between these
two notches.
5 Do not allow the level to drop below the

1

Introduction

This Chapter is designed to help the home

mechanic maintain the Ford Escort and Orion
models for peak performance, economy,
safety and long life.

On the following pages is a master

maintenance schedule, followed by Sections
dealing specifically with each item on the
schedule. Visual checks, adjustments,
component replacement and other helpful
items are included. Refer to the
accompanying illustrations of the engine
compartment and the underside of the vehicle
for the location of various components.

Servicing your Escort or Orion in

accordance with the mileage/time
maintenance schedule and the following

Sections will provide it with a planned
maintenance programme, which should result
in a long and reliable service life. This is a
comprehensive plan, so maintaining some
items but not others at the specified service
intervals will not produce the same results.

As you service your car, you will discover

that many of the procedures can - and should
- be grouped together, because of the nature
of the particular procedure you’re performing,
or because of the close proximity to one
another of two otherwise-unrelated
components.

For example, if the vehicle is raised for any

reason, you should inspect the exhaust,
suspension, steering and fuel systems while
you’re under the vehicle. When you’re
checking the tyres, it makes good sense to
check the brakes and wheel bearings,
especially if the roadwheels have already
been removed.

Finally, let’s suppose you have to borrow or

hire a torque wrench. Even if you only need to
tighten the spark plugs, you might as well
check the torque of as many critical fasteners
as time allows.

2

Routine maintenance

The first step of this maintenance

programme is to prepare yourself before the
actual work begins. Read through all the
Sections which are relevant to the procedures
you’re planning to carry out, then make a list of,
and gather together, all the parts and tools you
will need to do the job. If it looks as if you might
run into problems during a particular segment
of some procedure, seek advice from your
local parts man or dealer service department.

1•10

Weekly Checks

3.6C  Topping-up the engine oil level

(Zetec engine)

3.6B  Topping-up the engine oil level 

(CVH engine)

3.6A  Topping-up the engine oil level 

(HCS engine)

3.4  Engine oil dipstick MAXimum and

MINimum level markings

3.2  Engine oil dipstick location (arrowed)

on Zetec engines

Weekly checks

If the level is checked
immediately after driving the
vehicle, some of the oil will
remain in the engine upper

components, producing an inaccurate
dipstick reading.

minimum level notch, or oil starvation may
cause engine damage. Conversely, overfilling
the engine (adding oil above the maximum
level notch) may cause oil-fouled spark plugs,
oil leaks or oil seal failures.
6 The oil filler cap is screwed into the left-
hand front end of the cylinder head/rocker
cover; unscrew it to add oil (see
illustrations). When topping-up, use only the
correct grade and type of oil, as given in
“Lubricants, fluids and capacities” at the start
of this Chapter; use a funnel if necessary to
prevent spills. It takes approximately 0.5 to
1.0 litre of oil to raise the level from the
dipstick’s minimum level notch to its
maximum level notch. After adding the oil,
refit the filler cap hand-tight. Start the engine,
and allow it to idle while the oil is redistributed
around the engine - while you are waiting,
look carefully for any oil leaks, particularly
around the oil filter or drain plug. Stop the
engine; check the oil level again, after the oil
has had enough time to drain from the upper
block and cylinder head galleries.
7 Checking the oil level is an important
preventive maintenance step. A continually-
dropping oil level indicates oil leakage through
damaged seals and from loose connections,
or oil consumption past worn piston rings or
valve guides. If the oil looks milky in colour, or
has water droplets in it, the cylinder head
gasket may be blown - the engine’s
compression pressure should be checked
immediately (see Chapter 2). The condition of
the oil should also be checked. Each time you
check the oil level, slide your thumb and index
finger up the dipstick before wiping off the oil.
If you see small dirt or metal particles clinging
to the dipstick, the oil should be changed
(Section 16).

Coolant

Warning: Do not allow antifreeze
to come in contact with your skin
or painted surfaces of the
vehicle. Flush contaminated

areas immediately with plenty of water.
Don’t store new coolant, or leave old
coolant lying around, where it’s accessible
to children or pets - they’re attracted by its
sweet smell. Ingestion of even a small
amount of coolant can be fatal! Wipe up
garage-floor and drip-pan spills
immediately. Keep antifreeze containers
covered, and repair cooling system leaks
as soon as they’re noticed.

8 All vehicles covered by this manual are
equipped with a sealed, pressurised cooling
system. A translucent plastic expansion tank,
located on the right-hand side of the engine
compartment, is connected by a hose to the
thermostat housing. As the coolant heats up
during engine operation, surplus coolant
passes through the connecting hose into the
expansion tank; a connection to the radiator
bottom hose union allows coolant to circulate
through the tank and back to the water pump,
thus purging any air from the system. As the

engine cools, the coolant is automatically
drawn back into the cooling system’s main
components, to maintain the correct level.
9 While the coolant level must be checked
regularly, remember therefore that it will vary
with the temperature of the engine. When the
engine is cold, the coolant level should be
between the “MAX” and “MIN” level lines on
the tank, but once the engine has warmed up,
the level may rise to above the “MAX” level
line.
10 For an accurate check of the coolant
level, the engine must be cold. The level must
be between the “MAX” and “MIN” level lines
on the tank (see illustration). If it is below the
“MIN” level line, the coolant must be topped-
up as follows.
11 First prepare a sufficient quantity of
coolant mixture, using clean, soft water and
antifreeze of the recommended type, in the
specified mixture ratio. If you are using
antifreeze to Ford’s specification or equivalent
(see “Antifreeze - notes on renewal” in Section
28), mix equal quantities of water and
antifreeze to produce the 50/50 mixture ratio
specified when topping-up; if using any other
type of antifreeze, follow its manufacturer’s
manuals to achieve the correct ratio. If only
a small amount of coolant is required to bring
the system up to the proper level, plain water
can be used, but repeatedly doing this will
dilute the antifreeze/water solution in the
system, reducing the protection it should
provide against freezing and corrosion. To
maintain the specified antifreeze/water ratio, it
is essential to top-up the coolant level with
the correct mixture, as described here. Use
only ethylene/glycol type antifreeze, and do
not use supplementary inhibitors or additives.

Warning: Never remove the
expansion tank filler cap when
the engine is running, or has just
been switched off, as the cooling

system will be hot, and the consequent
escaping steam and scalding coolant
could cause serious injury.
12 If topping-up is necessary, wait until the
system has cooled completely (or at least 10
minutes after switching off the engine, if lack
of time means it is absolutely necessary to
top-up while the engine may still be warm).
Wrap a thick cloth around the expansion tank

filler cap, and unscrew it one full turn. If any
hissing is heard as steam escapes, wait until
the hissing ceases, indicating that pressure is
released, then slowly unscrew the filler cap
until it can be removed. If more hissing
sounds are heard, wait until they have
stopped before unscrewing the filler cap
completely. At all times, keep your face,
hands and other exposed skin well away from
the filler opening.
13 When the filler cap has been removed,
add coolant to bring the level up to the “MAX”
level line (see illustration). Refit the cap,
tightening it securely.
14 With this type of cooling system, the
addition of coolant should only be necessary
at very infrequent intervals. If topping-up is
regularly required, or if the coolant level drops
within a short time after replenishment, there
may be a leak in the system. Inspect the
radiator, hoses, expansion tank filler cap,
radiator drain plug and water pump. If no leak
is evident, have the filler cap and the entire
system pressure-tested by your dealer or
suitably-equipped garage; this will usually
show up a small leak not otherwise visible. If
significant leakage is found at any time, use
an antifreeze hydrometer to check the
concentration of antifreeze remaining in the
coolant.
15 Coolant hydrometers are available at
most automotive accessory shops. If the
specific gravity of a sample taken from the
expansion tank (when the engine is switched
off and fully cooled down) is less than that
specified, the coolant mixture strength has
fallen below the minimum. If this is found,
either the coolant strength must be restored
by adding neat antifreeze to Ford’s
specification (if that is what is in the system)
or by draining and flushing the system, then
refilling it with fresh coolant mixture of the
correct ratio (if any other type of antifreeze is
being used).
16 When checking the coolant level, always
note its condition; it should be relatively clear.
If it is brown or rust-coloured, the system
should be drained, flushed and refilled. If
antifreeze has been used which does not
meet Ford’s specification, its corrosion
inhibitors will lose their effectiveness with
time; such coolant must be renewed regularly,

Weekly Checks  

1•11

3.13  Topping-up the coolant level with

specified antifreeze mixture

3.10  Coolant reservoir MAXimum and

MINimum level marks

1

even if it appears to be in good condition,
usually at the intervals suggested in
“Antifreeze - notes on renewal” in Section 28.

Windscreen/tailgate and
headlight washer fluid

17 Fluid for the windscreen/tailgate washer
system (and, where applicable, the headlight
washer system) is stored in a plastic reservoir,
which is located at the left-hand front corner
of the engine compartment. In milder
climates, plain water can be used to top-up
the reservoir, but the reservoir should be kept
no more than two-thirds full, to allow for
expansion should the water freeze. In colder
climates, the use of a specially-formulated
windscreen washer fluid, available at your
dealer or any car accessory shop, will help
lower the freezing point of the fluid (see
illustration). Do not use regular (cooling
system) antifreeze - it will damage the
vehicle’s paintwork.

Battery electrolyte

18 On models not equipped with a sealed
battery (see Section 9), check the electrolyte
level of all six battery cells. The level must be
approximately 10 mm above the plates; this
may be shown by maximum and minimum
level lines marked on the battery’s casing. If
the level is low, use a coin to release the
filler/vent cap, and add distilled water. Install
and securely retighten the cap.

Caution: Overfilling the cells may
cause electrolyte to spill over
during periods of heavy charging,
causing corrosion or damage.

Refer also to the warning at the beginning
of Section 9.

Brake fluid

19 The brake fluid reservoir is located on the
top of the brake master cylinder, which is
attached to the front of the vacuum servo unit.
The “MAX” and “MIN” marks are indicated on
the side of the translucent reservoir, and the
fluid level should be maintained between
these marks at all times (see illustration).
20 The brake fluid inside the reservoir is
readily visible. With the vehicle on level

ground, the level should normally be on or just
below the “MAX” mark.
21 Progressive wear of the brake pads and
brake shoe linings causes the level of the
brake fluid to gradually fall; however, when
the brake pads are renewed, the original level
of the fluid is restored. It is not therefore
necessary to top-up the level to compensate
for this minimal drop, but the level must never
be allowed to fall below the minimum mark.
22 If topping-up is necessary, first wipe the
area around the filler cap with a clean rag
before removing the cap. When adding fluid,
pour it carefully into the reservoir, to avoid
spilling it on surrounding painted surfaces
(see illustration). Be sure to use only the
specified hydraulic fluid (see “Lubricants,
fluids and capacities” at the start of this
Chapter) since mixing different types of fluid
can cause damage to the system.

Warning: Brake hydraulic fluid
can harm your eyes and damage
painted surfaces, so use extreme
caution when handling and

pouring it. Wash off spills immediately with
plenty of water. Do not use fluid that has
been standing open for some time, as it
absorbs moisture from the air. Excess
moisture can cause corrosion and a
dangerous loss of braking effectiveness.
23 When adding fluid, it is a good idea to
inspect the reservoir for contamination. The
system should be drained and refilled if
deposits, dirt particles or contamination are
seen in the fluid.

24 After filling the reservoir to the correct
level, make sure that the cap is refitted
securely, to avoid leaks and the entry of
foreign matter.
25 If the reservoir requires repeated
replenishing to maintain the correct level, this
is an indication of an hydraulic leak
somewhere in the system, which should be
investigated immediately.

Power steering fluid

26 See Section 5 of this Chapter.

4

Tyre and tyre pressure
checks

1

1 Periodic inspection of the tyres may spare
you from the inconvenience of being stranded
with a flat tyre. It can also provide you with
vital information regarding possible problems
in the steering and suspension systems
before major damage occurs.
2 The original tyres on this vehicle are
equipped with tread wear indicator (TWI)
bands, which will appear when the tread
depth reaches approximately 1.6 mm. Most
tyres have a mark around the tyre at regular
intervals to indicate the location of the tread
wear indicators, the mark being TWI, an
arrow, or the tyre manufacturer’s symbol (see
illustration).

1•12

Weekly Checks

4.2  The TWI marks on the side of the tyre

shows the position of the tread wear

indicator bands

3.22  Topping-up the fluid level in the brake

master cylinder reservoir

3.19  Brake master cylinder showing

“MAX” and “MIN” marks

3.17  Checking the level of fluid in the

washer reservoir

Tread wear can be monitored with a
simple inexpensive device known as a
tread depth indicator gauge.