Ford Orion. Manual - part 17

Remove the oil filler cap; if No 4 cylinder
exhaust cam lobe is pointing to the rear of the
vehicle and slightly downwards, it is No 1
cylinder that is correctly positioned. If the lobe
is pointing horizontally forwards, rotate the
crankshaft one full turn (360

∞

) clockwise until

the pulley notches align again, and the lobe is
pointing to the rear and slightly down. No 1
cylinder will then be at TDC on the
compression stroke.
11 Once No 1 cylinder has been positioned
at TDC on the compression stroke, TDC for
any of the other cylinders can then be located
by rotating the crankshaft clockwise 180

∞

at a

time and following the firing order (see Speci-
fications).
12 An alternative method of locating TDC is
to remove the cylinder head cover (see
Section 5) and to rotate the crankshaft
(clockwise, as described in paragraph 8
above) until the inlet valves for the cylinder
concerned have opened and just closed
again. Insert a length of wooden dowel
(approximately 150 mm/6 in long) or similar
into the spark plug hole until it rests on the
piston crown, and slowly further rotate the
crankshaft (taking care not to allow the dowel
to be trapped in the cylinder) until the dowel
stops rising - the piston is now at the top of its
compression stroke, and the dowel can be
removed.
13 There is a “dead” area around TDC (as the
piston stops rising, pauses and then begins to
descend) which makes difficult the exact

location of TDC by this method; if accuracy is
required, either establish carefully the exact
mid-point of the dead area, or refer to the
timing marks (paragraph 9 above).

5

Cylinder head cover -
removal and refitting

1

1 Remove the air inlet hose and inlet duct as
described in Chapter 4B.
2 Disconnect the accelerator cable from the
throttle linkage as described in Chapter 4B.
3 Remove the timing belt upper cover (see
Section 9).
4 Disconnect the crankcase breather hose
from the cylinder head cover union (see
illustration).
5 Unplug the HT leads from the spark plugs
and withdraw them, unclipping the leads from
the cover.
6 Working progressively, unscrew the
cylinder head cover retaining bolts, noting the
spacer sleeve and rubber seal at each, then
withdraw the cover (see illustration).
7 Discard the cover gasket; this must be
renewed whenever it is disturbed. Check that
the sealing faces are undamaged, and that the
rubber seal at each retaining bolt is
serviceable; renew any worn or damaged
seals.
8 On refitting, clean the cover and cylinder

head gasket faces carefully, then fit a new
gasket to the cover, ensuring that it locates
correctly in the cover grooves (see
illustration).
9 Refit the cover to the cylinder head, then
insert the rubber seal and spacer sleeve at
each bolt location (see illustration). Start all
bolts finger-tight, ensuring that the gasket
remains seated in its groove.
10 Working in a diagonal sequence from the
centre outwards, and in two stages (see
Specifications), tighten the cover bolts to the
specified torque wrench setting.
11 Refit the HT leads, clipping them into
place so that they are correctly routed; each is
numbered, and can also be identified by the
numbering on its respective coil terminal.
12 Reconnect the crankcase breather hose,
and refit the timing belt upper cover.
Reconnect and adjust the accelerator cable,
then refit the air inlet hose and duct (see
Chapter 4B).

6

Inlet manifold - 
removal and refitting

2

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

smoke, or allow naked 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 clothes dryer or water heater) is
installed. If you spill petrol on your skin,
rinse it off immediately. Have a fire
extinguisher rated for petrol fires handy,
and know how to use it.

Removal

1 Park the vehicle on firm, level ground and
apply the handbrake firmly.
2 Depressurise the fuel system (see Chap-
ter 4B).
3 Disconnect the battery negative (earth) lead
- see Chapter 5, Section 1.
4 Remove the air inlet hose and duct as
described in Chapter 4B.
5 Referring to Chapter 4B if necessary,

2C•6 Zetec engine – in-car engine repair procedures

5.9  Ensure rubber seal is fitted to each

cover bolt spacer, as shown

5.8  Ensure gasket is located correctly in

cover groove

5.6  Removing cylinder head cover

5.4  Disconnecting crankcase breather

hose from cylinder head cover union

4.9B  . . . use a straight edge extended out

from the sump (arrowed) if greater

accuracy is required

disconnect the accelerator cable from the
throttle linkage (see illustrations).
6 Disconnect the crankcase breather hose
from the cylinder head cover union.
7 Unbolt the upper part of the exhaust
manifold heat shield.
8 Remove the two screws securing the wiring
“rail” to the top of the manifold - this is simply
so that it can be moved as required to reach
the manifold bolts. Unplug their electrical
connectors to disconnect the camshaft
position sensor and the coolant temperature
sensor, then unclip the wiring from the ignition
coil bracket, and secure it to the manifold.
9 Remove the three screws securing the
wiring “rail” to the rear of the manifold.
Releasing its wire clip, unplug the large
electrical connector (next to the fuel pressure
regulator) to disconnect the wiring of the
manifold components from the engine wiring
loom.
10 Marking or labelling them as they are
unplugged, disconnect the vacuum hoses as
follows:
a)

One from the rear of the throttle housing
(only the one hose - there is no need to
disconnect the second hose running to
the fuel pressure regulator).

b)

One from the union on the manifold’s left-
hand end (see illustration).

c)

The braking system vacuum servo unit
hose (see Chapter 9 for details).

11 Equalise the pressure in the fuel tank by
removing the filler cap, then undo the fuel

feed and return lines connecting the engine to
the chassis (see Chapter 4B). Plug or cap all
open fittings.
12 Unbolt the earth lead from the cylinder
head rear support plate/engine lifting eye,
then unscrew the bolt securing the support
plate/lifting eye.
13 Unscrew the nuts and bolts securing the
manifold to the cylinder head, and withdraw it.
Take care not to damage vulnerable
components as the manifold assembly is
manoeuvred out of the engine compartment.

Refitting

14 Refitting is the reverse of the removal
procedure, noting the following points:
a)

When using a scraper and solvent to
remove all traces of old gasket material
and sealant from the manifold and
cylinder head, be careful to ensure that
you do not scratch or damage the mating
faces of either components. If the gasket
was leaking, have the mating surfaces
checked for warpage at an automotive
machine shop.

b)

Provided the relevant mating surfaces are
clean and flat, a new gasket will be
sufficient to ensure the joint is gastight.
Do not use any kind of silicone-based
sealant on any part of the fuel system or
inlet manifold.

c)

Fit a new gasket, then locate the manifold
on the head and install the nuts and bolts
(see illustration).

d)

Tighten the nuts/bolts in three or four
equal steps to the torque listed in this
Chapter’s Specifications. Work from the
centre outwards, to avoid warping the
manifold.

e)

Refit the remaining parts in the reverse
order of removal - tighten all fasteners to
the torque wrench settings specified.

f)

Before starting the engine, check the
accelerator cable for correct adjustment
and the throttle linkage for smooth
operation.

h)

When the engine is fully warmed-up,
check for signs of fuel, inlet and/or
vacuum leaks.

i)

Road-test the vehicle, and check for
proper operation of all disturbed
components.

7

Exhaust manifold - removal,
inspection and refitting

1

Warning: The engine must be
completely cool before beginning
this procedure.

Note: In addition to the new gasket and any
other parts, tools or facilities needed to carry
out this operation, a new plastic guide sleeve
will be required on reassembly.

Removal

1 Disconnect the battery negative (earth) lead
- see Chapter 5, Section 1.
2 Remove the air inlet hose and duct as
described in Chapter 4B.
3 Drain the cooling system (see Chapter 1).
4 Disconnect the coolant hose and the
coolant pipe/hose from the thermostat
housing; secure them clear of the working
area.
5 Unbolt the exhaust manifold heat shield,
and withdraw both parts of the shield (see
illustration).
6 While the manifold can be removed with the
pulse-air system components attached -
unbolt the filter housing and disconnect its
vacuum hose if this is to be done - it is easier

Zetec engine – in-car engine repair procedures  2C•7

6.10  Disconnecting the vacuum hoses

from the inlet manifold

6.5B  . . . then release the cable adjusting

clip and withdraw the cable from the

support bracket

6.5A  Disconnect the end of the

accelerator cable from the throttle 

linkage   . . .

7.5  Exhaust manifold heat shield upper

part securing bolts (arrowed)

6.14  Always renew inlet manifold gasket -

do not rely on sealants

2C

to remove the pulse-air assembly first, as
described in Chapter 6 (see illustration).
7 Unplug the oxygen sensor electrical
connector, to avoid straining its wiring.
Unscrew the nuts to disconnect the exhaust
system front downpipe from the manifold (see
Chapter 4B).
8 Remove the nuts and detach the manifold
and gasket (see illustration). When removing
the manifold with the engine in the vehicle,
additional clearance can be obtained by
unscrewing the studs from the cylinder head;
a female Torx-type socket will be required
(see illustration).
9 Always fit a new gasket on reassembly, to
carefully-cleaned components (see below).
Do not attempt to re-use the original gasket.

Inspection

10 Use a scraper to remove all traces of old
gasket material and carbon deposits from the
manifold and cylinder head mating surfaces. If
the gasket was leaking, have the manifold
checked for warpage at an automotive
machine shop, and have it resurfaced if
necessary. 

Caution: When scraping, be very
careful not to gouge or scratch
the delicate aluminium alloy
cylinder head.

11 Provided both mating surfaces are clean
and flat, a new gasket will be sufficient to
ensure the joint is gastight. Do not use any

kind of exhaust sealant upstream of the
catalytic converter.
12 Note that the downpipe is secured to the
manifold by two bolts, with a coil spring,
spring seat and self-locking nut on each. On
refitting, tighten the nuts until they stop on the
bolt shoulders; the pressure of the springs will
then suffice to make a gastight joint (see
illustrations).
13 Do not overtighten the nuts to cure a leak
- the bolts will shear; renew the gasket and
the springs if a leak is found. The bolts
themselves are secured by spring clips to the
manifold, and can be renewed easily if
damaged (see illustration).

Refitting

14 Refitting is the reverse of the removal
procedure, noting the following points:
a)

Position a new gasket over the cylinder
head studs, and fit a new plastic guide
sleeve to the stud nearest to the thermostat
housing, so that the manifold will be
correctly located (see illustration). Do not
refit the manifold without this sleeve.

b)

Refit the manifold, and finger-tighten the
mounting nuts.

c)

Working from the centre out, and in three
or four equal steps, tighten the nuts to the
torque wrench setting given in the Speci-
fications Section of this Chapter.

d)

Refit the remaining parts in the reverse
order of removal. Tighten all fasteners to
the specified torque wrench settings.

e)

Refill the cooling system (see Chapter 1).

f)

Run the engine, and check for exhaust
leaks. Check the coolant level when fully
warmed-up to normal operating
temperature.

8

Crankshaft pulley - 
removal and refitting

1

1 Remove the auxiliary drivebelt - either
remove the drivebelt completely, or just
secure it clear of the crankshaft pulley,
depending on the work to be carried out (see
Chapter 1).

2C•8 Zetec engine – in-car engine repair procedures

7.14  Fit plastic guide sleeve to stud

(arrowed) when refitting exhaust manifold

7.13  Release spring clip to extract

securing bolt from manifold, when

required

7.12B  Renew exhaust system downpipe-

to-manifold gasket to prevent leaks

7.12A  Showing exhaust downpipe-to-

manifold securing bolts - note coil spring,

and shoulder on bolt

7.8B  . . . studs can be unscrewed also, if

required, to provide additional working

space

7.8A  Unscrew nuts (arrowed) to remove

exhaust manifold . . .

7.6  Pulse-air system (sleeve nuts arrowed)

need not be removed unless required -

assembly can be withdrawn with exhaust

manifold

2 If necessary, rotate the crankshaft until the
timing marks align (see Section 4).
3 The crankshaft must now be locked to
prevent its rotation while the pulley bolt is
unscrewed. To do this, remove the starter
motor (Chapter 5) and lock the starter ring
gear teeth using a suitable screwdriver.
4 Unscrew the pulley bolt and remove the
pulley (see illustrations).
5 Refitting is the reverse of the removal
procedure; ensure that the pulley’s keyway is
aligned with the crankshaft’s locating key, and
tighten the pulley bolt to the specified torque
wrench setting.

9

Timing belt covers - 
removal and refitting

4

Upper cover

1 Unscrew the cover’s two mounting bolts
and withdraw it.
2 Refitting is the reverse of the removal
procedure; ensure that the cover edges
engage correctly with each other, and note the
torque wrench setting specified for the bolts.

Middle cover

3 Unscrew the nut securing the power
steering pipe support clip to the stud at the
rear of the middle cover. Lift the power
steering fluid reservoir upwards out of its
mounting bracket and move it clear, as far as
the hoses will allow, for access. If insufficient
clearance is obtained, disconnect the fluid
unions as necessary, and collect the fluid in a
suitable container. Plug or cover any
disconnected unions.
4 Slacken the water pump pulley bolts.
5 Remove the timing belt upper cover (see
paragraph 1 above).
6 Remove the auxiliary drivebelt (see Chapter 1).
7 Unbolt and remove the water pump pulley.
8 Unscrew the middle cover fasteners (one
bolt at the front, one at the lower rear, one
stud at the top rear) and withdraw the cover
(see illustration).
9 Refitting is the reverse of the removal
procedure. Ensure that the cover edges
engage correctly with each other, and note
the torque wrench settings specified for the
various fasteners.
10 If the power steering hoses where
disconnected, bleed the system as described
in Chapter 10 after reconnection.

Lower cover

11 Remove the crankshaft pulley (see
Section 8).
12 Unscrew the cover’s three securing bolts,
and withdraw it (see illustration).
13 Refitting is the reverse of the removal
procedure; ensure the cover edges engage
correctly with each other, and note the torque
wrench settings specified for the various
fasteners.

Zetec engine – in-car engine repair procedures  2C•9

9.8  Timing belt and cover details

8.4B  Ensure pulley is located on

crankshaft Woodruff key on reassembly

8.4A  Unscrew pulley bolt to release

crankshaft pulley

9.15  Timing belt inner shield fasteners

(arrowed)

9.12  Removing timing belt lower cover -

bolt locations arrowed

2C

1  Timing belt upper 

cover

2  Inlet camshaft 

toothed pulley

3  Exhaust camshaft 

toothed pulley

4  Timing belt
5  Timing belt 

tensioner

6  Crankshaft 

toothed pulley

7  Timing belt middle 

cover

8  Timing belt lower 

cover

9  Crankshaft pulley

10  Water pump pulley