Target Audience:
Do-it-yourselfers and experienced mechanics seeking to maintain or repair their Ford Orion
Value Proposition:
Inexpensive way to keep vehicle working properly, providing detailed illustrations, diagrams, and step-by-step instructions.
Content Features:
Detailed illustrations, diagrams, wiring schematics, specifications, step-by-step instructions, notes, cautions, warnings, numbered instructions, bold figure numbers, troubleshooting, and electrical service procedures.
Engine Mechanical:
Yes (General Information, Engine Mechanical System)
Engine Electrical:
Yes (Engine Electrical System)
Emission Control:
Yes (Emission Control System)
Fuel System:
Yes (Fuel System)
Suspension:
Yes (Suspension System)
Clutch:
Yes (Clutch System)
Manual Transmission:
Yes (Manual Transaxle System)
Automatic Transmission:
Yes (Automatic Transaxle System)
Drivetrain:
Yes (Driveshaft and Axle)
Steering:
Yes (Steering System)
Brakes:
Yes (Brake System)
Body Interior Exterior:
Yes (Body Interior and Exterior)
Body Electrical:
Yes (Body Electrical System)
Restraints:
Yes (Restraint)
Exhaust System:
Yes (Coverage of exhaust components, catalytic converter, and related systems)
Cooling System:
Yes (Radiator, fan, thermostat, water pump, coolant hoses)
Air Conditioning:
Yes (If factory fitted, including refrigerant handling precautions and component service)
Wheels And Tires:
Yes (Specifications for wheel sizes, tire sizes, inflation pressures, and wheel alignment)
Maintenance:
Yes (Routine maintenance, fluid changes, filter replacements, tune-ups)
Troubleshooting:
Yes (Diagnostic procedures, fault finding for all systems)
Repair:
Yes (Step-by-step repair instructions for all covered systems)
Overhaul:
Yes (Component disassembly, cleaning, inspection, reassembly, and adjustment)
Electrical Diagnostics:
Yes (Wiring diagrams, troubleshooting combined with electrical service procedures)
Adjustments:
Includes procedures for setting ignition timing, idle speed, clutch adjustment, parking brake adjustment, etc.
Depth:
Comprehensive (Suitable for DIY enthusiasts and professional mechanics, covering basic maintenance to complex repairs and diagnostics)
Diagnostics:
Detailed diagnostic procedures for engine management, fuel injection, ignition, ABS (if fitted), and other electronic systems.
Engine Options:
1.4L CVH-EA/EFI, 1.6L CVH-EFI, 1.8L DOHC Zetec-R, 1.8L Diesel (DOHC DI Turbo)
Typical Horsepower Range:
Approximately 75-130 PS (56-97 kW) depending on engine variant.
Typical Torque Range:
Approximately 115-165 Nm (85-122 lb-ft) depending on engine variant.
Fuel Delivery:
Multi-point fuel injection (MPI) for petrol engines, Diesel injection for diesel engines.
Ignition Type:
Electronic ignition system (Distributorless Ignition System - DIS on some later models)
Body Styles:
4-door Sedan
Wheelbase Mm:
2606 mm (approx. 102.6 inches)
Length Mm:
4350-4430 mm (approx. 171.3-174.4 inches)
Width Mm:
1700-1720 mm (approx. 66.9-67.7 inches)
Height Mm:
1380-1400 mm (approx. 54.3-55.1 inches)
Curb Weight Kg:
1050-1200 kg (approx. 2315-2645 lbs), varies by engine and trim
Crash Test Data:
Limited public availability for this specific model year range in many regions. European NCAP testing standards evolved significantly during this period.
Braking System:
Front ventilated discs, rear drums; ABS optional on higher trims.
Seatbelts:
Three-point front seatbelts, two-point rear seatbelts (three-point rear seatbelts often optional or standard on later models).
Airbags:
Driver airbag typically optional or standard on late models (1996-1997), not universally equipped.
Audio System:
Factory fitted AM/FM radio with cassette player; later models may have CD compatibility. Speaker configurations vary by trim level.
Dashboard Features:
Analog instrument cluster (speedometer, tachometer, fuel gauge, engine temperature gauge), warning lights, basic climate controls.
Cruise Control:
Optional on higher trim levels, particularly on 1.8L Zetec models.
Auxiliary Ports:
Not typically equipped with auxiliary or USB ports in factory configuration.
Oil Change Interval:
Typically 10,000-15,000 km (6,000-9,000 miles) or 12 months, whichever comes first, depending on driving conditions and oil type used.
Spark Plug Replacement:
Intervals vary by spark plug type (copper, platinum, iridium); typically 20,000-60,000 km (12,000-37,000 miles).
Engine Oil Type:
API SG/SH or ACEA A2/A3 compliant. Viscosity grades such as 5W-30, 10W-40, or 15W-40, depending on climate and manufacturer recommendation. (e.g., Ford recommend WSS-M2C153-E).
Coolant Type:
Ethylene glycol-based antifreeze/coolant, typically mixed 50/50 with distilled water. Ford specification WSS-M97B44-C or equivalent.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Transmission Fluid Manual:
Gear oil, e.g., API GL-4, SAE 75W-90 or 80W-90.
Transmission Fluid Automatic:
Automatic Transmission Fluid (ATF) meeting Ford specification WSS-M2C195-A or MERCON. Often a Dexron-II/III type.
Common Problems:
Corrosion (wheel arches, sills, boot floor), aging electrical components (connectors, wiring loom insulation), aging rubber hoses and mounts, minor coolant leaks, clutch wear, exhaust system rust.
Ford Europe History:
The Ford Orion was a key model in Ford of Europe's compact car lineup, developed from the Ford Escort.
Generation Overview:
The Orion nameplate was used for the saloon (sedan) version of the Ford Escort from the Mk3 generation (1983) through to the Mk5 generation (ending in 1997). The 1990-1997 models correspond to the Escort Mk5 and Mk6 platforms.
Manufacturing Locations:
Primarily manufactured in Germany (Saarlouis) and the UK (Dagenham).
Production Period:
1983-1993 (Orion Mk3), 1993-1997 (Orion Mk5/Mk6 - essentially Escort Mk5/Mk6 saloon variants).
