Escort.Orion 1991 (08.1990-09.2001): Mechanical Repairs
General
Choose Sections to see everything in a chapter, or a chapter title to start at its first page.
1 General Information12 pages
100 About this Manual4 pages
101 General Service Information7 pages
- 101-01 Health and Safety Precautions › Description and Operation › Introduction
- 101-02 Vehicle Identification › Description and Operation › Vehicle Identification Plate Location
- 101-03 Standard Workshop Practices › Description and Operation › Vehicle in Workshop
101-05 Solvents, Sealers and Adhesives › Description and Operation2 pages
- 101-04 Application and Use of Specifications › Description and Operation › Bolt Head Identification Marks - Standard Hardware
- 101-06 Road or Roller Testing › Description and Operation › Road or Roller Testing
- 195 Quick Reference › 195-01 List of Abbreviations › SpecificationsIntroduction
2 Chassis104 pages
- 211 Wheels, Tyres › 211-01 Wheels, Tyres › SpecificationsGeneral Specifications
212 Standard Braking System42 pages
212-01 Standard Braking System27 pages
- SpecificationsGeneral Specifications
Description and Operation26 pages
- Description and Operation
Removal and Installation25 pages
- Valve - Light Laden-Load Apportioning (Van) - Adjust (12 136 0)
- Brake System (Conventional) - Bleed (12 141 0)
- Brake System (Pressure) - Bleed (12 141 0)
- Disc Pads - Front - Remove And Install (Both Sides) (12 234 0)
- Disc Pads - Rear (RS 2000) (Both Sides) - Remove And Install (12 238 0)
- Caliper Assembly - Front - Remove And Install (One Side) (12 243 0)
- Disc - Rear Brake (RS 2000) - Remove And Install (12 225 0)
- Caliper Piston Housing - Front - Remove And Install (One Side) (12 245 0)
- Shoes - Rear Brake (RS 2000 Handbrake) (One Side) - Remove And Install (12 285 0)
- Caliper Assembly - Rear (RS 2000) (One Side) - Remove And Install (12 253 0)
- Shoes - Rear Brake - Remove And Install (12 285 0)
- Brake Pedal - Remove And Install (12 333 0)
- Back Plate - Rear Brake - Remove And Install (One Side) (12 313 0)
- Brake Fluid Reservoir - Remove And Install (12 341 0)
- Connecting Link - Servo Operating - Remove And Install (12 338 0)
- Master Cylinder - Remove And Install (12 343 0)
- Brake Vacuum Pump - Renew (12 414 0)
- Servo - Remove And Install (12 451 0)
- Vacuum Hose - Servo - Remove And Install (12 481 0)
- Handbrake (Vehicles built 1-95 onwards) - Adjust (12 662 0)
- Lever Assembly - Handbrake - Remove And Install (12 664 0)
- Handbrake (Vehicles built up to 12-94) - Adjust (12 662 0)
- Rear Cable - Handbrake - Remove And Install (12 675 0)
- Valve - Light Laden-Load Apportioning (Van) - Remove And Install (12 752 0)
- Primary Cable - Handbrake - Remove And Install (12 673 0)
212-02 Anti-lock Braking System (Teves Mk. 20-I)(96 MY Onwards)5 pages
- SpecificationsGeneral Specifications
Description and Operation4 pages
212-03 Anti-lock Braking System (SCS)7 pages
- SpecificationsGeneral Specification
Removal and Installation6 pages
- Brake System - Bleed (SCS) (12 141 0)
- Modulator - Left-Hand Side - Remove And Install (12 760 0)
- Brake System - Bleed (Conventional) (12 141 0)
- Drive Belt - Modulator - Remove And Install (Left-Hand Side) (12 762 0)
- Modulator - Right-Hand Side - Remove And Install (12 761 0)
- Drive Belt - Modulator - Remove And Install (Right-Hand Side) (12 762 0)
212-04 Anti-lock Braking System (Teves Mk. IV)3 pages
213 Steering21 pages
213-01 Manual Steering8 pages
- SpecificationsGeneral Specifications
Description and Operation7 pages
- Description and Operation
Removal and Installation6 pages
- Steering Gear Assembly - Remove And Install (13 116 0)
- Gaiter - Steering Rack - Remove And Install (13 134 0)
- Track Rod - Remove And Install (Steering Gear Assembly Removed) (13 263 5)
- Steering Wheel - Remove And Install (13 524 0)
- Steering Wheel - Centralise (13 523 0)
- Steering Column Assembly - Remove And Install (13 542 0)
213-02 Power Assisted Steering13 pages
- SpecificationsGeneral Specifications
Description and Operation12 pages
- Description and Operation
Removal and Installation11 pages
- Power Steering System - Bleed (13 416 1)
- Track Rod - Remove And Install (Steering Gear Assembly Removed) (13 263 5)
- Steering Gear Assembly - Remove And Install (13 116 0)
- Pump Assembly - Power Steering - Remove And Install (CVH and PTE) (13 434 0)
- Pump Assembly - Power Steering - Remove And Install (Zetec) (13 434 0)
- Pump Assembly - Power Steering (Endura-DE and TD without Air Conditioning) - Remove And Install (13 434 0)
- Pump Assembly - Power Steering - Remove And Install (Endura-DE and TD with Air Conditioning) (13 434 0)
- Pump Assembly - Power Steering - Remove And Install (Pre-Endura-DE) (13 434 0)
- Fluid Cooler - Power Steering - Remove And Install (13 444 0)
- Fluid Hoses - Power Steering - Remove And Install (13 442 0)
- Seal - Pinion Assembly - Renew (13 468 0)
214 Front Axle, Suspension and Driveshafts21 pages
214-01 Front Suspension11 pages
- SpecificationsGeneral Specifications
Description and Operation10 pages
- Description and Operation
Removal and Installation9 pages
- Toe-In - Adjust (14 111 3)
- Front Wheel Alignment - Check (14 111 0)
- Stabiliser Bar - Remove And Install (14 752 0)
- Subframe - Remove And Install (14 240 0)
- Arm Assembly - Lower - Right-hand Side - Remove And Install (14 707 0)
- Wheel Bearing - Front Inner And Outer - Renew (Hub Or Spindle Carrier Assembly Removed) (14 411 4)
- Spindle Carrier - Remove And Install (14 343 0)
- Suspension Unit - Front - Renew (Suspension Unit Assembly Removed) (14 783 4)
- Suspension Unit Assembly - Front - Remove And Install (14 781 0)
214-02 Front Axle and Driveshafts10 pages
- SpecificationsGeneral Specifications
Removal and Installation9 pages
- Seal - Inner - Right-hand Front Axle Driveshaft - Renew (14 304 0)
- Front Axle Driveshaft - Left - Remove and Install (14 320 0)
- Seal - Inner - Left-hand Front Axle Driveshaft - Renew (14 303 0)
- Front Axle Driveshaft - Right - Dismantle and Assemble (front axle driveshaft removed) (14 321 8)
- Front Axle Driveshaft - Right - Remove and Install (14 321 0)
- Gaiter - Front Driveshaft - Inner - Remove and Install (14 336 0)
- Driveshaft Joint - Outer (14 326 0)
- Intermediate Driveshaft - Remove and Install (14 330 0)
- Gaiter - Front Driveshaft - Outer - Remove and Install (14 338 0)
215 Rear Axle and Suspension19 pages
215-01 Rear Axle and Suspension12 pages
- SpecificationsGeneral Specifications
Description and Operation11 pages
- Description and Operation
Removal and Installation10 pages
- Rear Axle Assembly - Remove And Install (Saloon) (15 214 0)
- Rear Axle Assembly - Remove And Install (Van) (15 214 0)
- Bearings - Rear Wheel - Inner And Outer - Renew (Hub Assembly Removed) (15 413 4)
- Rear Axle Assembly - Remove And Install (Wagon) (15 214 0)
- Suspension Unit Assembly - Rear - Remove And Install (15 781 0)
- Suspension Unit - Rear - Renew (Suspension Unit Assembly Removed) (15 783 4)
- Shock Absorber - Rear - Remove And Install (Van) (15 791 0)
- Rear Spring Assembly - Remove And Install (Van) (15 621 0)
- Bush - Pivot - Rear Suspension - Renew (15 730 0)
- Shock Absorber - Rear - Remove And Install (Wagon) (15 791 0)
215-02 Rear Axle, Suspension and Driveshafts7 pages
- SpecificationsGeneral Specifications
Removal and Installation6 pages
- Rear Axle and Suspension Assembly - Remove and Install (15 212 0)
- Rear Axle Assembly - Remove and Install (15 214 0)
- Rear Axle Assembly - Dismantle and Assemble (15 214 8)
- Bearings - Rear Wheel - Inner and Outer - Renew (hub asssembly removed) (15 413 4)
- Shaft - Rear Axle - Remove and Install (15 231 0)
- Stub Axle - Rear - Remove and Install (15 363 0)
3 Powertrain301 pages
316 Manual Transmission and Clutch24 pages
316-01 B5 Manual Transmission and Clutch7 pages
- SpecificationsGeneral Specifications
Description and Operation6 pages
- Description and Operation
Removal and Installation5 pages
- B5 Transmission (with HCS engine) - Remove and Install (16 114 0)
- Transmission - Remove and Install (16 114 0)
- Transmission - Dismantle and Assemble (16 118 8)
- Clutch Pedal Free Travel - Adjust (16 713 0)
- Clutch Disc and Pressure Plate - Remove and Install (Engine or Transmission Removed) (16 724 4)
316-02 Manual Transmission and Clutch7 pages
- SpecificationsGeneral Specifications
Description and Operation6 pages
- Description and Operation
Removal and Installation5 pages
- Transmission Assembly - Remove and Install (16 114 0)
- Transmission Assembly - Dismantle and Reassemble (Transmission Removed) (16 118 8)
- Clutch Pedal Free Travel - Adjust (16 713 0)
- Transmission Assembly - Renew (Transmission Assembly Removed) (16 115 5)
- Clutch Disc and Pressure Plate - Remove and Install (Engine Or Transmission Removed) (16 724 4)
316-03 MTX 75 Manual Transmission and Clutch7 pages
- SpecificationsGeneral Specifications
Description and Operation6 pages
- Description and Operation
Removal and Installation5 pages
- MTX 75 Manual Transmission (with 1,8 Zetec engine) - Remove and Install (16 114 0)
- Transmission Assembly - Remove and Install (16 114 0)
- MTX 75 Transmission - Dismantle and Assemble (16 118 8)
- Selector Mechanism - Dismantle and Assemble (16 284 8)
- Clutch Disc and Pressure Plate - Remove and Install (Engine or Transmission Removed) (16 724 4)
316-04 MTX 75 Transmission 4x43 pages
317 Automatic Transmission › 317-01 CTX Automatic Transmission15 pages
- SpecificationsGeneral Specifications
Description and Operation14 pages
- Description and Operation
Removal and Installation13 pages
- Automatic Transmission - Remove and Install (17 214 0)
- Automatic Transmission - Dismantle and Assemble (Transmission Removed) (17 214 8)
- Speedometer Drive Pinion - Remove and Install (17 382 0)
- Valve Body Assembly Dismantle and Assemble (17 234 8)
- Selector Cable - Adjust (17 666 0)
- Selector Lever Assembly Remove and Install (17 634 0)
- Cam Plate Actuating Cable - Remove and Install (17 681 0)
- Selector Cable - Remove and Install (17 667 0)
- Start Inhibitor Switch - Remove and Install (17 694 0)
- Cam Plate Actuating Cable - Adjust (17 680 0)
- Automatic Transmission Fluid Cooler Pipes - Remove and Install (17 857 0)
- Oil Seal - Driveshaft-Planet Carrier - Change (transmission removed) (17 144 4)
- Oil Seal - Transmission Selector Lever - Renew (17 676 0)
321 Engine89 pages
321-01 1,4 PTE Engine15 pages
- SpecificationsGeneral Specifications
Description and Operation14 pages
- Description and Operation
Removal and Installation13 pages
- Oil Pressure - Engine Hot - Check (21 113 0)
- Compression - Engine Hot - Check (21 111 0)
- Engine and Transmission Assembly - Remove and Install (21 132 0)
- Engine Assembly - Dismantle and Assemble (Engine Removed) (21 134 8)
- Oil Pan - Remove And Install (Transmission Removed) (21 154 4)
- Cylinder Head - Remove and Install (21 163 0)
- Cylinder Head - Renew (New Head Supplied With Valves) (Cylinder Head Removed) (21 165 5)
- Seals - Valve Stem - Renew (All) (21 238 0)
- Camshaft - Remove and Install (21 283 0)
- Timing Belt - Remove and Install (21 304 0)
- Oil Seal - Crankshaft Front - Renew (21 467 0)
- Seal - Camshaft - Renew (21 288 0)
- Seal - Crankshaft Rear - Renew (Engine or Transmission Removed) (21 468 4)
321-02 1,6 CVH Engine11 pages
- SpecificationsGeneral Specifications
Removal and Installation10 pages
- Oil Pressure - Engine Hot - Check (21 113 0)
- Compression Pressure - Engine Hot - Check (21 111 0)
- Engine and Transmission Assembly - Remove and Install (21 132 0)
- Engine - Dismantle and Assemble (Engine Removed) (21 134 8)
- Cylinder Head - Remove and Install (21 163 0)
- Cylinder Head - Renew (New Head Supplied With Valves) (Cylinder Head Removed) (21 165 5)
- Valve Stem Seals - Renew (21 238 0)
- Camshaft - Remove and Install (21 283 0)
- Seal - Camshaft - Renew (21 288 0)
- Timing Belt - Remove and Install (21 304 0)
321-03 1,3 HCS Engine10 pages
- SpecificationsGeneral Specifications
Description and Operation9 pages
- Description and Operation
Removal and Installation8 pages
- Compression - Check - Engine Hot (21 111 0)
- Oil Pressure - Check - Engine Hot (21 113 0)
- Engine - Remove and Install (21 134 0)
- Engine - Dismantle and Reassemble (engine removed) (21 134 8)
- Seals - Valve Stem - Renew (21 238 0)
- Cylinder Head - Remove and Install (21 163 0)
- Crankshaft Front Oil Seal - Renew (21 467 0)
- Crankshaft Rear Oil Seal - Renew (engine or transmission removed) (21 468 4)
321-04 1,3 Endura Engine3 pages
- Specifications
Description and Operation2 pages
321-05 DOHC 16V Engine (Zetec-Zetec-E)15 pages
- SpecificationsGeneral Specifications
Description and Operation14 pages
- Description and Operation
Removal and Installation13 pages
- Oil Pressure - Engine Hot - Check (21 113 0)
- Compression Pressure - Engine Hot - Check (21 111 0)
- Engine and Transmission Assembly - Remove and Install (21 132 0)
- Engine - Dismantle and Assemble (Engine Removed) (21 134 8)
- Sump - Remove and Install (21 154 0)
- Cylinder Head - Remove and Install (21 163 0)
- Cylinder Head - Renew (New Head Supplied With Valves) (Cylinder Head Removed) (21 165 6)
- Valve Stem Seals - Renew (21 238 0)
- Camshafts - Remove and Install (21 284 0)
- Timing Belt - Remove and Install (21 304 0)
- Seal - Crankshaft Rear - Renew (Engine or Transmission Removed) (21 468 4)
- Oil Seal - Crankshaft Front - Renew (21 467 0)
- Oil Pump - Remove and Install (21 714 0)
321-06 1,8 Diesel Engine3 pages
Description and Operation2 pages
- Specifications
321-07 1,8 Endura-DE (TC) Engine3 pages
Description and Operation2 pages
- Specifications
321-08 1,8 Endura-DE (TCI) Engine14 pages
- SpecificationsGeneral Specifications
Description and Operation13 pages
- Description and Operation
Removal and Installation12 pages
- Compression Pressure - Engine Hot - Check (21 111 0)
- Oil Pressure - Engine Hot - Check (21 113 0)
- Engine and Transmission Assembly - Remove and Install (21 132 0)
- Engine - Dismantle and Assemble (Engine Removed) (21 134 8)
- Valve Clearances - Adjust (21 213 0)
- Cylinder Head - Remove and Install (21 163 0)
- Valve Stem Seals - Renew (21 238 0)
- Camshaft - Remove and Install (21 283 0)
- Seal - Camshaft - Renew (21 288 0)
- Timing Belt - Remove and Install (21 304 0) (Vehicles with a mechanical timing belt tensioner)
- Oil Seal - Crankshaft Front - Renew (21 467 0)
- Timing Belt - Remove and Install (21 304 0) (Vehicles with an automatic timing belt tensioner)
321-09 2.0l DOHC 16V Engine15 pages
- SpecificationsGeneral Specifications
Description and Operation14 pages
- Description and Operation
Removal and Installation13 pages
- Oil Pressure - Engine Hot - Check (21 113 0)
- Compression - Engine Hot - Check (21 111 0)
- Engine And Transmission Assembly - Remove And Install (21 132 0)
- Engine - Dismantle and Assemble (engine removed) (21 134 8)
- Cylinder Head - Renew (cylinder head removed) (21 165 6)
- Cylinder Head - Remove And Install (21 163 0)
- Seals - Valve Stem - Renew (All) (21 238 0)
- Valve Guide - Ream (One) (Valve Removed) (21 233 4)
- Valve Seat - Cut (One) (Valve(s) Removed) (21 231 9)
- Camshaft - Remove and Install (21 283 0)
- Seal - Crankshaft Front - Renew () (21 467 0)
- Seal - Crankshaft Rear - Remove (Engine or Transmission Removed) (21 468 4)
- Timing Chain - Renew (21 314 0)
323 Fuel System81 pages
323-01 General Fuel System17 pages
- SpecificationsGeneral Specifications
Description and Operation16 pages
- Description and Operation
Removal and Installation15 pages
- Fuel Trap (1.4 CVH TBI Variants) - Remove And Install (22 623 0)
- Fuel Pump (Fuel Injected Variants) - Renew (23 534 0)
- Fuel Pump (1.4 - 1.6 CVH TBI Variants) - Remove And Install (23 534 0)
- Fuel Pump (1.1 - 1.3 HCS Variants) - Remove And Install (23 534 0)
- Fuel Filter (1.6 CVH EFI Variants) - Renew (23 545 0)
- Fuel Filter (2.0 DOHC Variants) - Renew (23 545 0)
- Fuel Pump (Four-Wheel Drive Variants) - Renew (23 534 0)
- Fuel Filter (Zetec Variants up to 96 MY) - Remove And Install (23 545 0)
- Fuel Tank (Four-Wheel Drive Variants) - Remove And Install (23 554 0)
- Fuel Tank (Front-Wheel Drive Variants) - Remove And Install (23 554 0)
- Fuel Tank (Van) - Remove And Install (23 554 0)
- Filler Pipe - Fuel Tank (Front-Wheel Drive Variants) - Remove And Install (23 572 0)
- Filler Pipe - Fuel Tank (Van) - Remove And Install (23 572 0)
- Switch - Fuel Shut-off (All) - Renew (33 577 0)
- Filler Pipe - Fuel Tank (Four-Wheel Drive Variants) - Remove And Install (23 572 0)
323-02 Fuel System - 1,1-1,3 HCS Engines7 pages
- SpecificationsGeneral Specifications
Description and Operation6 pages
323-03 Fuel System - 1,4-1,6 CVH Engines6 pages
- SpecificationsGeneral Specifications
Description and Operation5 pages
323-04 Fuel Injection Equipment - 2.0 DOHC 16V Engine4 pages
- SpecificationsGeneral Specifications
Description and Operation3 pages
323-05 Fuel Injection Equipment - Zetec-Zetec-E Engines8 pages
- SpecificationsGeneral Specifications
Description and Operation7 pages
- Description and Operation
Removal and Installation6 pages
- Fuel Pressure Regulator (Zetec) - Remove And Install (23 266 0)
- Cable - Accelerator (Zetec) - Adjust (23 811 0)
- Fuel Injectors (Zetec) - Remove And Install (23 455 0)
- Cable - Accelerator (Zetec-E) - Adjust (23 811 0)
- Fuel Injectors (Zetec-E) - Remove And Install (23 455 0)
- Fuel Pressure Regulator (Zetec-E) - Remove And Install (23 266 0)
323-06 Fuel Injection Equipment - 1,3 HCS TBI Engine6 pages
- SpecificationsGeneral Specifications
Description and Operation5 pages
323-07 Fuel Injection Equipment - 1.4 PTE - PT-E Engines4 pages
- SpecificationsGeneral Specifications
Description and Operation3 pages
- Description and Operation
Removal and Installation2 pages
323-08 Fuel Injection Equipment - Diesel Engines13 pages
- SpecificationsGeneral Specifications
Description and Operation12 pages
- Description and Operation
Removal and Installation11 pages
- Fuel Injection Pump - Idle Speed (Air-Conditioned Variants) - Adjust (23 413 0)
- Fuel Injection Pump - Idle Speed (Non Air-Conditioned Variants) - Adjust (23 413 0)
- Fuel Injection Pump (Normally aspirated diesel engines) - Remove And Install (23 414 0)
- Fuel Injection Pump (Turbocharged diesel engines) - Remove And Install (23 414 0)
- Element - Fuel Filter - Renew (23 546 0)
- Fuel Injector (All) - Renew (23 455 0)
- Charge Air Cooler - Remove And Install (23 620 0)
- Turbocharger (Intercooled Variants) - Remove And Install (23 612 0)
- Turbocharger (Non-Intercooled Variants) - Remove And Install (23 612 0)
- Heater - Diesel Fuel - Remove And Install (23 769 0)
- Glow Plugs (All) - Remove And Install (23 777 0)
323-09 Fuel Injection Equipment - 1.4 CVH TBI Engine5 pages
- SpecificationsGeneral Specifications
Description and Operation4 pages
323-10 Fuel Injection Equipment - 1.6 CVH EFI Engine7 pages
Description and Operation6 pages
- SpecificationsGeneral Specification
323-11 Fuel Injection Equipment - 1.3 Endura-E Engine4 pages
- SpecificationsGeneral Specifications
Description and Operation3 pages
- Description and Operation
Removal and Installation2 pages
324 Cooling System23 pages
324-01 Cooling System - Petrol Engines17 pages
- SpecificationsGeneral Specifications
Description and Operation16 pages
- Description and Operation
Removal and Installation15 pages
- Motor - Fan (Zetec) - Remove And Install (24 222 0)
- Cooling System - Drain And Refill (24 122 0)
- Motor - Fan (1.4 PTE-PTE-E) - Remove And Install (24 222 0)
- Motor - Fan (2.0 DOHC 16V) - Remove And Install (24 222 0)
- Motor - Fan (Endura-E) - Remove And Install (24 222 0)
- Radiator (2.0 DOHC 16V without Air Conditioning) - Remove And Install (24 254 0)
- Radiator (Zetec) - Remove And Install (24 254 0)
- Radiator (2.0 DOHC 16V with Air Conditioning) - Remove And Install (24 254 0)
- Radiator (Endura-E) - Remove And Install (24 254 0)
- Water Pump Assembly (Zetec) - Remove And Install (24 404 0)
- Water Pump Assembly (CVH) - Remove And Install (24 404 0)
- Water Pump Assembly (2.0 DOHC 16V) - Remove And Install (24 404 0)
- Thermostat (1.4 PTE-PTE-E) - Remove And Install (24 454 0)
- Water Pump Assembly (HCS) - Remove And Install (24 404 0)
- Thermostat (2.0 DOHC 16V) - Remove And Install (24 454 0)
324-02 Cooling System – Diesel Engine6 pages
- SpecificationsGeneral Specifications
Description and Operation5 pages
325 Exhaust System › 325-01 Exhaust System11 pages
- SpecificationsGeneral Specifications
Description and Operation10 pages
- Description and Operation
Removal and Installation9 pages
- Exhaust System (TC Diesel) - Renew (25 205 0)
- Exhaust System (Diesel) - Renew (25 205 0)
- Catalytic Converter (Zetec and Diesel) - Remove And Install (25 250 0)
- Exhaust System (HCS) - Renew (25 205 0)
- Exhaust System (Zetec) - Renew (25 205 0)
- Catalytic Converter (Diesel with Downpipe-Catalytic Converter Assembly) - Remove And Install (25 250 0)
- Catalytic Converter (Zetec 96 MY Onwards) - Remove And Install (25 250 0)
- Catalytic Converter (HCS) - Remove And Install (25 250 0)
- Catalytic Converter (HCS with Downpipe-Catalytic Converter Assembly) - Remove And Install (25 250 0)
326 Starting system › 326-01 Starting System3 pages
329 Engine Management55 pages
329-01 Engine Management - 1.1 - 1.3 HCS Engines2 pages
329-02 Engine Management - 1,4-1,6 CVH Engines2 pages
329-03 Engine Management - 2.0 DOHC 16V Engine6 pages
- SpecificationsGeneral Specifications
Description and Operation5 pages
329-04 Engine Management - Zetec-Zetec-E Engines4 pages
- SpecificationsGeneral Specifications
Description and Operation3 pages
329-05 Engine Management - 1,3 HCS TBI Engine5 pages
- SpecificationsGeneral Specifications
Description and Operation4 pages
329-06 Engine Management - 1.4 PTE - PT-E Engines › Description and Operation4 pages
329-07 Engine Management - Diesel Engines12 pages
- SpecificationsGeneral Specifications
Description and Operation11 pages
- Description and Operation
Removal and Installation10 pages
- Sensor - Engine Coolant Temperature - Remove And Install (21 190 0)
- Valve-Gasket - Exhaust Gas Recirculation (Turbocharged Non-Intercooled Engines) - Renew (23 312 0)
- Module - Powertrain Control (Turbocharged Intercooled Engines) - Remove And Install (29 200 0)
- Valve-Gasket - Exhaust Gas Recirculation (Turbocharged Intercooled Engines) - Renew (23 312 0)
- Sensor - Crankshaft Position - Check And Adjust Alignment (29 231 0)
- Module - Powertrain Control (Turbocharged Non-Intercooled Engines) - Remove And Install (29 200 0)
- Actuator - Idle Speed Compensation System (Turbocharged Non-Intercooled Engines) - Remove And Install (29 315 0)
- Electronic Vacuum Regulator (Turbocharged Intercooled Engines) - Remove And Install (29 245 0)
- Cable - Actuator - Idle Speed Compensation System (Turbocharged Non-Intercooled Engines) - Remove And Install (29 316 0)
- Electronic Vacuum Regulator (Turbocharged Non-Intercooled Engines) - Remove And Install (29 245 0)
329-08 Engine Management - 1.4 CVH TBI Engine › Description and Operation8 pages
- Description and Operation
Removal and Installation7 pages
- Motor - Throttle Plate Control - Remove And Install (23 255 0)
- Pipe Assembly - Pulsed Secondary Air Injection - Renew (23 316 0)
- Valve - Evaporative Emission Canister Purge - Remove And Install (33 772 0)
- Canister - Evaporative Emission - Remove And Install (29 250 0)
- Sensor - Manifold Absolute Pressure - Remove And Install (29 224 0)
- Module - Powertrain Control - Remove And Install (29 200 0)
- Module - Electronic Ignition System - Remove And Install (29 205 0)
329-09 Engine Management - 1.6 CVH EFI Engine9 pages
- SpecificationsGeneral Specifications
Description and Operation8 pages
- Description and Operation
Removal and Installation7 pages
- Sensor - Heated Oxygen - Renew (29 220 0)
- Valve - Idle Air Control - Remove And Install (23 323 0)
- Valve - Evaporative Emission Canister Purge (83 US Emission Level) - Remove And Install (33 772 0)
- Sensor - Manifold Absolute Pressure - Remove And Install (29 224 0)
- Module - Powertrain Control - Remove And Install (29 200 0)
- Module - Electronic Ignition System - Remove And Install (29 205 0)
- Canister - Evaporative Emission (83 US Emission Level) - Remove And Install (29 250 0)
329-10 Engine Management - 1.3 Endura-E Engine3 pages
4 Electrical136 pages
431 Charging System › 431-01 Charging System16 pages
- SpecificationsGeneral Specifications
Description and Operation15 pages
- Description and Operation
Removal and Installation14 pages
- Drive Belt - Alternator (2.0 DOHC 16V with Air Conditioning) - Remove And Install (31 413 0)
- Drive Belt - Alternator (Zetec) - Remove And Install (31 413 0)
- Drive Belt - Alternator (CVH with Power Assisted Steering) - Remove And Install (31 413 0)
- Drive Belt - Alternator (HCS - Endura-E) - Remove And Install (31 413 0)
- Drive Belt - Alternator (1.8 Diesel) - Remove And Install (31 413 0)
- Alternator Assembly (Zetec) (Up To 95½ MY) - Remove And Install (31 414 0)
- Alternator Assembly (Zetec) (95½ MY onwards) - Remove And Install (31 414 0)
- Alternator Assembly (1.8 Diesel) - Remove And Install (31 414 0)
- Alternator Assembly (Zetec) (96 MY onwards)) - Remove And Install (31 414 0)
- Alternator Assembly (2.0 DOHC 16V) - Remove And Install (31 414 0)
- Alternator Assembly (Endura-E) - Remove And Install (31 414 0)
- Alternator Assembly (1.8 Diesel with Power Assisted Steering) - Remove And Install (31 414 0)
- Alternator Assembly (HCS) - Remove And Install (31 414 0)
- Alternator Assembly (CVH with Power Assisted Steering) - Remove And Install (31 414 0)
432 Exterior Electrical Systems › 432-01 Exterior Electrical Systems14 pages
- SpecificationsGeneral Specifications
Description and Operation13 pages
- Description and Operation
Removal and Installation12 pages
- Headlamp - Remove and Install (Escort 91 and 93) (32 115 0)
- Headlamps - Align (32 113 0)
- Windscreen Wiper Motor - Remove and Install (32 524 0)
- Bracket - Windscreen Wiper Motor and Linkage - Remove and Install (32 550 0)
- Headlamp - Remove and Install (Escort 95 1-2) (32 115 0)
- Headlamp - Remove and Install (XR3i) (32 115 0)
- Reservoir - Windscreen Washer - Remove and Install (Escort 95 1-2) (32 622 0)
- Pivot Shaft - Windscreen Wiper - Remove and Install (one) (32 563 0)
- Motor - Headlamp Levelling - Remove and Install (Escort 95 1-2) (32 650 0)
- Wiper Arms - Adjust (32 591 0)
- Motor - Headlamp Levelling - Remove and Install (XR3i) (32 650 0)
- Nozzles - Headlamp Wash - Remove and Install (Escort 95 1-2) (32 678 0)
433 Interior Electrics - Basic System62 pages
433-01 Basic Interior Electrical System38 pages
- SpecificationsGeneral Specifications
Description and Operation37 pages
- Description and Operation
Removal and Installation36 pages
- Bezel - Instrument Cluster (95½ MY Onwards) - Remove And Install (33 212 0)
- Instrument Cluster Assembly (Up To 95½ MY) - Remove And Install (33 214 0)
- Printed Circuit - Instrument Cluster (95 MY Onwards) - Remove And Install (Instrument Cluster Removed) (33 224 4)
- Instrument Cluster Assembly (95½ MY Onwards) - Remove And Install (33 214 0)
- Printed Circuit - Instrument Cluster (Up To 95½ MY) - Remove And Install (Instrument Cluster Removed) (33 224 4)
- Clock (95½ MY Onwards) - Remove And Install (33 374 0)
- Gauge - Fuel (Up To 95½ MY) - Remove And Install (Instrument Cluster Removed) (33 284 4)
- Cable - Speedometer - Inner And Outer - Remove And Install (33 256 0)
- Head - Speedometer (Up To 95½ MY) - Remove And Install (Instrument Cluster Removed) (33 254 4)
- Tachometer (Up To 95½ MY) - Remove And Install (Instrument Cluster Removed) (33 264 4)
- Sender Unit - Fuel Tank - Remove And Install (33 286 0)
- Slip Ring - Horn - Remove And Install (33 391 0)
- Lock Barrel - Ignition Switch - Remove And Install (33 513 0)
- Cigar Lighter Assembly (Up To 95½ MY) - Remove And Install (33 384 0)
- Cigar Lighter Assembly (95½ MY Onwards) - Remove And Install (33 384 0)
- Switch - Heated Windscreen (95½ MY Onwards) - Remove And Install (33 571 0)
- Switch - Auxiliary-Fog Lamp (95½ MY Onwards) - Remove And Install (33 556 0)
- Switch - Handbrake Warning Light (Up To 95½ MY) - Remove And Install (33 546 0)
- Switch - Handbrake Warning Light (95½ MY Onwards) - Remove And Install (33 546 0)
- Switch - Rear Fog Lamp (95½ MY Onwards) - Remove And Install (33 557 0)
- Switch - Headlamp Levelling - Remove And Install (33 515 0)
- Switch - Window Operating (95½ MY Onwards) - Remove And Install (33 532 0)
- Switch - Stop Light - Remove And Install (33 548 0)
- Switch - Heated Rear Window (95½ MY Onwards) - Remove And Install (33 572 0)
- Relay - Window Operating - Remove And Install (33 732 0)
- Switch - Blower Motor - Heater (95½ MY Onwards) - Remove and Install (33 574 0)
- Switch - Multifunction (Steering Column) - Remove And Install (33 612 0)
- Relay - Window Operating (Cabriolet) - Remove And Install (33 732 0)
- Switch - Blower Motor - Heater (Up To 95½ MY) - Remove and Install (33 574 0)
- Actuator Assembly - Front Door Latch - Renew (33 779 0)
- Motor - Sliding Roof Operating - Remove And Install (33 786 0)
- Actuator Assembly - Rear Door Latch - Renew (33 780 0)
- Actuator - Luggage Compartment Door-Liftgate-Tailgate - Renew (33 781 0)
- Motor - Window Operating - Front Door (Cabriolet) - Remove And Install (33 782 0)
- Motor - Window Operating - Rear Door (Cabriolet) - Remove And Install (33 783 0)
- Mask Assembly - Heater Control Illumination (95½ MY Onwards) - Remove And Install (33 790 0)
433-02 Auxiliary Warning System6 pages
- SpecificationsGeneral Specifications
Description and Operation5 pages
- Description and Operation
Removal and Installation4 pages
- Module - Auxiliary Warning (up to 95½) - Remove And Install (33 641 0)
- Sender Unit - Fuel Tank (up to 95½) - Remove And Install (33 286 0)
- Module - Lights On Warning (95 MY onwards) - Remove And Install (33 643 0)
- Switch - Low Washer Fluid (up to 95½) - Remove And Install (33 607 0)
433-03 Anti-Theft Systems18 pages
- SpecificationsGeneral Specifications
Description and Operation17 pages
- Description and Operation
Removal and Installation16 pages
- Switch - Door Ajar (Front Door) - Remove And Install (33 507 0)
- Switch - Tailgate Ajar - Remove And Install (33 508 0)
- Switch - Door Lock - Key Activated - Alarm System - Remove And Install (33 506 0)
- Switch - Luggage Compartment Lid Ajar - Remove And Install (33 509 0)
- Switch - Door Ajar (Rear Door) - Remove And Install (33 507 0)
- Switch - Luggage Compartment Lamp (Cabriolet Only) - Remove And Install (33 529 0)
- Switch - Alarm - Glove Compartment (Cabriolet Only) - Remove And Install (33 521 0)
- Module - Anti-theft Alarm-Double Locking - Remove And Install (33 644 0)
- Module - Immobiliser (PATS) - Remove and Install (33 660 0)
- Switch - Anti-theft Alarm Inhibit - Luggage Compartment (95½ MY) - Remove And Install (33 535 0)
- Switch - Hood - Remove And Install (33 539 0)
- Transceiver - Immobiliser (PATS) - Remove And Install (33 662 0)
- Horn - Alarm System (Up To 94 MY) - Remove And Install (33 774 0)
- Buzzer - Alarm System (Up To 95½ MY) - Remove And Install (33 775 0)
- Horn - Alarm System (Van) - Remove And Install (33 774 0)
- Horn - Alarm System (94 MY Onwards) - Remove And Install (33 774 0)
434 Heating and Ventilation31 pages
434-01 Heating and Ventilation13 pages
- SpecificationsGeneral Specifications
Removal and Installation12 pages
- Switch - Blower Motor - Heater - Remove and Install (Escort 91 and 93) (33 574 0)
- Switch - Blower Motor - Heater - Remove and Install (Escort 95½) (33 574 0)
- Heater Controls - Front - Remove and Install (Escort 91 and 93) (34 311 0)
- Heater Controls - Front - Remove and Install (Escort 95½) (34 311 0)
- Blower Motor - Remove and Install (34 374 0)
- Heater Assembly - Remove and Install (34 354 0)
- Resistor Assembly - Blower Motor - Heater - Remove and Install (Vehicles Without Air Conditioning) (34 382 0)
- Vent - Face Level - Remove and Install (Driver Side) (Escort 91 and 93) (34 488 0)
- Resistor Assembly - Blower Motor - Heater - Remove and Install (Escort 95½ With Air Conditioning) (34 382 0)
- Vent - Face Level (Centre) - Remove and Install (Escort 95½) (34 489 0)
- Vent - Face Level - Remove and Install (Driver Side) (Escort 95½) (34 488 0)
- Vent - Face Level (Centre) - Remove and Install (Escort 91 and 93) (34 489 0)
434-02 Air Conditioning18 pages
- SpecificationsGeneral Specifications
Description and Operation17 pages
- Description and Operation
Removal and Installation16 pages
- Switch - De-ice - Evaporator - Remove and Install (33 560 0)
- Refrigerant Lines - Disconnect and Connect (air conditioning drained)
- Refrigerant - Air Conditioning - Drain and Fill (34 620 0)
- Evaporator - Air Conditioning - Remove and Install (34 622 0)
- Expansion Valve - Air Conditioning - Remove and Install (34 623 0)
- Vacuum Control Motor - Air Recirculation - Remove and Install (34 601 0)
- Condenser - Air Conditioning - Remove and Install (34 632 0)
- Compressor - Air Conditioning - Remove and Install (34 626 0)
- Compressor Clutch - Remove and Install (34 628 0)
- Accumulator-Dehydrator - Air Conditioning - Remove and Install (34 630 0)
- High Pressure Switch - Air Conditioning - Remove and Install (34 631 0)
- Line - Compressor to Expansion Valve - Remove and Install (34 640 0)
- Line - Accumulator-Dehydrator to Condenser - Remove and Install (34 643 0)
- Line - Compressor to Condenser - Remove and Install (34 641 0)
- Vacuum Reservoir - Air Conditioning - Remove and Install (34 635 0)
- Line - Expansion Valve to Dehydrator - Remove and Install (34 642 0)
438 Audio System › 438-01 In-Car Entertainment › Description and Operation13 pages
- Description and Operation
Removal and Installation12 pages
- Radio Receiver-Cassette Player (Up To 96 MY) - Remove And Install (38 222 0)
- Radio Receiver-Cassette Player (96 MY Onwards) - Remove And Install (38 222 0)
- Radio Loudspeaker - Front Door (One) - Remove And Install (38 268 0)
- Radio Loudspeaker - Rear Quarter Panel (Cabriolet) - Remove And Install (38 275 0)
- Radio Loudspeaker - Loadspace Trim Panel - Remove And Install (38 284 0)
- Autochanger - (CD) Player - Remove And Install (38 446 0)
- Graphic Equaliser - Remove And Install (38 452 0)
- Mast - Radio Antenna - Remove And Install (38 364 0)
- Radio Antenna - Electrically Operated (Cabriolet) - Remove And Install (38 362 0)
- Power Amplifier - Radio Receiver-Cassette Player (93 MY Onwards) - Remove And Install (38 456 0)
- Power Amplifier - Radio Receiver-Cassette Player (Up To 92 MY) - Remove And Install (38 456 0)
- Radio Antenna - Manual - Remove And Install (38 352 0)
5 Body and Paint101 pages
540 Seats, Seat Belts, Air Bags28 pages
540-01 Seats12 pages
- SpecificationsGeneral Specifications
Description and Operation11 pages
- Description and Operation
Removal and Installation10 pages
- Seat Assembly - Front Bucket (Pyrotechnic Pretensioner) - Remove And Install (40 100 0)
- Seat Assembly - Front Bucket (Mechanical Pretensioner) - Remove And Install (40 100 0)
- Cover And Pad Assembly - Backrest - Front Seat (95 MY Onwards (Sports Seat)) - Remove And Install (40 106 0)
- Cover And Pad Assembly - Backrest - Front Seat (95½ MY Onwards) - Remove And Install (40 106 0)
- Cover And Pad Assembly - Cushion - Front Seat (Up To 95½ MY) - Remove And Install (40 104 0)
- Cover And Pad Assembly - Cushion - Front Seat (95 MY Onwards) - Remove And Install (40 104 0)
- Cover And Pad Assembly - Backrest - Front Seat (Up To 95½ MY) - Remove And Install (40 106 0)
- Backrest - Rear Seat (Cabriolet) - Remove And Install (40 128 0)
- Side Bolster - Rear Seat Backrest - Remove And Install (40 135 0)
- Slide - Front Seat (Up To 95½ MY) - Remove And Install (40 420 0)
540-02 Seat Belts8 pages
- SpecificationsGeneral Specifications
Description and Operation7 pages
- Description and Operation
Removal and Installation6 pages
- Stalk - Front Seat (Pyrotechnic Pretensioner) - Remove And Install (40 232 0)
- Belt - Front Seat - Remove And Install (40 222 0)
- Stalk - Front Seat (Mechanical Pretensioner) - Remove And Install (40 232 0)
- Belt - Rear Seat - Remove And Install (40 248 0)
- Pretensioner - Stalk - Seat - Deploy (40 234 0)
- Belt - Rear Seat - Remove And Install (Cabriolet) (40 248 0)
540-03 Air Bags8 pages
- SpecificationsGeneral Specifications
Description and Operation7 pages
- Description and Operation
Removal and Installation6 pages
- Control Module - Air Bag - Remove And Install (33 650 0)
- Clockspring - Air Bag Control - Remove And Install (33 392 0)
- Module - Driver Air Bag - Remove And Install (40 700 0)
- Module - Passenger Air Bag - Remove And Install (95½ MY Onwards) (40 701 0)
- Module - Passenger Air Bag - Remove And Install (Up To 95½ MY) (40 701 0)
- Module - Air Bag - Deploy (Outside the Vehicle) (40 702 0)
541 Body Closures › 541-01 Body Closures10 pages
- SpecificationsGeneral Specifications
Description and Operation9 pages
- Description and Operation
Removal and Installation8 pages
- Sliding Roof Assembly - Remove And Install (41 114 0)
- Handle - Door Exterior - Remove And Install (41 333 0)
- Barrel - Door Lock - Overhaul (Barrel Removed) (41 336 8)
- Lock Assembly - Front Door - Remove And Install (41 351 0)
- Lock - Luggage Compartment Lid - Remove And Install (41 726 0)
- Lock Assembly - Rear Door - Remove And Install (41 352 0)
- Tailgate Assembly - Remove And Install (41 654 0)
- Lock Assembly - Tailgate - Remove And Install (41 666 0)
542 Windows › 542-01 Windows20 pages
- SpecificationsGeneral Specifications
Description and Operation19 pages
- Description and Operation
Removal and Installation18 pages
- Windscreen - Remove And Install (42 114 0)
- Glass - Door Window - Front (Powered) - Remove And Install (42 314 0)
- Regulator Assembly - Door Window (Front (Cabriolet)) - Remove And Install (42 338 0)
- Runners - Window - Front Door (Cabriolet) - Remove And Install (42 333 0)
- Regulator Assembly - Door Window (Rear) - Remove And Install (42 338 0)
- Glass - Door Window - Front (Cabriolet) - Remove And Install (42 314 0)
- Runners - Window - Front Door - Remove And Install (42 333 0)
- Glass - Door Window - Rear - Remove And Install (42 315 0)
- Regulator Assembly - Door Window (Front (Powered)) - Remove And Install (42 338 0)
- Glass - Fixed Rear Quarter Window (Wagon) - Remove And Install (42 514 0)
- Regulator - Winding Rear Quarter Window - Remove And Install (42 584 0)
- Glass - Fixed Rear Quarter Window (5-Door) - Remove And Install (42 514 0)
- Glass - Opening Rear Quarter Window - Remove And Install (42 536 0)
- Glass - Rear Window - Remove And Install (42 614 0)
- Glass - Rear Door Window (Van) (42 634 0)
- Glass - Rear Window (Cabriolet) - Remove And Install (42 614 0)
- Glass - Tailgate Window - Remove And Install (42 654 0)
- Glass - Tailgate Window (Wagon) - Remove And Install (42 654 0)
543 Interior and Exterior Trim43 pages
543-01 Interior Trim21 pages
- SpecificationsGeneral Specifications
Removal and Installation20 pages
- Headlining (Saloon) - Renew (43 612 0)
- Trim Panel - B Pillar - Remove And Install (43 617 0)
- Trim Panel - C Pillar (5-Door Variant) - Remove And Install (43 618 0)
- Headlining (Van) - Renew (43 612 0)
- Trim Panel - C Pillar (4-Door Variant) - Remove And Install (43 618 0)
- Trim Panel - A Pillar - Remove And Install (43 616 0)
- Crash Padding - Facia (95½ MY Onwards) - Remove And Install (43 644 0)
- Crash Padding - Facia (Up To 95½ MY) - Remove And Install (43 644 0)
- Trim Panel - Front Door (95½ MY Onwards) - Remove And Install (43 705 0)
- Crash Padding - Facia (Up To 95½ MY) - Renew (Assembly Removed) (43 644 4)
- Trim Panel - Front Door (Up To 95½ MY) - Remove And Install (43 705 0)
- Crash Padding - Facia (95½ MY Onwards) - Renew (Assembly Removed) (43 644 4)
- Panel - Load Space Trim (Wagon) - Remove And Install (43 746 0)
- Trim Panel - Rear Door - Remove And Install (43 706 0)
- Centre Console (95½ MY Onwards) - Remove And Install (43 814 0)
- Centre Console (Up To 95½ MY) - Remove And Install (43 814 0)
- Floor Covering - Front And Rear (3 Door Variants) - Remove And Install (43 832 0)
- Floor Covering - Front And Rear (4 And 5 Door Variants) - Remove And Install (43 832 0)
- Cover - Rear Wheelhouse - Remove And Install (43 841 0)
- Floor Covering - Front (Van) - Remove And Install (43 834 0)
543-02 Exterior Trim10 pages
- SpecificationsGeneral Specifications
Removal and Installation9 pages
- Liner - Wheelhouse - Remove And Install (43 228 0)
- Moulding - Roof (Van Only) - Remove And Install (43 345 0)
- Mirror - Door (Manual) (One) - Remove And Install (43 364 0)
- Mirror - Door (Powered) (One) - Remove And Install (43 364 0)
- Bumper Assembly - Front - Remove And Install (43 423 0)
- Bumper Assembly - Rear (4-Door Variant) - Remove And Install (43 443 0)
- Glass - Door Mirror (95 MY Onwards) - Renew (43 366 0)
- Spoiler - Tailgate (Wagon) - Remove And Install (43 492 0)
- Spoiler - Tailgate (Hatchback) - Remove And Install (43 492 0)
543-03 Convertible Roof12 pages
- SpecificationsGeneral Specifications
Description and Operation11 pages
- Description and Operation
Removal and Installation10 pages
- Convertible Roof Cover - Outer - Remove And Install (43 582 0)
- Convertible Roof Assembly - Remove And Install (43 581 0)
- Convertible Roof Cover - Outer - Renew (43 583 0)
- Frame - Convertible Roof - Remove And Install (Insulation & Headlining Removed) (43 584 4)
- Damper-Hydraulic Ram - Convertible Roof Assembly - Remove And Install (43 588 0)
- Seal - Windscreen Frame Header - Convertible Roof - Remove And Install (43 596 0)
- Hydraulic Hose - Convertible Power Roof - Remove And Install (43 592 0)
- Hydraulic System - Convertible Power Roof - Bleed (43 591 5)
- Motor And Pump Assembly - Convertible Power Roof - Remove And Install (43 595 0)
- Rear Quarter Trim Panel - Remove And Install (43 731 0)
- Panel - Luggage Compartment Lid Trim - Remove And Install (43 745 0)