1991 Ford Orion Ghia Si (w/o cat) – Workshop Service & Repair Manual

1. Check the Fuel System: Ensure that the fuel filter is clean and replace it if necessary. Inspect the fuel pump for proper operation.
2. Examine the Ignition System: Inspect spark plugs and ignition wires for wear and replace any faulty components.
3. Inspect the Air Intake: Clean or replace the air filter to ensure proper airflow to the engine.

Check Engine Sensors: Test the throttle position sensor and mass air flow sensor for proper operation and replace them if needed.

1. Check Transmission Fluid: Verify the transmission fluid level and top it up if it's low. Replace old fluid if it's dirty or burnt.
2. Inspect Transmission Lines: Look for leaks or damage in the transmission lines and repair or replace them as needed.
3. Check for Error Codes: Use an OBD scanner to check for any diagnostic trouble codes related to the transmission and address the issues accordingly.

Examine the Transmission Filter: Replace the transmission filter if it's clogged to ensure proper fluid flow and shifting performance.

1. Inspect Fuses: Check all fuses related to the electrical system and replace any that are blown.
2. Examine Wiring: Inspect wiring for damage or corrosion and repair any issues found.
3. Test Battery and Alternator: Ensure the battery is fully charged and the alternator is functioning properly.

Check Ground Connections: Ensure all ground connections are secure and free of corrosion to maintain proper electrical flow.

1. Inspect Brake Pads and Rotors: Check the condition of the brake pads and rotors for wear. Replace them if they are worn out or damaged.
2. Check Brake Fluid: Ensure the brake fluid level is adequate and top it up if necessary. Replace old or contaminated brake fluid.
3. Examine Brake Lines: Inspect brake lines for leaks or damage and repair or replace them as needed.
4. Test Brake System Components: Check the brake calipers and master cylinder for proper operation and replace any faulty components.

1. Clean Affected Areas: Remove surface rust with a wire brush and clean the affected areas with a rust remover.
2. Apply Rust Inhibitor: Apply a rust-inhibiting primer to the cleaned areas to prevent further corrosion.
3. Paint and Seal: Repaint the treated areas with automotive paint and seal to protect against future rust.

Inspect Regularly: Regularly inspect the vehicle for new rust spots and address them promptly to prevent spread.