1991 Ford Orion 4-Door Body Repair Manual (PDF Download) – Rear Wing, Boot Lid & Rear Panel Workshop Guide

Downloadable 1991 Ford Orion Body Repair Manual – Rear Wing, Boot Lid, and Rear Panel Workshop Guide (PDF)

Looking for an in-depth and reliable repair manual for the 1991 Ford Orion 4-door saloon? This comprehensive digital guide is a must-have for automotive repair professionals, restorers, body shops, or classic Ford enthusiasts working on the rear body section of the 1991 Ford Orion.

Delivered as a high-resolution instant PDF download, this manual gives you immediate access to essential factory data on removal and replacement procedures for key rear-end body panels — including the rear wing, tail lamp panel, rear panel, and boot lid. It’s a practical, highly technical guide developed for hands-on application, loaded with illustrations, paint codes, MET operations, panel dimensions, part numbers, and recommended service procedures.

What’s Inside This Workshop Manual

This 1991 Ford Orion repair supplement covers everything you need to carry out precise and safe structural body repairs, including welding points, panel preparation, part illustrations, and finishing techniques.

Chapters & Key Sections

• Model Introduction – Technical summary of the 1991 Ford Orion, including suspension, engine types, and body structure
• Full Model Line-Up – Lists engine variants and trims (Ghia, LX, GLX, Injection, CFi models, etc.)
• Vehicle Identification Points – Where and how to locate identification plates and paint codes
• Paint Colour Codes – Full list of factory-original colours (metallic, non-metallic, pearlescent) with paint code references
• Panel Specifications – Details on boot lid, rear wing, rear panel, tail lamp panel and their service condition
• Step-by-Step Panel Replacement Instructions – Removal and reinstallation guides with notes on plug welding, tack brazing, spot weld locations, and adhesive application
• Illustrated Diagrams – Reference diagrams with weld points and cutting lines
• Service Parts Breakdown – Full index and illustrations of rear-end parts and sections (dogleg reinforcements, sill panels, wheel arches, etc.)
• MET Operations – Guidelines on mechanical, electrical, and trim removal and reinstall procedures
• Paint Refinishing Techniques – Proper process for non-metallic and metallic paint systems, including sealing and stone chip finish
• Replacement Time Schedules – Professional panel replacement time estimates for individual panels and combinations, under both metallic and non-metallic systems
• Corrosion Protection Guidelines – Timed procedures for applying underbody vinyl, cavity wax, and rust protection to repaired areas

Why Buy This Manual?

Unlike generic workshop guides, this supplement is laser-focused on one of the most vulnerable areas of the Ford Orion — the rear body structure. Whether you're repairing accident damage, restoring a classic daily driver, or replacing worn panels, this guide delivers accurate, vehicle-specific data to help you do it right the first time.

Ideal For:

• Professional panel beaters and vehicle body repair technicians
• Classic Ford restoration hobbyists and collecto