Boot lock jammed.
Brake discs warped and shattered (at high speed!)
Fuel Injector Needle snapped.
Central locking faults (after a break-in)
Camshaft needed replacing at 60000 miles.
Valve stem oil seals needed replacing at 64000.
I can't really moan too much about this car as it served me well for 4 years, however there were a few problems.
For some reason, fords do not particularly like the cold weather very much. My Orion was no exception to this rule. It would refuse to start on many a cold morning, meaning I was spending quite a few pennies on trying to fix this rather annoying problem.
The central locking was totally screwed by a youth, who tried, but failed to break in to my car.
On the plus side, the Orion is an ideal car for someone who wants cheap insurance (group 9) and a quick car. Lets face it, the 1600i is basically and xr3i with a boot, so its not slow!
I kept the car fairly standard (ford alloys and boot spoiler) and it still looked the business when I sold it, however I heard that the person I sold the car to crashed it soon after, never mind...