Ford Orion. Manual - part 30

4 Remove the retaining bolts, and remove the
drivebelt pulley from the water pump.
5 Loosen off the coolant hose securing clips,
and disconnect the hoses from the water
pump.
6 Unscrew the retaining bolts, and withdraw
the water pump from the engine (see
illustration).

Refitting

7 Clean all traces of gasket from the engine
and the water pump mating faces. Ensure that
the mating faces are clean and dry. Note that
the water pump gasket fitted during
production is integral with the timing cover
gasket, and this will need to be cut away
using a sharp knife, keeping as close to the
timing cover as possible.
8 No provision is made for the repair of the

water pump; if it is noisy or defective in any
way, it must be renewed.
9 Refitting is a reversal of the removal
procedure. Use a new gasket, lightly smeared
with jointing compound, and tighten the
retaining bolts to the specified torque setting
(see illustration).
10 Refit and adjust the auxiliary drivebelt as
described in Chapter 1.
11 Refill the cooling system as described in
Chapter 1, and reconnect the battery.

9

Water pump (CVH engine) -
removal and refitting

4

Note: Refer to the warnings given in Section 1
of this Chapter before starting work.

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Drain the cooling system (see Chapter 1).
3 Remove the timing belt and tensioner (see
Chapter 2B). If the belt is fouled with coolant,
it must be renewed as a matter of course.
4 Loosen off the coolant hose retaining clip,
and detach the coolant hose from the water
pump (see illustration).
5 Unscrew and remove the four bolts
securing the water pump to the front end face
of the cylinder block, and then withdraw the
pump from the vehicle (see illustration).

Refitting

6 Clean the engine water pump mating faces.
Ensure that the mating faces are clean and
dry.
7 No provision is made for the repair of the
water pump; if it is noisy or defective in any
way, it must be renewed.
8 Refitting is a reversal of the removal
procedure. Tighten the retaining bolts to the
specified torque, and ensure that the coolant
hose connection to the water pump is
securely made.
9 Refit the timing belt and tensioner as
described in Chapter 2B.
10 Top-up the cooling system as described
in Chapter 1, and reconnect the battery.

10 Water pump (Zetec engine) -

removal and refitting

4

Note: Refer to the warnings given in Section 1
of this Chapter before starting work.

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Drain the cooling system (see Chapter 1).
3 Remove the timing belt and tensioner (see
Chapter 2C). If the belt is fouled with coolant,
it must be renewed as a matter of course.
4 Disconnect the radiator bottom hose from
the pump union. It is easier to reach this union
if the power steering pump is unbolted and
moved aside, as described in Chapter 10.
There is no need to disconnect any of the
power steering system hoses.
5 Unbolt and remove the water pump (see
illustration). If the pump is to be renewed,
unbolt the timing belt guide pulleys, and
transfer them to the new pump.

Refitting

6 Clean the mating surfaces carefully; the
gasket must be renewed whenever it is
disturbed (see illustration).
7 On refitting, use grease to stick the new
gasket in place, refit the pump, and tighten
the pump bolts to the specified torque wrench
setting.

3•8 Cooling, heating and air conditioning systems

10.6  Always use a new gasket, and clean

all mating surfaces carefully

10.5  Unscrew the bolts (arrowed) to

remove the water pump

9.5  Removing the water pump from the

CVH engine

9.4  Detach the coolant hose from the

water pump

8.9  Refitting the water pump to the

engine. Note the new gasket

8.6  Unscrew the water pump retaining

bolts (arrowed)

8 The remainder of refitting is a reversal of the
removal procedure. Refit the timing belt and
tensioner as described in Chapter 2C, noting
that a new tensioner spring and retaining pin
must be fitted if the timing belt has been
removed for the first time. Tighten all
fasteners to the specified torque wrench
settings, and refill the system with coolant as
described in Chapter 1.

11 Heater/ventilation

components - removal and
refitting

1

Heater blower motor

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 For improved access, refer to Chapter 4 for
details, and remove the air cleaner (where
applicable).
3 Peel back the seal strip from the top edge
of the bulkhead.
4 Cut the ties and detach the hose and wiring
loom from the bulkhead.
5 Undo the six retaining bolts, and remove
the cover from the air chamber (see
illustration).
6 Release the heater blower cover from its
guides, and remove it.
7 Disconnect the wires from the blower
motor, then undo the two retaining nuts and
withdraw the blower motor from the air
chamber (see illustration).
8 To remove the motor from its housing, prise
free the locking clips and release the securing
lugs using a pin punch (see illustration).
Detach the connector from the blower resistor
unit, bend the retaining tabs up, and then
separate the motor (with resistor) from the
retainer. Remove the motor from the housing.

Refitting

9 Refitting is a reversal of the removal
procedure. When reassembling the blower
motor housing covers, ensure that the
locating lugs are fully engaged.

Heater blower motor resistor

Removal

10 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
11 For improved access, refer to Chapter 4
for details, and remove the air cleaner (where
applicable).
12 Peel back the seal strip from the top edge
of the bulkhead.
13 Cut the ties and detach the hose and
wiring loom from the bulkhead.
14 Undo the six retaining bolts, and remove
the cover from the air chamber.
15 Detach the wiring connector and the
multi-plug from the resistor unit. Bend up the
securing tabs, and withdraw the resistor unit
from the heater motor assembly.

Refitting

16 Refit in the reverse order of removal.
Ensure that the resistor retaining tabs are fully
engaged and secure.

Heater unit and matrix

Removal

17 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
18 Drain the cooling system as described in
Chapter 1.
19 Undo the retaining clips, and detach the
heater coolant supply and return hoses at
their bulkhead connections (see illustration).
20 A small amount of coolant (about half a
litre), will have remained in the heater matrix
after draining. In order to prevent the
possibility of the coolant spilling onto the
carpets during the removal of the heater, it is
advisable to blow through one of the
connections to eject the remaining coolant
out through the other open connection.
21 Undo the two retaining screws, and
detach the heater matrix cover plate and
gasket from the bulkhead.
22 Refer to Chapter 12 for details, and
remove the radio/cassette unit from the facia.
23 Undo the two retaining screws, and
remove the stowage unit from under the
radio/cassette aperture.
24 Peel back the front door weatherstrip
(seal) from the “A” pillar adjacent to the facia.

Undo the retaining screw, and remove the “A”
pillar trim. Repeat the procedure on the
opposite side.
25 Undo the two retaining screws, and
remove the upper steering column shroud.
26 Similarly, undo the four retaining screws
and remove the lower steering column
shroud.
27 Referring to Chapter 11, undo the facia
retaining screws as necessary.
28 Undo the single retaining screw, and
withdraw the multi-function switch from the
steering column. Disconnect the wiring multi-
plugs.
29 Refer to Chapter 11 for details, and
remove the centre console.
30 Pull free the covers from the right- and
left-hand heater control levers, then unclip
and disconnect the cables from their
connections on the heater unit each side.
31 Prise free the cover from each of the three
facia securing bolt apertures on the top face
of the facia, also the cover from the
radio/cassette recess.
32 Unscrew and remove the ten Torx-type
retaining bolts, and pull the facia rearwards to
partially withdraw it, taking care not to stretch
the wiring harnesses under the facia (see
Chapter 11).

Cooling, heating and air conditioning systems  3•9

11.8  Heater blower unit locking clip (A)

removal

11.7  Heater blower motor unit

A  Resistor multi-plug
B  Earth lead
C  Blower unit securing nuts

11.5  Air chamber and associated

components

A  Bulkhead cover
B  Cover retaining bolts
C  Blower cover guides
D  Blower cover

11.19  Coolant heater hose connections to

heater at bulkhead

A  Coolant hoses

C  Screws

B  Cover plate

D  Clip

3

33 Pull free the footwell air vent from the
heater housing connection.
34 Pull free the air ducts from the heater
housing connections (two each side, and two
in the centre).
35 Undo the two retaining nuts, and
disconnect the heater housing from the cowl
panel by withdrawing it downwards and
removing it from the side (see illustration).
36 To remove the heater matrix (radiator)
from the heater unit, undo the two retaining
screws and carefully withdraw it (see
illustration).

Refitting

37 Refitting is a reversal of the removal
procedure. When fitting the heater unit into
position, engage the lugs of its flange with the
support bracket on the cowl panel, and guide
the matrix into position through the opening in
the bulkhead.
38 Check that all wiring, coolant hose and air
duct connections are securely made. Tighten
the housing retaining nuts to the specified
torque.
39 On completion, refill the cooling system
as described in Chapter 1, then reconnect the
battery.

Face-level air vent (right-hand)

Removal

40 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
41 Undo the two retaining screws from its

upper edge, and withdraw the instrument
panel surround.
42 Undo the two retaining screws, and
withdraw the face-level vent from the facia.
Where applicable, detach the wiring
connectors from the switches in the panel.

Refitting

43 Refitting is the reversal of removal.

Face-level air vent (left-hand)

Removal

44 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
45 Open the glovebox lid, then unscrew the
vent retaining screw from the underside of the
box roof (directly under the vent). Carefully
prise free and remove the vent (see
illustration).

Refitting

46 Refitting is the reversal of removal.

Face-level air vent (centre)

Removal

47 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
48 Undo the two retaining screws from its
upper edge, and withdraw the instrument
panel surround.
49 Carefully prise free the three heater/fresh
air and blower/air conditioning switch control
knobs. Loosen off the centre air vent retaining
screws, and partially withdraw the air vent unit

just enough to allow access to the wiring
connectors on the inside face of the unit (see
illustrations).
50 Where applicable, disconnect the wiring
multi-plugs from the heated rear window and
rear foglight or heated windscreen switches,
then remove the centre air vent unit.

Refitting

51 Refitting is the reversal of removal.

12 Heater/air conditioning

controls - removal and
refitting

1

Heater/air conditioning control
panel

Removal

1 Remove the centre face-level air vent as
described in the previous Section.
2 Pull free the covers, then disconnect the
control cables from each side of the heater
unit. The right-hand side cable operates the
temperature control valve, and the left-hand
cable operates the air distribution valve (see
illustration).
3 Undo the two screws securing the heater
control panel to the facia. Withdraw the panel
from the facia just enough to allow the heater
blower/air conditioning switch wiring plug to
be detached, then fully withdraw the control
panel, and feed the control cables through the
facia aperture (see illustrations).

3•10 Cooling, heating and air conditioning systems

11.49C  . . . and partially withdraw the air

vent unit

11.49B  . . . undo the retaining screws . . .

11.49A  Prise free the control knobs . . .

11.45  Prising free the left-hand side vent

11.36  Heater unit showing matrix retaining

screws (A), matrix (B) and unit locating

lugs (C)

11.35  Left-hand (A) and right-hand (B)

heater housing securing nuts (arrowed)

Refitting

4 Refit in the reverse order of removal. Ensure
that the control cables are correctly re-routed
(with no tight bends). Check that the cables
and the wiring connectors are securely
refitted.

Heater/air conditioning control
cables

Removal

5 Remove the control panel as previously
described.
6 Bend the retaining tabs straight, and then
detach the cover from the baseplate to open
the heater control unit (see illustration).
7 Cut the cable retaining clips free, then
release the cables from the toothed guide
strips to remove them. Note that the retaining
clips will need to be renewed during
reassembly.

Refitting

8 Refitting is a reversal of the removal
procedure.

13 Air conditioning system -

general information and
precautions

General information

The air conditioning system consists of a

condenser mounted in front of the radiator, an
evaporator mounted adjacent to the heater
matrix, a compressor mounted on the engine,

a dehydrator, and the plumbing connecting all
of the above components (see illustration).

A blower fan forces the warmer air of the

passenger compartment through the
evaporator core (rather like a radiator in
reverse), transferring the heat from the air to
the refrigerant. The liquid refrigerant boils off
into low-pressure vapour, taking the heat with
it when it leaves the evaporator.

Precautions

Warning: The air conditioning
system is under high pressure.
Do not loosen any fittings or
remove any components until

after the system has been discharged. Air
conditioning refrigerant should be properly
discharged into an approved type of

container, at a dealer service department
or an automotive air conditioning repair
facility capable of handling the refrigerant
safely. Always wear eye protection when
disconnecting air conditioning system
fittings.

When an air conditioning system is fitted, it

is necessary to observe the following special
precautions whenever dealing with any part of
the system, its associated components, and
any items which necessitate disconnection of
the system:
a)

While the refrigerant used on later models
- R134a - is less damaging to the
environment than the previously-used
R12, both are very dangerous substances.
They must not be allowed into contact
with the skin or eyes, or there is a risk of

Cooling, heating and air conditioning systems  3•11

12.3B  Control panel removal

12.3A  Control panel retaining screws

(arrowed)

12.2  Heater temperature control cable

connection on the right-hand side of the

heater unit

13.1  Air conditioning system layout

12.6  Heater control unit retaining tabs (A),

cover (B) and baseplate (C)

3

A   Compressor
B   Compressor-to-condenser pipe
C   Compressor-to-expansion valve
D   Evaporator and blower
E   Expansion valve

F   Expansion valve-to-dehydrator pipe
G   High-pressure switch
H   Dehydrator
J   Dehydrator-to-condenser pipe
K   Condenser