Ford Orion. Manual - part 61

Additional fuses (in engine compartment)

Note: Fuse ratings and circuits are liable to change from year to year. Consult the handbook supplied with the vehicle, or consult a Ford dealer,
for specific information.

No

Rating (amps)

Circuit(s) protected

A

80  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Supply cables to main fuse block

B

60  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Supply cables to main fuse block

C

60  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Supply cables to main fuse block

D

40/50  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling fan

E

50  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heated rear window

Relays

No

Colour

Circuit

R1

Grey  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heated windscreen

R2

Red  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Windscreen wiper intermittent control

R3

Grey  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heated rear windscreen

R4

Dark green  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Anti-lock braking (system)

R5

Violet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Anti-lock braking (pump)

R6

White/Yellow  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main beam

R7

Orange  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear wiper intermittent control

R8

Green/Red/Yellow  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CFi delay relay or EFi supply relay or EEC IV supply relay

R9

Brown  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel pump

10

Brown  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Magnetic clutch (air conditioning system)

11

Green  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning system

12

Brown  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine running

13

Spare

14

Spare

15

Spare

16*

Spare

16**

Violet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel pump

17

Yellow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Interior light delay

18

Green  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electric windows

19

Grey  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear foglight (module)

20

Spare

21

-/White  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Busbar/front foglights (module)

22

Blue  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Headlight washer system

23

White  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dip beam

24

-/Red or Yellow  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Busbar/automatic transmission/alarm

25

White  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front foglights

26

Black  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering lock/starter switch

27

Spare

* Early models    ** Later models

12•2 Body electrical system 

Bulbs

Wattage

Headlights (halogen H4)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60/65
Sidelights  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Front indicator lights  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Side indicator repeater lights . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Tail lights (Hatchback/Saloon)  . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Brake stop-lights (Hatchback/Saloon) . . . . . . . . . . . . . . . . . . . . 21
Brake stop-/tail lights (Estate/Van)  . . . . . . . . . . . . . . . . . . . . . . 21/5
Reversing lights  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Rear direction indicators  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Rear foglights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Bulbs

Wattage

Rear number plate light  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Instrument panel warning lights . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Hazard warning light switch bulb  . . . . . . . . . . . . . . . . . . . . . . . 1.3
Instrument panel illumination bulb . . . . . . . . . . . . . . . . . . . . . . . 2.6
Clock illumination bulb  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Cigar lighter illumination bulb  . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Glovebox illumination light bulb  . . . . . . . . . . . . . . . . . . . . . . . . 10
Luggage area illumination bulb  . . . . . . . . . . . . . . . . . . . . . . . . . 10
Courtesy light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Torque wrench settings

Nm

lbf ft

Wiper motor (original) to mounting bracket  . . . . . . . . . . . . . . . . . . . . . .

8 to 12

6 to 7.5

Wiper motor (new) to mounting bracket  . . . . . . . . . . . . . . . . . . . . . . . . .

10 to 12

7.5 to 9

Wiper motor bracket to bulkhead (or tailgate)  . . . . . . . . . . . . . . . . . . . .

6 to 8

4.5 to 6

Wiper motor arm-to-spindle nut  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22 to 24

16 to 17

Wiper arm nut:

Stage 1  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 to 18

12.5 to 13.5

Stage 2 (after operating wiper)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 to 18

12.5 to 13.5

Horn-to-body retaining nuts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25 to 35

18 to 26

1

General information

Warning: Before carrying out any
work on the electrical system,
read through the precautions
given in “Safety first!” at the
beginning of this manual.

The electrical system is of 12-volt negative

earth type. Power for the lights and all
electrical accessories is supplied by a
lead/acid battery, which is charged by the
engine-driven alternator.

This Chapter covers repair and service

procedures for the various electrical
components not associated with the engine.
Information on the battery, ignition system,
alternator, and starter motor can be found in
Chapter 5.

All 1994-model year Escorts are fitted with

a driver’s air bag, which is designed to
prevent serious chest and head injuries to the
driver during an accident. A similar bag for the
front seat passenger is also available (see
illustration). The combined sensor and
electronic for the air bag is located next to the
steering column inside the vehicle, and
contains a back-up capacitor, crash sensor,
decelerometer, safety sensor, integrated
circuit and microprocessor. The air bag is
inflated by a gas generator, which forces the
bag out of the module cover in the centre of
the steering wheel. A “clock spring” ensures
that a good electrical connection is
maintained with the air bag at all times - as
the steering wheel is turned in each direction,
the spring winds and unwinds.

An anti-theft alarm system is fitted as

standard equipment on most models, and is
triggered if the vehicle is broken into through
the doors, bonnet, boot or tailgate. The alarm
will also be triggered if the ignition or audio
equipment is tampered with. Additionally,
from the 1994 model year onwards, a Passive
Anti-Theft System (PATS) is fitted. This

system, (which works independently of the
standard alarm) prevents the engine from
being started unless a specific code,
programmed into the ignition key, is
recognised by the PATS transceiver.

It should be noted that, when portions of

the electrical system are serviced, the cable
should be disconnected from the battery
negative terminal, to prevent electrical shorts
and fires. 

Caution: When disconnecting the
battery for work described in the
following Sections, refer to
Chapter 5, Section 1.

2

Electrical fault-finding -
general information

2

Note:  Refer to the precautions given in
“Safety first!” and in Section 1 of this Chapter
before starting work. The following tests relate
to testing of the main electrical circuits, and
should not be used to test delicate electronic
circuits (such as engine management systems,
anti-lock braking systems, etc), particularly
where an electronic control module is used.
Also refer to the precautions given in Chap-
ter 5, Section 1.

General

1 A typical electrical circuit consists of an
electrical component, any switches, relays,
motors, fuses, fusible links or circuit breakers
related to that component, and the wiring and
connectors which link the component to both
the battery and the chassis. To help to
pinpoint a problem in an electrical circuit,
wiring diagrams are included at the end of this
manual.
2 Before attempting to diagnose an electrical
fault, first study the appropriate wiring diagram,
to obtain a complete understanding of the
components included in the particular circuit
concerned. The possible sources of a fault can
be narrowed down by noting if other
components related to the circuit are operating
properly. If several components or circuits fail
at one time, the problem is likely to be related
to a shared fuse or earth connection.
3 Electrical problems usually stem from
simple causes, such as loose or corroded
connections, a faulty earth connection, a
blown fuse, a melted fusible link, or a faulty
relay (refer to Section 3 for details of testing
relays). Visually inspect the condition of all
fuses, wires and connections in a problem
circuit before testing the components. Use
the wiring diagrams to determine which
terminal connections will need to be checked
in order to pinpoint the trouble-spot.
4 The basic tools required for electrical fault-
finding include a circuit tester or voltmeter (a
12-volt bulb with a set of test leads can also
be used for certain tests); an ohmmeter (to
measure resistance and check for continuity);
a battery and set of test leads; and a jumper

wire, preferably with a circuit breaker or fuse
incorporated, which can be used to bypass
suspect wires or electrical components.
Before attempting to locate a problem with
test instruments, use the wiring diagram to
determine where to make the connections.
5 To find the source of an intermittent wiring
fault (usually due to a poor or dirty
connection, or damaged wiring insulation), a
“wiggle” test can be performed on the wiring.
This involves wiggling the wiring by hand to
see if the fault occurs as the wiring is moved.
It should be possible to narrow down the
source of the fault to a particular section of
wiring. This method of testing can be used in
conjunction with any of the tests described in
the following sub-Sections.
6 Apart from problems due to poor
connections, two basic types of fault can
occur in an electrical circuit - open-circuit, or
short-circuit.
7 Open-circuit faults are caused by a break
somewhere in the circuit, which prevents
current from flowing. An open-circuit fault will
prevent a component from working.
8 Short-circuit faults are caused by a “short”
somewhere in the circuit, which allows the
current flowing in the circuit to “escape” along
an alternative route, usually to earth. Short-
circuit faults are normally caused by a
breakdown in wiring insulation, which allows a
feed wire to touch either another wire, or an
earthed component such as the bodyshell. A
short-circuit fault will normally cause the
relevant circuit fuse to blow.

Finding an open-circuit

9 To check for an open-circuit, connect one
lead of a circuit tester or the negative lead of a
voltmeter either to the battery negative
terminal or to a known good earth.
10 Connect the other lead to a connector in
the circuit being tested, preferably nearest to
the battery or fuse. At this point, battery
voltage should be present, unless the lead
from the battery or the fuse itself is faulty
(bearing in mind that some circuits are live
only when the ignition switch is moved to a
particular position).
11 Switch on the circuit, then connect the
tester lead to the connector nearest the circuit
switch on the component side.
12 If voltage is present (indicated either by
the tester bulb lighting or a voltmeter reading,
as applicable), this means that the section of
the circuit between the relevant connector
and the switch is problem-free.
13 Continue to check the remainder of the
circuit in the same fashion.
14 When a point is reached at which no
voltage is present, the problem must lie
between that point and the previous test point
with voltage. Most problems can be traced to
a broken, corroded or loose connection.

Finding a short-circuit

15 To check for a short-circuit, first
disconnect the load(s) from the circuit (loads

Body electrical system  12•3

1.3  Air bag system components

12

Electronic control module

Warning light

Container

Inflator

Bag

Cover

Clock spring

are the components which draw current from
a circuit, such as bulbs, motors, heating
elements, etc).
16 Remove the relevant fuse from the circuit,
and connect a circuit tester or voltmeter to the
fuse connections.
17 Switch on the circuit, bearing in mind that
some circuits are live only when the ignition
switch is moved to a particular position.
18 If voltage is present (indicated either by
the tester bulb lighting or a voltmeter reading,
as applicable), this means that there is a
short-circuit.
19 If no voltage is present during this test,
but the fuse still blows with the load(s)
reconnected, this indicates an internal fault in
the load(s).

Finding an earth fault

20 The battery negative terminal is
connected to “earth” - the metal of the
engine/transmission and the vehicle body -
and many systems are wired so that they only
receive a positive feed, the current returning
via the metal of the car body. This means that
the component mounting and the body form
part of that circuit. Loose or corroded
mountings can therefore cause a range of
electrical faults, ranging from total failure of a
circuit, to a puzzling partial failure. In
particular, lights may shine dimly (especially
when another circuit sharing the same earth
point is in operation), motors (eg wiper motors
or the radiator cooling fan motor) may run
slowly, and the operation of one circuit may
have an apparently-unrelated effect on
another. Note that on many vehicles, earth
straps are used between certain components,
such as the engine/transmission and the
body, usually where there is no metal-to-
metal contact between components, due to
flexible rubber mountings, etc.
21 To check whether a component is
properly earthed, disconnect the battery (refer
to Chapter 5, Section 1) and connect one lead
of an ohmmeter to a known good earth point.
Connect the other lead to the wire or earth
connection being tested. The resistance
reading should be zero; if not, check the
connection as follows.
22 If an earth connection is thought to be
faulty, dismantle the connection, and clean
both the bodyshell and the wire terminal (or
the component earth connection mating
surface) back to bare metal. Be careful to
remove all traces of dirt and corrosion, then
use a knife to trim away any paint, so that a
clean metal-to-metal joint is made. On
reassembly, tighten the joint fasteners
securely; if a wire terminal is being refitted,
use serrated washers between the terminal
and the bodyshell, to ensure a clean and
secure connection. When the connection is
remade, prevent the onset of corrosion in the
future by applying a coat of petroleum jelly or
silicone-based grease, or by spraying on (at
regular intervals) a proprietary ignition sealer
or a water-dispersant lubricant.

3

Fuses and relays - 
general information

Note: It is important to note that the ignition
switch and the appropriate electrical circuit
must always be switched off before any of the
fuses (or relays) are removed and renewed. In
the event of the fuse/relay having to be
removed, the vehicle anti-theft system must
be de-activated and the battery earth lead
detached. When disconnecting the battery,
reference should be made to Chapter 5,
Section 1.
1 The main fuse and relay block is located
below the facia panel on the driver’s side
within the vehicle. The fuses can be inspected
and if necessary renewed, by unclipping and
removing the access cover. Each fuse
location is numbered - refer to the fuse chart
in the Specifications at the start of this
Chapter to check which circuits are protected
by each fuse. Plastic tweezers are attached to
the inside face of the cover to remove and fit
the fuses (see illustration).
2 To remove a fuse, use the tweezers
provided to pull it out of the holder. Slide the
fuse sideways from the tweezers. The wire
within the fuse is clearly visible, and it will be
broken if the fuse is blown.
3 Always renew a fuse with one of an
identical rating. Never renew a fuse more than
once without tracing the source of the trouble.
The fuse rating is stamped on top of the fuse.
4 Additional “main” fuses are located
separately in a box positioned in front of the
battery and these are accessible for

inspection by first raising and supporting the
bonnet, then unclipping and hinging back the
cover from the fusebox (see illustration).
Each of these fuses is lettered for identifi-
cation - refer to the Specifications at the start
of this Chapter to check which circuits they
protect. To remove fuses A, B and C, it is first
necessary to remove the fusebox. Fuses D
and E can be removed from their locations by
carefully pulling them free from the location
socket in the box. In the event of one of these
fuses blowing, it is essential that the circuits
concerned are checked and any faults
rectified before renewing the faulty fuse. If
necessary, entrust this task to a Ford dealer
or a competent automotive electrician.
5 With the exception of the indicator flasher
relay and where applicable, the Cabriolet
powered roof relays, the remainder of the
relays are fitted to the reverse side of the “in-
vehicle” fuse board. To inspect a relay
mounted on the main fuse board, disconnect
the battery, remove the fusebox cover and
unclip the fusebox. Unscrew the six securing
screws to detach and remove the lower facia
panel on the driver’s side. Carefully withdraw
the fuse/relay block.
6 The various relays can be removed from
their respective locations on the fuse board by
carefully pulling them from the sockets (see
illustration).
7 The direction indicator flasher relay is
attached to the base of the multi-function
switch unit. Access to the relay is made by
undoing the retaining screws and removing
the steering column lower shroud. The relay
can then be withdrawn from the base of the
switch (see illustration).

12•4 Body electrical system 

3.7  Direction indicator flasher relay

removal

3.6  Relay locations on the underside of the

fuse board

3.4  Additional “main” fuses at the front of

the battery

3.1  Fuse removal using tweezers

8 The Cabriolet powered roof system has four
relays. Relays I and II (and a thermal cut-out)
are located beneath the instrument panel,
relays III and IV (together with a 15 amp fuse)
are located in the left-hand side of the
luggage area, next to the powered roof
hydraulic pump. Removal of the appropriate
trim panel and where applicable, the
associated components, gives access to the
relay(s) for inspection and renewal (refer to
Chapter 11).
9 If a system controlled by a relay becomes
inoperative and the relay is suspect, listen to
the relay as the circuit is operated. If the relay
is functioning, it should be possible to hear it
click as it is energised. If the relay proves
satisfactory, the fault lies with the
components or wiring of the system. If the
relay is not being energised, then it is not
receiving a main supply voltage or a switching
voltage, or the relay is faulty.

4

Switches - 
removal and refitting

1

Ignition switch

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Undo the two upper and four lower
retaining screws, and remove the upper and
lower shrouds from the steering column.

3 Depress the two ignition switch-to-lock
securing tabs, and withdraw the switch from
the lock (see illustrations).
4 Undo the six retaining screws, and remove
the lower facia panel on the driver’s side.
Unclip the fusebox panel, then detach the
ignition switch wiring multi-plug connector
from the fusebox. Release the switch wire
from the tie clips and remove the switch.
5 Refitting is a reversal of the removal
procedure. When relocating the switch to the
steering lock, the barrel driveshaft must align
with the switch shaft as it is pushed into
position. Check the switch for satisfactory
operation on completion.

Steering column multi-function
switch

6 Remove the steering wheel as described in
Chapter 10.
7 Undo the two upper and four lower
retaining screws, and remove the upper and
lower steering column shrouds.
8 Undo the single retaining screw, and
withdraw the switch upwards from the
steering column. Detach the wiring connector
and cable tie clips from the switch (see
illustrations).
9 Separate the indicator/hazard warning relay
and switch from the indicator switch unit.
10 Refit in the reverse order of removal. Refer
to Chapter 10 for information required when
refitting the steering wheel.

Facia switches

11 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
12 The facia and associated panel-mounted
switches are secured in position by integral
plastic or metal retaining clips. In some
instances, it is possible to release the switch
from the panel using a suitable small
screwdriver inserted between the switch and
the facia to lever the switch from its aperture,
but take care not to apply too much force
when trying this method.

13 Once the switch is released and partially
withdrawn from the panel, detach the wiring
connector and remove the switch (see
illustration).
14 Refitting is a reversal of removal.

Courtesy light switches

15 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
16 With the door open, undo the retaining
screw and withdraw the switch from the door
pillar. Pull out the wiring slightly, and tie a
piece of string to it, so that it can be retrieved
if it drops down into the door pillar.
17 Disconnect the wiring from the switch.
18 Refitting is a reversal of removal.

Luggage area light switch

19 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
20 Open the tailgate, undo the two securing
screws and remove the rear trim panel to gain
access to the rear side of the switch.
21 Release the switch side retaining clips
using a thin-bladed screwdriver, and push the
switch from its location in the body.

Body electrical system  12•5

4.3B  . . . and remove the ignition switch

4.3A  Depress the lock tabs . . .

4.13  Facia switch removal

4.8B  . . . lift the switch clear and detach

the wiring connector

4.8A  Undo the retaining screw . . .

12

Where a switch is reluctant to
be released, remove the
section of the facia panel or
the adjoining

panel/component to allow access to
the rear side of the switch and
compress the retaining clips to enable
the switch to be withdrawn.