Ford Orion. Manual - part 63

8 Turn the bulbholder a quarter-turn to align
the shoulders with the slots, then remove it
and pull the capless bulb from the bulbholder
(see illustration).
9 Fit the new bulb in reverse order.

Heater control panel
illumination

10 Undo the two retaining screws from its
upper edge, and withdraw the instrument
panel surround.
11 Pull free the heater control knobs, then
undo the heater control panel retaining
screws. Withdraw the panel from the facia just
enough to gain access to the bulbs on its rear
face (see illustration).
12 Twist the bulbs anti-clockwise to remove
them.
13 Refit in the reverse order of removal, and
check for satisfactory operation on
completion.

Automatic transmission selector
illumination

14 Prise out the lever quadrant cover (taking
care not to scratch the console), then pull the
bulbholder from under the selector lever
position indicator, untwist and remove the
bulb from the holder.
15 Fit the new bulb in the reverse order of
removal.

Glovebox light

16 Open the glovebox, then undo the two

retaining screws and withdraw the light/switch
unit.
17 Prise free the switch/bulbholder, then
untwist and remove the bulb from the holder
(see illustration).
18 Fit the new bulb using a reversal of the
removal procedure.

Hazard warning light tell-tale

19 Pull free the cover from the switch, then
pull free the bulb from the switch/holder.
20 Refit in the reverse order of removal, and
check for satisfactory operation.

Clock illumination

21 Engage the hooked ends of a pair of
circlip pliers in the two holes in the underside
of the clock bezel as shown, and carefully pull
free the clock from its aperture in the facia.
The bulbholder can then be untwisted and
withdrawn from the rear face of the clock and
the bulb renewed (see illustrations).
22 Refit in the reverse order of removal.

Cigar lighter illumination

23 Remove the lighter (Section 12), then
withdraw the illumination ring from the facia.
Remove the bulb from the illumination ring.
24 Refit in the reverse order of removal.
Check for satisfactory operation on
completion.

7

Exterior light units - 
removal and refitting

2

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1), before
removing any of the light units.

Headlight

2 Open and support the bonnet, then on pre-
1993 models, undo the four retaining screws
along the top edge of the grille panel, and lift
the panel clear. On 1993-on XR3i models,
undo the four screws, release the two clips
and remove the plastic support bracket above
the radiator.
3 Remove the front indicator as described
later in this Section.
4 Detach the wiring connections from the
headlight and sidelight in the rear of the
appropriate headlight unit.
5 Working through the cut-out of the direction
indicator, unscrew the headlight lower
retaining screw, then undo the two upper
securing screws from the points indicated
(see illustration). On later models, there is an
additional upper retaining screw. Withdraw
the headlight forwards from the vehicle.
6 If a new headlight is to be fitted, remove the
headlight and sidelight bulbs/holders, and
transfer them to the new light unit as
described in Section 5. The individual parts of
the headlight are not otherwise renewable.

12•10 Body electrical system 

7.5  Headlight unit retaining screws

(arrowed)

6.21B  . . . for access to the bulbholder

6.21A  Pull free the clock from the facia . . .

6.17  Glovebox light switch/bulbholder

removal

6.11  Heater control panel illumination bulb

locations (arrowed)

6.8  Bulbholder removal from the

instrument panel

7 Refitting is a reversal of the removal
procedure. When fitting the headlight into
position, ensure that the location pin sits in its
recess, and note the arrangement of the
insulating washers on the retaining screws
(see illustrations). Loosely locate the
headlight, and temporarily fit the indicator to
check that the gap between the headlight and
the indicator is even. Fully tighten the upper
retaining screws, then remove the indicator to
tighten the lower headlight screw.
8 When the headlight and indicator units are
fitted and their wiring connectors attached,
check the lights for satisfactory operation
before fitting the front grille panel.
9 Finally adjust the headlight beam alignment
as described in Section 8.

Front direction indicator

All models except XR3i

10 Unhook the retaining spring from the rear
of the direction indicator (see illustration
5.14).
11 Move the direction indicator forwards in
order to release it.
12 Turn the bulbholder and release it from
the rear of the direction indicator.
13 Remove the direction indicator from the
vehicle.
14 Refitting is a reversal of removal. Check
that the operation of the indicator is
satisfactory on completion.

XR3i models

15 Insert a small screwdriver between the top
edge of the light and the bumper, and lift up
the retaining clip (see illustration 5.18).
16 Carefully withdraw the indicator assembly
from the bumper.
17 Turn the bulbholder and release it from
the rear of the direction indicator.
18 Refitting is a reversal of removal. Check
that the operation of the indicator is
satisfactory on completion.

Front sidelight (XR3i models)

19 Unhook the retaining spring from the rear
of the sidelight unit.
20 Move the sidelight forwards in order to
release it.
21 Turn the bulbholder and release it from
the rear of the sidelight.
22 Remove the sidelight from the vehicle.

23 Refitting is a reversal of removal. Check
that the operation of the sidelight is
satisfactory on completion.

Front foglight (XR3i models)

24 Insert a small screwdriver between the top
edge of the direction indicator light and the
bumper, and lift up the retaining clip (see
illustration 5.18).
25 Carefully withdraw the direction indicator
from the bumper.
26 Turn the bulbholder and release it from
the rear of the direction indicator.
27 Swing back the direction indicator
retaining spring clip then ease the foglight out,
on the spring clip side, and pull it forward (see
illustration 5.28).
28 Detach the bulbholder and remove the
unit.
29 Refitting is a reversal of removal. Check
that the operation of the foglight is
satisfactory on completion.

Direction indicator side repeater

30 Raise and support the bonnet. Detach the
indicator wiring multi-plug at the bulkhead,
and attach a length of string to the connector
end of the wire going to the side repeater.
This will act as a guide to feed the wire back
through the body channels when refitting the
repeater unit.
31 Rotate the light in a clockwise direction to
release it from the body panel, and withdraw it
from the vehicle. When the wiring connector
and string are drawn through, they can be
separated and the string left in position.

32 Refitting is a reversal of removal. Attach
the wire to the string and draw it through the
body panels, then disconnect the string and
reconnect the light multi-plug at the bulkhead.
When the light is refitted, check for
satisfactory operation.

Rear light cluster

33 Working in the luggage area, release the
rear bulbholder (according to type) from the
side concerned as described in Section 5.
34 Unscrew the mounting nuts and withdraw
the rear light lens from the rear of the vehicle
(see illustration).
35 Renew the seal gasket if it is in poor
condition. Refit in the reverse order to
removal, and check for satisfactory operation
of the rear lights on completion.

Number plate lights

36 Prise the number plate light from the rear
bumper using a small screwdriver, then
disconnect the wiring plug (see photo 13.26).
37 Refitting is a reversal of removal.

Rear foglight (1993 model year
onwards)

38 With the tailgate open, undo the ten
retaining screws and withdraw the tailgate
inner trim panel.
39 Disconnect the bulbholder multi-plug,
then undo the retaining nut and remove the
foglight.
40 Refitting is a reversal of removal.

8

Headlight beam alignment -
checking and adjustment

2

1 Accurate adjustment of the headlight beam
is only possible using optical beam-setting
equipment, and this work should therefore be
carried out by a Ford dealer or service station
with the necessary facilities.
2 Temporary adjustment can be made when
the headlight has been removed and refitted,
or to compensate for normal adjustment
whenever a heavy load is being carried. Turn
the adjustment screws on the top and rear of
the headlight to make the adjustment (see
illustration).

Body electrical system  12•11

7.7B  Headlight retaining screw showing

washer arrangement

7.7A  Headlight engagement pin

8.2  Horizontal (A) and vertical (B) headlight

beam adjustment screws

7.34  Rear light lens showing the retaining

nuts

12

3 Before making any adjustments to the
headlight settings, it is important that the tyre
pressures are correct, and that the vehicle is
standing on level ground. Bounce the front of
the vehicle a few times to settle the
suspension. Ideally, somebody of normal size
should sit in the driver’s seat during the
adjustment, and the vehicle should have a full
tank of fuel.
4 Whenever temporary adjustments are
made, the settings must be reset as soon as
possible once the vehicle is in normal use.

9

Instrument panel - 
removal and refitting

1

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Although not strictly necessary, in order to
withdraw the instrument panel, the removal of
the steering wheel will provide much
improved access, particularly when detaching
(and subsequently reconnecting) the
speedometer cable and wiring multi-plugs
from the rear of the unit. Refer to Chapter 10
for steering wheel removal and refitting
procedures.
3 Undo the two retaining screws from the
underside top edge of the instrument panel
bezel and withdraw the bezel, releasing it from

the location clips each side and underneath
(see illustration).
4 Unscrew and remove the four instrument
panel retaining screws, and carefully withdraw
the panel to the point where the wiring multi-
plugs and the speedometer cable can be
detached from the rear (see illustrations).
Note that it may be necessary to push the
speedometer cable through the from the
engine compartment side to allow the
instrument panel to be sufficiently withdrawn.
Take care when handling the instrument panel
whilst it is removed, and position it in a safe
place where it will not get knocked or
damaged. If a tachometer is fitted, do not lay
the panel on its face for extended periods, as
the silicone fluid in the tachometer may well
be released.

Refitting

5 Refitting is a reversal of removal. On
completion check the function of all electrical
components.

10 Instrument panel

components - 
removal and refitting

1

Removal

1 Remove the instrument panel as described
in Section 9. As mentioned, take particular
care when handling the panel.

Printed circuit

2 Untwist and remove all of the illumination
light bulbs/holders from the rear of the
instrument panel (see illustration).
3 Carefully release and remove the wiring
multi-plug connector from the rear face of the
panel. Pull free the printed circuit, releasing it
from the securing pins and the air-cored
gauge terminals on the rear face of the panel
(see illustration).

Speedometer

4 Remove the odometer reset knob, then
release the four securing clips and remove the
two bulbs and the panel surround from the
panel. Withdraw the speedometer (see
illustration).

Tachometer

5 Remove the odometer reset knob, release
the securing clips, remove the two bulbs and
the panel surround from the panel.
6 Applying great care, detach the printed
circuit from the air-cored gauge terminals,
and remove the tachometer from the panel.
Do not lay the gauge on its face for extended
periods, as the silicone fluid in the tachometer
may well be released.

Fuel/temperature gauge

7 Remove the odometer reset knob, release
the securing clips, remove the two bulbs and
the panel surround from the panel.
8 Applying great care, detach the printed

12•12 Body electrical system 

10.4  Speedometer removal from the

instrument cluster

10.3  Printed circuit removal (A) and

refitting (B) to/from the rear face of the

instrument panel

10.2  Rear face of the instrument panel

showing bulbholder locations

9.4B  Detach the wiring multi-plugs from

the instrument panel

9.4A  Instrument cluster retaining screws

9.3  Instrument panel bezel retaining screw

locations (arrowed)

circuit from the air-cored gauge terminals.
Undo the two retaining screws, and remove
the fuel/temperature gauge from the panel
(see illustration).

Refitting

9 Refitting is a reversal of removal. When
refitting the printed circuit, ensure that it is
gently pushed back into contact with the
securing pins and gauge terminals.

11 Speedometer cable - 

removal and refitting

1

1 Remove the instrument panel as described
in Section 9.
2 Unscrew the speedometer cable from the
pinion/speed sensor on the transmission.
3 Release the cable ties and retaining clips in
the engine compartment, and withdraw the
cable grommet from the bulkhead.
4 Note the cable routing for use when
refitting. Pull the speedometer cable through
into the engine compartment, and remove it
from the car (see illustration).
5 Refitting is the reversal of removal. Ensure
that the cable is routed as noted before
removal, secured with the relevant clips and
cable ties, and that the grommet is properly
located in the bulkhead.

12 Cigar lighter - 

removal and refitting

1

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Pull out the ashtray and reaching through
its aperture in the facia, disconnect the wiring
from the cigar lighter.
3 Push the cigar lighter out of its location, and
disconnect the wiring (see illustration).
4 Extract the lighter element, then reaching
through with a thin-bladed screwdriver, unclip

and release the lighter body from the
illumination ring.
5 If required, the lighter illumination ring can
be pulled free and withdrawn from the facia.

Refitting

6 Refitting is a reversal of removal.

13 Clock - 

removal and refitting

1

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Proceed as described in Section 6,
paragraph 21, and carefully prise the clock
from the facia. Disconnect the wiring plug
from the rear face of the clock.

Refitting

3 Refitting is a reversal of removal. Reset the
clock on completion.

14 Horn - 

removal and refitting

1

Removal

1 The horn(s) are located on the body front
valance, behind the front bumper (see

illustration). To remove a horn, first apply the
handbrake, then jack up the front of the
vehicle and support it on axle stands.
2 Disconnect the horn wiring plug(s).
3 Unscrew the nut securing the horn(s) to the
mounting bracket, and remove the horn(s)
from the vehicle.

Refitting

4 Refitting is a reversal of removal.

15 Wiper arms - 

removal and refitting

1

1 With the wiper(s) “parked” (ie in the normal
at-rest position), mark the positions of the
blade(s) on the screen, using a wax crayon or
strips of masking tape.
2 Lift up the plastic cap from the bottom of
the wiper arm, and loosen the nut one or two
turns (see illustration).
3 Lift the wiper arm, and release it from the
taper on the spindle by moving it from side to
side.
4 Completely remove the nut and washer,
then withdraw the wiper arm from the spindle.

Refitting

5 Refitting is a reversal of the removal
procedure. Make sure that the arm is fitted in
the previously-noted position.

Body electrical system  12•13

12.3  Cigar lighter components

11.4  Withdrawing the speedometer cable

through the bulkhead

10.8  Air-cored fuel/temperature gauge

removal from the instrument cluster

15.2  Windscreen wiper arm retaining nut

14.1  Horn location

12

A

Wiring connectors

B Illumination ring

C Lighter body
D Element