Ford Orion. Manual - part 64

A

Cap

B Circlip
C Special washer

(1.8 mm)

D Special washer

(0.15 mm)

E

Bush

F

Wave washer

G Pivot shaft

16 Windscreen wiper motor and

linkage - removal and refitting

2

Removal

Wiper motor

1 Operate the wiper motor, then switch it off
so that it returns to its rest position.
2 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
3 Unscrew and remove the link arm-to-motor
spindle retaining nut (see illustration).
Disengage the arm from the spindle.
4 Undo the three wiper motor retaining bolts,
then move the wiper motor sideways from its
mounting bracket.
5 Detach the wiper motor wiring multi-plug,
withdraw the wiper motor and remove its
insulating cover.

Linkage

6 Remove the windscreen wiper arms (and
blades) from the pivots as described in
Section 15.
7 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1). Move the wiper
linkage to the required position for access to
the linkage balljoints, then carefully prise free

the linkages from their ball pins using a
suitable open-ended spanner as a lever (see
illustrations).
8 Remove the rubber seal from the pivot
bushes. Where the surfaces of the ball pins
are damaged, the pivot shaft and/or motor
must be renewed. The rubber seals which are
located over the edge of the pivot bushes
must be renewed during refitting.

Refitting

9 Refitting is a reversal of removal. Lubricate
the pivot bushes and the rubber seals during
reassembly. When reconnecting the link arm
on the motor spindle, ensure that the arm lug
engages in the slot in the taper of the motor
spindle. Check for satisfactory operation on
completion.

17 Windscreen wiper pivot

shaft - removal and refitting

2

Removal

1 Operate the wiper motor, then switch it off
so that it returns to its rest position.
2 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).

3 Remove the windscreen wiper arms as
described in Section 15.
4 Detach and remove the cowl grille. This is
secured by six plastic screws and two cross-
head screws located under plastic caps (see
illustration).
5 Unscrew and remove the four wiper motor
bracket retaining bolts, then remove the wiper
motor bracket assembly (see illustration).
Disconnect the wiring multi-plug as the motor
bracket assembly is withdrawn.
6 Prise free the wiper linkage from the pivot
shaft using a suitable open-ended spanner.
7 Pull free the pivot shaft cap from the
housing, release the circlip, withdraw the two
special washers and remove the pivot shaft.
The special washer and spring washer can
then be removed from the shaft (see
illustration).

Refitting

8 Refitting is a reversal of removal. Lubricate
the pivot shaft, bushes and rubber seals
during reassembly. When reconnecting the
link arm on the motor spindle, ensure that the
arm lug engages in the slot in the taper of the
motor spindle. Check for satisfactory
operation on completion.

12•14 Body electrical system 

17.7  Wiper pivot shaft components

17.5  Wiper motor bracket retaining bolt

locations

17.4  Remove the plastic screws (A) and

the cross-head screws (B) to remove the

cowl grille

16.7B  Windscreen wiper linkage-to-pivot

shaft connection

16.7A  Windscreen wiper linkage to motor

balljoint connection

A

Pivot bush

B Wiper motor arm

C Rubber seal

A

Pivot bush

B Rubber seal

C Pivot shaft

16.3  Windscreen wiper motor showing link

arm-to-spindle connection (A) and two of

the wiper motor-to-mounting retaining

bolts (B)

18 Tailgate wiper motor

assembly - 
removal and refitting

1

Removal

1 Operate the wiper, then switch it off so that
it returns to its rest position. Note that the
wiper motor will only operate with the tailgate
shut, as the spring-tensioned connector pins
must be in contact with the contact plates.
2 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
3 Remove the wiper arm with reference to
Section 15.
4 Unscrew the nut from the spindle housing
protruding through the tailgate.
5 Undo the eight plastic screws (early
models), ten screws (later models) and
remove the trim panel from inside the tailgate.

7 Unbolt and remove the wiper assembly
from inside the tailgate (see illustrations).
8 If necessary, the wiper motor can be
detached from its mounting bracket by
unscrewing the three retaining bolts (see
illustration). As they are detached, note the
location of the washers and insulators.

Refitting

9 Refitting is a reversal of removal. When the
wiper arm is refitted, its park position should

be set correctly. On Hatchback models, the
distance from the point where the arm meets
the centre of the wiper blade should be 
90 ± 5 mm from the bottom of the rear
window. On Estate models, this distance
should be 75 ± 5 mm.

19 Windscreen/tailgate washer

system components -
removal and refitting

1

Removal

Washer pump

1 To remove the pump from the reservoir,
first syphon out any remaining fluid from the
reservoir, then detach the washer hoses and
the wiring multi-plug to the washer pump. The
pump can now be pulled (or if required),
levered free from the reservoir (see
illustration).

Reservoir and pump

2 To remove the washer reservoir and pump,
first unscrew and remove the reservoir
retaining bolt in the engine compartment (see
illustration).
3 Refer to Chapter 11 for details, and remove
the wheel arch liner trim on the left-hand side.
4 Detach the pump multi-plug, the washer
low fluid level switch multi-plug (where fitted)
and the pump hoses, and disconnect them
from the reservoir. Drain any fluid remaining in

the reservoir/pump into a suitable container.
5 Unscrew and remove the two reservoir
retaining bolts from under the wheel arch,
then remove the reservoir and pump from the
vehicle.
6 If required, pull or prise free the pump to
remove it from the reservoir.

Hoses

7 The hose system to the windscreen
washers is in sections, with nylon connector
pieces where required. This means that any
section of hose can be renewed individually
when required. Access to the hoses in the
engine compartment is good, but it will be
necessary to detach and remove the
insulation panel from the underside of the
bonnet to allow access to the hoses and
connections to the washer nozzles.

Body electrical system  12•15

18.7B  Tailgate wiper motor and mounting

bolts (arrowed) on Estate models

18.7C  Removing the wiper motor from the

tailgate (Hatchback models)

18.7A  Tailgate wiper motor and mounting

bolts (arrowed) on Hatchback models

18.6  Tailgate wiper earth lead and in-line

connector

19.2  Washer reservoir retaining bolt in the

engine compartment

19.1  Washer pump and hose locations

under the front wheel arch

18.8  Tailgate wiper motor-to-mounting

bracket bolts (Hatchback models)

12

8 The front washer reservoir also supplies the
rear tailgate washer by means of a tube
running along the left-hand side within the
body apertures.

Nozzles

9 These are secured to the body panels by
retaining tabs which are an integral part of the
washer nozzle stem. To remove a washer
nozzle, first detach and remove the insulation
from the underside of the bonnet, or the
appropriate trim piece (according to type) for
the tailgate washer (see illustration).
10 Using suitable needle-nosed pliers,
squeeze together the nozzle retaining tabs,
twist the nozzle a quarter of a turn, and
withdraw it from its aperture in the body (see
illustration). Once withdrawn, the hose can
be detached and the nozzle removed. Do not
allow the hose to fall into the body whilst the
nozzle is detached - tape the hose to the body
to prevent this.

Refitting

11 Refitting is a reversal of removal. Always
renew the pump-to-reservoir seal washer, and
ensure that all connections are securely
made. When reconnecting the pump hoses,
ensure that the hose marked with white tape
is connected to the corresponding white
connection on the pump.
12 On completion, top-up the washer
reservoir using a suitable washer additive and
check that the operation of the washers is
satisfactory. If necessary, adjust the washer

jets by inserting a pin into the centre of the jet
and directing the flow at the top part of the
windscreen/rear window.

20 Radio/cassette player -

removal and refitting

4

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1). If the radio has
a security code, make sure this is known
before disconnecting the battery.
2 In order to release the radio retaining clips,
two U-shaped rods must be inserted into the
special holes on each side of the radio (see
illustration). If possible, it is preferable to
obtain purpose-made rods from an audio
specialist, as these have cut-outs which snap
firmly into the clips so that the radio can be
pulled out. Pull the unit squarely from its
aperture, or it may jam. If the unit proves
difficult to withdraw, remove the cassette tray
(or where applicable, the CD player) from
beneath the unit, then reach through the
aperture and ease it out from behind. From
1993 model year onwards, it will first be
necessary to remove the two side bezels
using a Ford tool, to gain access to the
removal tool holes.
3 With the radio/cassette sufficiently
withdrawn, disconnect the feed, earth, aerial

and speaker leads (see illustration). Where
applicable, also detach and remove the
plastic support bracket from the rear of the
unit.

Refitting

4 Refitting is a reversal of removal. When the
leads are reconnected to the rear of the unit,
press it into position to the point where the
retaining clips are felt to engage. Reactivate
the unit in accordance with the code and the
manuals given in the Ford Audio Operating
Manual supplied with the vehicle.

21 Compact disc player -

removal and refitting

1

The removal and refitting procedures for

this (where fitted) are similar to those
described for the radio/cassette player in the
previous Section, but do not remove the bezel
securing screws above the CD player.

22 Speakers - 

removal and refitting

3

Removal

Door-mounted speaker

1 Remove the trim panel from the door
concerned as described in Chapter 11. Undo
the speaker retaining screws, then withdraw
the speaker from the door and disconnect the
wiring  (see illustration). Note that the
speaker must not be detached from its
moulding.

Rear quarter panel-mounted speaker
(Cabriolet models)

2 Lower the hood. If the hood is manually-
operated, lock it in the lowered position, then
pull free the roof release lever knob.
3 Remove the quarter window regulator or lift
switches (according to type), and remove the
rear quarter trim panel as described in
Chapter 11. Undo the three retaining screws

12•16 Body electrical system 

22.1  Door-mounted speaker removal

20.3  Wiring and aerial lead connections on

the rear face of the radio/cassette

20.2  Radio/cassette removal

19.10  Washer nozzle removal

19.9  Remove trim for access to the

tailgate washer nozzle

and withdraw the speaker (see illustration).
Disconnect the wiring from the speaker. Note
that the speaker must not be detached from
its moulding.

Rear parcel shelf-mounted speaker
(Saloon models)

4 Detach the wiring connector from the
speaker, then loosen off (but do not remove),
the speaker retaining bolt sufficiently to allow
the speaker to be withdrawn, leaving the
bracket and bolt in position in the speaker
recess (see illustration).

Rear parcel tray-mounted speaker
(Hatchback models)

5 Unscrew the three retaining screws, lower
the speaker from the parcel tray, then detach
the wiring connections (see illustration). Note
that the speaker and its moulding must not be
separated.

Luggage area trim-mounting speaker
(Estate models)

6 Remove the appropriate luggage area side
trim panel as described in Chapter 11 for
access to the speaker.
7 Unscrew the three retaining screws,
withdraw the speaker and detach the wiring
connections (see illustrations). Note that the
speaker and its moulding must not be
separated.

Refitting

8 Refitting is a reversal of removal.

23 Radio aerial - 

removal and refitting

1

Removal

Manual type (Hatchback, Saloon and
Estate models)

1 Remove the trim cover from the access
aperture in the headlining beneath the aerial
by carefully prising it free.

2 Working through the aperture in the
headlining, undo the single retaining screw,
withdraw the aerial and detach the cable base
from the roof (see illustration).

Manual type (Cabriolet models)

3 Open the boot lid, disconnect its support
strut from the left-hand side panel, then undo
the two retaining screws and remove the
luggage area side trim panel.
4 Unscrew and remove the aerial mast, then
unscrew and remove the collar retaining nut to
remove the spacer and upper seal washer
(see illustration).
5 Working within the luggage area side of the
quarter panel, unscrew the lead and remove
the aerial.

Electric aerial (Cabriolet models)

6 Open the boot lid, disconnect its support
strut from the left-hand side panel, then undo
the two retaining screws and remove the
luggage area side trim panel.

Body electrical system  12•17

22.5  Rear parcel shelf-mounted speaker

(Hatchback models)

22.4  Remove the retaining bolt (A) and

detach the wiring connector (B) to remove

the rear parcel shelf-mounted speaker on

Saloon models

22.3  Rear quarter panel speaker retaining
screws and wiring connector on Cabriolet

models

22.7B  Detach the wiring from the speaker

22.7A  Luggage area-mounted speaker

(Estate models)

23.2  Roof-mounted aerial retaining screw

23.4  Manual aerial components on Cabriolet models

12

A

Top collar nut

B Spacer
C Seal washer
D Lower aerial section