Ford Orion. Manual - part 65

7 Unscrew the aerial upper retaining nut, then
remove the bezel and the seal washer.
8 Working from the luggage area side,
unscrew and remove the self-tapping screw
securing the aerial bottom bracket to the
apron.
9 Unscrew the knurled type nut to detach the
aerial from the base of the unit, then detach
the wiring and aerial lead at their connections,
and withdraw the aerial from the vehicle (see
illustration).

Refitting

10 Refitting is a reversal of removal. Ensure

that the contact surfaces of both the body
panel and the aerial are clean before fitting the
aerial into position.

24 Power amplifier - 

removal and refitting

1

Removal

1 This is fitted to models equipped with the
Premium Sound System, and is located in the
area between the glovebox and the bulkhead.

2 To remove the amplifier, undo the retaining
screw, lower the unit complete with its
support bracket, and detach the wiring multi-
plug connectors (see illustration). If required,
the bracket and the amplifier can be
separated by unscrewing the four Torx
screws.

Refitting

3 Refit in the reverse order of removal.

25 Anti-theft systems - 

general information

Anti-theft alarm system

1 This system provides an added form of
vehicle security (see illustration). When the
system is activated, the alarm will sound if the
vehicle is broken into through any one of the
doors, the bonnet, boot (or tailgate). The
alarm will also be triggered if the ignition
system is turned on or the radio/cassette
disconnected whilst the system is activated.
2 This system is activated/de-activated
whenever one of the front doors is
locked/unlocked by the key. The system
operates on all doors, the bonnet and boot lid
(or tailgate) whenever each door is individually

12•18 Body electrical system 

25.1  Anti-theft alarm system components and their locations

A

Trip switch (luggage
compartment)

B System module
C Alarm horn

D Alarm switch (bonnet)
E

Alarm switch (doors)

F

Activation switches

G Clock

24.2  Power amplifier securing bolts

23.9  Electric aerial wiring (A) and aerial (B)

connections

locked (or, in the case of central locking, when
the central locking is engaged). It is important
to note that opening the bootlid/tailgate first
when the system is activated will trigger the
alarm. In addition to the alarm being sounded,
the ignition/starting system is also
immobilised when the system is activated.
3 A further security feature included is that
even though the battery may be disconnected
whilst the system is activated, the alarm
activation continues as soon as the battery is
reconnected. Because of this feature, it is
important to ensure that the system is de-
activated before disconnecting the battery at
any time, such as when working on the
vehicle.
4 The system incorporates a diagnostic mode
to enable Ford technicians to quickly identify
any faults in the system.

Anti-theft alarm system
activation and check

5 Fully insert the door lock key into the lock of
the front door (driver’s or passenger side),
turn the key as far as possible, and hold in this
position for one second. With the doors,
bonnet and boot lid/tailgate all closed, a
twenty-second activation delay starts from
this point, although access to the luggage
area is still possible within the activation
period without triggering the alarm. When the
bootlid/tailgate is closed, the activation period
of twenty seconds restarts.
6 The initial activating period is confirmed by
the control light in the clock flashing on and
off rapidly; when the activation period is
complete, the control light flashes at a
reduced rate.
7 De-activation of the alarm system can only
be made by unlocking either of the front doors
with the key. This also applies when the alarm
has been triggered. If the bootlid/tailgate is
opened before one of the front doors is
unlocked, the alarm will be tripped, and can
only be stopped by unlocking one of the front
doors.
8 Any malfunctions in the system will be
indicated by the action of the control light as
soon as the ignition is switched on. When the
system
is in good order, the control light will come on
for five seconds; where a system fault exists,
the light will stay on for twenty seconds.
9 As well as the above-mentioned features,
models fitted with central locking incorporate
a double locking system, whereby the inner
door handles are also locked. This system is
activated by turning the door key fully to the
rear (unlocked) position, then to the front
(locked) position within a period of four
seconds. A sound buzzer indicates that the
vehicle is double-locked. When this system is
in operation, it can only be de-activated using
the door key to unlock one of the front doors.
In the event of the battery going flat or an
electrical fault in the system developing whilst
the system is activated, the doors can still be
unlocked in the normal manner using the key.

10 The bootlid/tailgate remote release fitted
to the centre console is only active when the
ignition is switched off and double locking is
not engaged.
11 Any malfunctions in this system are
indicated by the control light in the clock in
the same manner as that described for the
conventional anti-theft alarm system
(paragraph 8).
12 In the event of a fault in the system being
indicated, first check that all doors, the
bonnet and the bootlid/tailgate are fully
closed. If the system switches are checked,
ensure that their wiring connections are good
and secure, also that the switch plungers are
clean and are able to move freely.

Passive Anti-Theft System
(PATS)

13 From 1994 model year onwards, a
Passive Anti-Theft System (PATS) is fitted.
This system, (which works independently of
the standard alarm system) is a vehicle
immobiliser which prevents the engine from
being started unless a specific code,
programmed into the ignition key, is
recognised by the PATS transceiver.
14 The PATS transceiver, fitted around the
ignition switch, decodes a signal from the
ignition key as the key is turned from position
“O” to position “II”. If the coded signal
matches that stored in the memory of the
PATS module, the engine will start. If the
signal is not recognised, the engine will crank
on the starter but will not fire.
15 The PATS status is indicated by the LED
control light in the clock as used for the anti-
theft alarm system.

26 Anti-theft system

components - 
removal and refitting

1

Removal

1 Before disconnecting any components of
the anti-theft alarm system, first check that
the system is de-activated, then disconnect
the battery negative (earth) lead (refer to
Chapter 5, Section 1).

Door lock switch

2 Remove the trim panel and the insulation
sheet from the door, as described in Chap-
ter 11.
3 Detach the wiring multi-plug connector
from the alarm switch in the door (see
illustration).
4 Release the snap-lock catch, withdraw the
switch from the door lock cylinder, and
remove it from the door.

Door lock ajar switch

5 Remove the trim panel and the insulation
sheet from the door, as described in Chap-
ter 11.
6 Detach the wiring multi-plug from the door
lock ajar switch.
7 Remove the door lock as described in
Chapter 11.
8 Release the retaining clip, and detach the
door ajar switch from the door lock. It is
probable that the retaining clip will break
when releasing the switch, in which case it will
need to be renewed.

Bootlid/tailgate ajar switch

9 Undo the retaining screws, and remove the
trim panel from the bootlid or tailgate (as
applicable).
10 Detach the wiring loom multi-plug, then
referring to Chapter 11 for details, remove the
lock from the bootlid/tailgate.
11 Release the retaining clip and detach the
ajar switch from the lock unit. It is probable
that the retaining clip will break when
releasing the switch, in which case it will need
to be renewed.

Bonnet alarm switch

12 Grip the switch flange, and pull the switch
up and clear of its aperture in the front cross-
panel (see illustration).
13 Disconnect the wiring connector and
remove the switch.

Alarm horn

14 Where the vehicle is fitted with ABS,
detach and remove the ABS module as
described in Chapter 9.
15 Detach the wiring from the horn, undo the
horn bracket retaining bolts, and remove the

Body electrical system  12•19

26.12  Bonnet alarm switch removal (anti-

theft alarm system)

26.3  Door lock switch wiring connector (A)

and retaining catch (B)

12

horn together with its retaining bracket (see
illustration).

Alarm system module

16 Detach and remove the cowl side trim
kick panel.
17 Detach the wiring multi-plug from the
module, then release the module from the four
retaining clips and remove it.

PATS transceiver

18 Undo the two upper and four lower
retaining screws, and remove the steering
column upper and lower shrouds.
19 Undo the five screws and withdraw the
detachable lower facia panel from beneath
the steering column.
20 Undo the single screw, and withdraw the
PATS transceiver from the ignition
switch/steering lock barrel (see illustration).
21 Release the wiring harness from the clips
on the steering column, trace the harness
under the facia, and disconnect the wiring
multi-plug. Remove the transceiver from the
car.

PATS module

22 Refer to Chapter 11 and remove the facia.
23 Disconnect the wiring multi-plug from the
PATS module, located on the bulkhead on the
passenger’s side.
24 Pull the module downwards to remove it
from the mounting bracket.

Refitting

18 The refitting of the respective components

is a reversal of the removal procedure. Ensure
that all component retaining clips are secure,
that the wiring looms are correctly routed, and
that the wiring connections are secure. Check
for satisfactory operation of the systems to
complete.

27 Air bag (driver’s side) -

removal and refitting

4

Warning: Handle the air bag with
extreme care as a precaution
against personal injury, and
always hold it with the cover

facing away from your body. If in doubt
concerning any proposed work involving
the air bag or its control circuitry, consult
a Ford dealer or other qualified specialist.
1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).

Warning: Before proceeding, wait
a minimum of 15 minutes, as a
precaution against accidental
firing of the air bag unit. This

period ensures that any stored energy in
the back-up capacitor is dissipated.
2 Undo the two screws, and remove the
steering column upper shroud.
3 Turn the steering wheel as necessary so
that one of the air bag retaining bolts
becomes accessible from the rear of the
steering wheel. Undo the bolt, then turn the
steering wheel again until the second bolt is
accessible. Undo this bolt also.
4 Withdraw the air bag from the steering
wheel far enough to access the wiring multi-
plug (see illustration). Some force may be
needed to free the unit from the additional
steering wheel spoke retainers.
5 Disconnect the multi-plug from the rear of
the unit, and remove it from the vehicle. 

Warning: Position the air bag in a
safe place, with the mechanism
facing downwards as a precaution
against accidental operation.

Warning: Do not attempt to open
or repair the air bag unit, or apply
any electrical current to it. Do not
use any air bag which is visibly

damaged or which has been tampered
with.

Refitting

6 Refitting is a reversal of the removal
procedure.

28 Air bag control module -

removal and refitting

4

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).

Warning: Before proceeding, wait
a minimum of 15 minutes, as a
precaution against accidental
firing of the air bag unit. This

period ensures that any stored energy in
the back-up capacitor is dissipated.
2 Undo the six screws and withdraw the
detachable lower facia panel from beneath
the steering column.
3 Disconnect the multi-plug from the module,
by pressing the locking tab upwards and
swivelling the retaining strap.
4 Unscrew the mounting bolts and remove
the module from the vehicle.

Refitting

5 Refitting is a reversal of the removal
procedure.

29 Air bag clock spring -

removal and refitting

3

Removal

1 Remove the steering wheel as described in
Chapter 10.
2 Disconnect the wires at the two horn
terminals in the centre of the steering wheel.
3 Undo the three retaining screws, and
remove the clock spring/horn slip ring from
the steering wheel (see illustration). As the
unit is withdrawn, note which aperture in the
steering wheel the air bag wiring passes
through, as an aid to reassembly.

12•20 Body electrical system 

29.3  Removing the air bag clock spring

assembly from the steering wheel

27.4  Withdrawing the air bag module from

the steering wheel

26.20  Undo the screw (arrowed) and

withdraw the PATS transceiver from the

ignition switch/steering lock barrel

26.15  Alarm system horn

Refitting

4 Apply a smear of molybdenum disulphide
grease to the horn slip rings.
5 Position the clock spring/horn slip ring on
the steering wheel, and secure with the
retaining screws.
6 Reconnect the two horn wires to their
terminals.
7 The clock spring must now be centred as
follows.
8 Depress the locking pin, and rotate the
clock spring outer rotor fully anti-clockwise
until it is tight (see illustration).
9 Now turn the outer rotor approximately 3.75
turns clockwise, then release the locking pin.
Ensure that the locking pin engages when it is
released.
10 Check that the relative position of the
direction indicator cancelling cam to the cable
connector on the clock spring assembly is as
shown (see illustration 29.8).
11 Refit the steering wheel as described in
Chapter 10.

30 Auxiliary warning system -

general information and
component renewal

1

1 An auxiliary warning system is available as
an option on certain models (see illustration).
The system has three functions - low fuel
warning, low washer fluid level warning, and
an “ignition off, lights on, driver’s door open”
warning.
2 The low fuel and washer fluid level warnings
are provided by warning lights in the
instrument panel and the “ignition off, lights

on, driver’s door open” warning is provided by
an audible alarm tone.
3 The warning lights are activated by floats
which monitor the fuel and fluid levels. The
float for the low fuel level is an integral part of
the fuel gauge sender, and activates the
warning light when the fuel level in the tank
drops to below 10 litres (2.2 gallons). The float
for the washer fluid level is contained in the
fluid reservoir, and consists of a magnet
which operates a reed switch inserted in the
side of the reservoir. When the fluid level falls
to the level of the reed switch, the magnet on
the float activates the switch to illuminate the
warning light.
4 The alarm tone for the “ignition off, lights
on, driver’s door open” warning is activated
by the driver’s door courtesy light switch if the
door is opened with the ignition switched off
and the lights left on.
5 The operation of the system is controlled by
a control module assembly located under the
facia above the fusebox.

Component renewal

Warning lights

5 The procedure for warning light bulb
renewal is contained in Section 6.

Low fuel level float

6 The low fuel level float is part of the fuel
gauge sender - removal and refitting
procedures are contained in Chapter 4.

Low washer fluid level reed 
switch 

7 Remove the windscreen washer reservoir
as described in Section 19.
8 Withdraw the switch from the side of the
reservoir by levering against the switch body.
9 Ensure that the sealing grommet is
correctly fitted in the reservoir, then 
push the switch fully into the grommet to 
refit.
10 Refit the washer reservoir as described in
Section 19.

Control module assembly

11 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
12 Undo the six screws and withdraw the
detachable lower facia panel from beneath
the steering column.
13 Unclip the control module, and
disconnect the multi-plug.
14 Refitting is a reversal of removal.

Body electrical system  12•21

29.8  Centring the air bag clock spring.

Depress locking pin (A) and rotate outer

rotor (B) anti-clockwise (“X” indicates

relative position of the direction indicator

cancelling cam to the cable connector -

see text)

30.1  Auxiliary warning system components

A

Control module

B Low fuel level float

C Instrument panel warning lights
D Low washer fluid level switch

12