Ford Orion. Manual — part 62

22 Disconnect the wiring connectors and
remove the switch (see illustration).
23 Refit in the reverse order of removal.

Rear wiper contact switch

24 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
25 Open the tailgate and remove its inner
trim panel.
26 Working through the access aperture in
the tailgate, use a thin-bladed screwdriver to
depress the switch retaining clips and extract
the switch from the panel (see illustration).
27 Disconnect the wiring connectors and
remove the switch.
28 Refit in the reverse order of removal.
Make sure that the pins and their contacts are
clean. On completion, check the operation of
the rear wipers, courtesy light, heated rear

window and the tailgate release/central
locking system.

Handbrake warning light switch

29 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
30 Refer to Chapter 11 for details, and
remove the front passenger (left-hand) seat
and the centre console.
31 Detach the wiring connector from the
handbrake warning light switch, then undo the
two retaining screws and remove the switch
(see illustration).
32 Refit in the reverse order of removal.
Check that the switch operates in a
satisfactory manner before refitting the
console and seat.

Brake stop-light switch

33 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
34 The brake stop-light switch is attached to
the brake pedal mounting bracket (see
illustration).
35 Detach the wiring connector from the
switch, then twist the switch through a quarter
of a turn (90º) and withdraw it from the
bracket (see illustration).
36 Refit in the reverse order of removal.
Ensure that the neck of the switch is against
the pedal before turning the switch 90º to
secure it.
37 Check that the switch operates in a
satisfactory manner to complete. The switch
should not operate during the first 2 mm of

pedal travel, but must operate within 20 mm of
pedal travel. If necessary, adjustment can be
made by removing the switch from the bracket
and turning the adjuster nut as required.

Heater/blower motor switch

38 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
39 Pull free and remove the heater control
knobs.
40 Unscrew and remove the two instrument
bezel retaining screws, and remove the bezel.
41 Undo the four retaining screws, and
remove the heater panel facia. Detach the
wiring connector to the heater panel
illumination bulb.
42 Compress the switch tabs to pull free the
switch, then detach the wiring multi-plug from
the switch (see illustration).
43 Refit in the reverse order of removal.

Electric window switches

44 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
45 Insert a thin-bladed screwdriver between
the switch and the console, then carefully
prise free the switch from its location. If the
switch is reluctant to release, do not apply
excessive force; remove the centre console
(see Chapter 11 for details) and release the
switch from the underside.
46 Detach the wire connector from the
switch, and remove it (see illustration).
47 Refit in the reverse order of removal, then
check the switch for satisfactory operation.

12•6 Body electrical system

4.46 Electric window switch removal

4.42 Heater blower motor switch removal

4.35 Brake stop-light switch removal

4.34 Brake stop-light switch location

4.31 Handbrake warning light switch

4.26 Contact switch unit in the tailgate

4.22 Luggage area contact switch removal

from the rear panel

Electric door mirror switch

48 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
49 Carefully prise free the switch using a
thin-bladed screwdriver as a lever, but insert a
suitable protective pad between the
screwdriver and the housing to avoid damage.
50 Detach the wiring multi-plug connector
and remove the switch (see illustration).
51 Refit in the reverse order of removal, then
adjust the mirror and check that the operation
of the switch is satisfactory.

Powered roof switch (Cabriolet)

52 This switch is removed in the same manner
as that described for the electric window
switches in paragraphs 44 to 47 above.

Starter inhibitor switch
(automatic transmission)

53 Disconnect the battery negative (earth)
lead (refer to Chapter 5, Section 1).
54 The starter inhibitor switch is located on the
transmission housing, and prevents the engine
from being started with the selector lever in any
position except “P” or “N”. Access to the switch
is gained after raising and supporting the
vehicle at the front end on axle stands.
55 Detach the switch multi-plug, then unscrew
and remove the switch from the transmission,
together with its O-ring. As the switch is
removed, catch any fluid spillage in a suitable
container, and plug the switch aperture in the
transmission to prevent any further loss.

56 Refitting is a reversal of the removal
procedure. Use a new O-ring, and tighten the
switch securely. Ensure that the wiring
connection is securely made. On completion,
check that the engine only starts when the
selector is in the “P” or “N” position.

5

Bulbs (exterior lights) -
renewal

1

Note: Ensure that all exterior lights are
switched off before disconnecting the wiring
connectors to any exterior light bulbs. The
headlight and front sidelight bulbs are
removable from within the engine
compartment with the bonnet raised. Note
that if a bulb fails, and has just been in use, it
will still be extremely hot, particularly in the
case of a headlight bulb.

Headlight

1 Pull free the wiring connector from the rear
of the headlight on the side concerned (see
illustration).
2 Prise free the protector cap from the rear of
the headlight unit, then compress the
retaining wire clips and pivot them out of the
way (see illustrations).
3 Withdraw the bulb from its location in the
headlight (see illustration).
4 Fit the new bulb using a reversal of the
removal procedure. Make sure that the tabs
on the bulb support are correctly located in
the lens assembly.

5 Check the headlight beam alignment as
described in Section 8.

Front sidelight

All models except XR3i

6 Compress the wire retaining clip, and
detach the wiring connector from the sidelight
(see illustration).
7 Pull free the sidelight bulbholder from its
location in the rear of the headlight (see
illustration).
8 Remove the bulb from the bulbholder.

Body electrical system 12•7

5.2A . . . remove the rubber protector

cap . . .

5.1 Detach the wiring connector . . .

4.50 Electric door mirror switch

5.7 . . . and withdraw the sidelight

bulbholder

5.2B . . . compress the clips . . .

5.6 Detach the wiring connector . . .

5.3 . . . and withdraw the headlight bulb

12

Take care not to touch the
bulb glass with your fingers -
if accidentally touched, clean
the bulb with methylated

spirit.

9 Fit the new bulb using a reversal of the
removal procedure. Check for satisfactory
operation on completion.

XR3i models

10 Unhook the retaining spring from the rear
of the sidelight, and move the sidelight
forwards in order to release it.
11 Grip the bulbholder and pull it free from
the sidelight (do not pull on the wire).
12 Depress and twist the bulb to remove it
from the bulbholder.
13 Fit the new bulb using a reversal of the
removal procedure. As the light is fitted into
position, engage its tags in the slots of the
headlight unit. Check for satisfactory
operation on completion.

Front direction indicator

All models except XR3i

14 Unhook the retaining spring from the rear
of the direction indicator, and move the

direction indicator forwards in order to release
it (see illustration).
15 Grip the bulbholder and pull it free from
the indicator (do not pull on the wire).
16 Depress and twist the bulb to remove it
from the bulbholder (see illustration).
17 Fit the new bulb using a reversal of the
removal procedure. As the light is fitted into
position, engage its tags in the slots of the
headlight (see illustration). Check for
satisfactory operation on completion.

XR3i models

18 Insert a small screwdriver between the top
edge of the direction indicator light and the
bumper, and lift up the retaining clip (see
illustration).
19 Carefully withdraw the light unit from the
bumper.
20 Turn the bulbholder and release it from
the rear of the light unit.
21 Withdraw the old bulb and fit the new.

22 Guide the indicator back into the bumper
until the retaining clip engages.
23 Check for satisfactory operation.

Front direction indicator side
repeater

24 Carefully prise the light from the front wing,
taking care not to damage the paintwork.
25 Pull out the bulbholder and wiring, then
remove the bulb (see illustration).
26 Fit the new bulb using a reversal of the
removal procedure, and check for satisfactory
operation.

Front foglight (XR3i models)

27 Withdraw the front direction indicator as
described previously.
28 Swing back the direction indicator
retaining spring clip then ease the foglight out
on the spring clip side, and pull it forward (see
illustration).
29 Detach the bulbholder and remove the bulb.
30 Refitting is a reversal of removal. Check
that the operation of the foglight is
satisfactory on completion.

Rear light cluster

Hatchback and Saloon models

31 On pre-1993 model year vehicles, working
in the luggage area, press the lock tabs
(recessed in the rear face of the bulbholder on
the side concerned) in towards the centre,
and pull free the bulbholder. On later models,
release the two clips and remove the light
cluster trim. Disconnect the wiring multi-plug,
press the bulbholder retainer upwards, and
pull free the bulbholder (see illustrations).

12•8 Body electrical system

5.31B On later models, press the

bulbholder retainer (arrowed) upwards and

pull free the bulbholder

5.31A Rear bulbholder removal on pre-

1993 Saloon and Hatchback models

5.28 On XR3i models, swing back the

direction indicator unit retaining spring

clip, then ease the foglight out on the

spring clip side

5.25 Side repeater light assembly

5.18 Using a screwdriver to release the

direction indicator light unit on XR3i models

5.17 Engage the tags in their locating slots

when refitting the front indicator unit

5.16 Front indicator bulb renewal

5.14 Front indicator unit retaining spring

32 Depress and twist the bulb concerned to
remove it from the holder (see illustration).
33 Fit the new bulb using a reversal of the
removal procedure. Relocate the holder by
pressing it in until the retainers engage. Refit
the multi-plug, where applicable. Check the
operation of the rear lights on completion.

Estate models

34 Prise back the rear trim cover on the side
concerned to gain access to the light from
within the luggage area. Press the lock tab
down, lift the holder a fraction and withdraw it
(see illustration).
35 Depress and twist free the bulb
concerned from the holder.
36 Fit the new bulb using a reversal of the
removal procedure. Relocate the holder by
sliding the lower end into position first, then

press the upper end into position so that it
clicks into place. Check the operation of the
rear lights on completion.

Van models

37 Working from within the rear of the vehicle
on the side concerned, turn the appropriate
bulbholder in an anti-clockwise direction and
withdraw the holder.
38 Depress and untwist the bulb to release it
from its holder.
39 Fit the new bulb using a reversal of the
removal procedure. Check the rear lights for
satisfactory operation on completion.

Number plate lights

40 Prise the number plate light from the rear
bumper using a small screwdriver (see
illustration).

41 Disconnect the wiring plug and earth lead
from the light.
42 On Hatchback, Saloon and Estate
models, prise open the plastic retaining clip to
withdraw the bulbholder from the light unit,
then depress and untwist the bulb to remove
it from the holder (see illustrations).
43 To remove the bulb on Van models, twist
the bulbholder anti-clockwise and withdraw it,
then pull free the bulb.
44 Fit the new bulb using a reversal of the
removal procedure. Check the operation of
the lights on completion.

Rear foglight (1993 model year
onwards)

45 With the tailgate open, release the cover
from the inner trim panel to access the
bulbholder.
46 Twist the bulbholder anti-clockwise and
withdraw it, then pull free the bulb.
47 Fit the new bulb using a reversal of the
removal procedure. Check the operation of
the light on completion.

6

Bulbs (interior lights) -
renewal

1

Courtesy lights

1 Prise out the light using a small flat-bladed
screwdriver (see illustration).
2 Release the festoon-type bulb from the
spring contacts.
3 Fit the new bulb using a reversal of the
removal procedure. Check the tension of the
spring contacts, and if necessary bend them
so that they firmly contact the bulb end caps.

Luggage area light

4 Prise free and withdraw the light (see
illustration).
5 Pull free the bulb from its holder and
remove it.
6 Fit the new bulb and refit the light using a
reversal of the removal procedure.

Instrument panel illumination
and warning lights

7 Remove the instrument panel as described
in Section 9.

Body electrical system 12•9

5.34 Rear light cluster removal on Estate

models

5.32 Removing a bulb from the bulbholder

6.4 Luggage area light removed for bulb

replacement

6.1 Roof-mounted courtesy light removal

5.42B . . . and separate the number plate

light unit and bulbholder

5.42A Prise open the clip . . .

5.40 Number plate light removal from the

bumper on Estate models

12