Ford Orion. Manual - part 57

from the front guide channel, then move it
carefully towards the outer panel. Carefully
pull the glass upwards to disengage it from
the large slider and simultaneously away from
the door mirror, and remove the glass from
the door.

Refitting

13 Refitting is a reversal of removal, but note
then following:
a)

When the glass is lowered into position in
the door on Cabriolet models, loosely fit
the retaining bolts, then close the window
to ensure that the glass fits correctly
before tightening the slider bolts to
secure.

b)

Where applicable, ensure that the wiring
looms in the door are clear of the window
and its regulating mechanism, and that
the connections are secure.

c)

On refitting the window glass, check that
it operates fully and freely before refitting
the insulation sheet and the door trim
panel.

12 Rear quarter window 

glass (Cabriolet models) -
removal and refitting

3

Removal

1 Open the roof, and lift the rear seat cushion.
2 Refer to Section 34 for details, and remove
the rear side quarter trim panel.
3 Where applicable, undo the speaker
retaining screws, partially withdraw the
speaker to detach the wiring connections, and
then remove the speaker.
4 Undo the screw, remove the cup washer,
and detach the roof frame main pillar bottom
seal (see illustration).
5 Remove the outer and inner weather strips.
6 Carefully peel back and remove the
insulation sheet. In order not to damage and
distort the insulation sheet, use a suitable
knife to cut through the peripheral adhesive
strip as the sheet is peeled progressively back
and away from the door. Avoid touching the

strip with the hands, as skin oils will adversely
affect its adhesive properties.
7 Reconnect the window regulator (handle or
switch, as applicable) and with the window
fully lowered, prise free and detach the
window regulator arm from the channel.
8 Raise the window, then unscrew the
shouldered bolt securing the regulator arm to
the support channel (see illustration). Tilt and
lift the glass from the car.

Refitting

9 Refitting is a reversal of removal, but note
then following:
a)

When the glass is lowered into position,
and the regulator arm-to-support bolt is
fitted, adjust the position of the glass by
loosening the adjuster bolts as required.
Tighten them once the necessary
adjustment has been made (see
illustration).

b)

Where applicable, ensure that the wiring
looms are clear of the window and its
regulating mechanism, and that the
connections are secure.

c)

On refitting the window glass, check that it
operates fully and freely before refitting the
insulation sheet and the quarter trim panel.

13 Rear quarter window

regulator (Cabriolet models)
- removal and refitting

3

Removal

1 Remove the rear quarter window as
described in the previous Section.
2 On models fitted with electric windows,

detach the wiring multi-plug from the
regulator motor.
3 Unscrew and remove the regulator arm
retaining bolts.
4 Unscrew and remove the three regulator
retaining bolts (to the right of the arm bolts),
then withdraw the regulator from the side
panel lower aperture.

Refitting

5 Refitting is a reversal of removal. Ensure
that the wiring connections are securely
made, and check the operation of the
regulator before refitting the window. Refer to
Section 12 for details on refitting the window.

14 Door window regulator -

removal and refitting

3

Removal 

1 Remove the door trim and the insulation
sheet as described in Section 10.
2 Locate the glass in the door so that the
guide channel can be detached from the
regulator. Disconnect the ball and socket(s)
(two per front door, one per rear door), then
lower the glass to the base of the door.
3 The regulator is secured by seven pop-
rivets (front door) or four pop-rivets (rear
door). Drill through the centre of each rivet,
detach the regulator from the door, and
withdraw it from the lower aperture (see
illustration).

11•8 Bodywork and fittings

14.3  Drilling out the door window

regulator rivets

12.9  Quarter window adjustment bolts on

Cabriolet models

A  Height adjustment     B  Lateral adjustment

12.8  Unscrewing the shouldered bolt

securing the regulator arm to the support

channel on Cabriolet models

12.4  Roof frame main pillar bottom seal

screw (arrowed) on Cabriolet models

11.10  Door window regulator retaining

bolts on the front doors of Cabriolet

models

A

Large slider bolts

B Regulator retaining bolts
C Small slider bolt

Refitting

4 Refitting is a reversal of removal. Obtain the
correct number of rivets to fit the regulator to
the door. Check that the operation of the
window regulator is satisfactory before
refitting the door trim.

15 Door lock, lock cylinder and

handles - removal and refitting

3

Removal

1 Remove the door inner trim panel and the
insulation sheet as described in Section 10.
Proceed as described below in the
appropriate sub-Section. On 1993-on
Cabriolet models, it will be necessary to

remove the door window glass, as described
in Section 11, for access to the door lock
components.

Door lock barrel

2 Slide free the barrel retaining clip, detach
the connecting rod and remove the lock barrel
(see illustrations).

Door lock 

3 Remove the lock barrel as described
above.
4 On models fitted with central locking, detach
the wiring multi-plugs from the lock motor
(attached to and removed with the lock).
5 Unscrew and remove the inner door release
retaining screw (see illustration).
6 Unscrew and remove the three (four on
1993-on Cabriolet models) door lock retaining
screws (see illustration).

7 Remove the window rear guide (rear doors
only).
8 Slide free the inner release from the door,
then withdraw the lock together with the
remote control inner release and cable. If
required, the connecting cable to the inner
release handle can be detached from the lock
by removing the cover, sliding the outer cable
from its locating slot in the lock, and then
withdrawing the inner cable from the
actuating pivot on the lock (see illustrations).
9 On models with central locking, undo the
two retaining screws to detach the lock from
the actuating motor.

Inner release handle

10 Slide free the inner release and detach it
from the door, then disconnect the release
operating cable from the release handle case
(see illustrations).

Bodywork and fittings  11•9

15.5  Inner door release and retaining

screw

15.2B  . . . and withdraw the lock barrel

from the door

15.2A  Remove the inner retaining clip . . .

15.10B  . . . and disconnect the cable from

the casing

15.10A  Detach the inner release handle . . .

15.8C  Remove cover to detach cable from

the lock

15.8B  . . . and the door lock with cable

15.8A  Remove the door release . . .

15.6  Door lock retaining screws

11

17.3  Undo the screw and remove the

mirror trim

Exterior release handle

11 Undo the two retaining screws, detach the
link rod from the release arm of the exterior
handle, and remove the handle from the door
(see illustration). Note that on the rear doors
it will be necessary to remove the blanking
plug in the edge of the door to gain access to
one of the handle securing screws (see
illustration).

Refitting

12 Refitting is a reversal of removal. Check
for satisfactory operation of the lock and its
associated components before refitting the
door trim. Check that the striker enters the
lock centrally when the door is closed. If
necessary, loosen it with a Torx key, re-
position and re-tighten it.

16 Door - 

removal and refitting

1

Removal

1 Fully open the door, then untwist and detach
the wiring multi-plug connector (see illustration).
2 Disconnect the door check strap by
unscrewing the Torx screw on the door pillar
(see illustration).
3 Support the door on blocks of wood.
4 Unscrew the door hinge pin retaining bolt
from each hinge (see illustration), then lift the
door clear of the hinges.

Refitting

5 Refitting is a reversal of removal. Check that
the striker enters the lock centrally when the door

is closed. If necessary, loosen it with a Torx key,
re-position and re-tighten it (see illustration).

17 Exterior mirror and glass -

removal and refitting

1

Removal

1 If the mirror glass is to removed, insert a
thin flat-bladed tool between the glass and
the housing, and carefully prise it free. Where
applicable, disconnect the wiring from the
connectors on the rear face of the mirror (see
illustrations).
2 To remove the mirror, first remove the door
trim as described in Section 10.
3 Undo the door mirror trim retaining screw,
and remove the trim (see illustration).

11•10 Bodywork and fittings

17.1B  . . . and detach the wiring

connectors, where applicable

17.1A  Prise free the door mirror glass . . .

16.5  Door striker - note Torx-head

securing bolt

16.4  Door hinge pin bolt (arrowed)

16.2  Door check strap screw (arrowed)

16.1  Disconnect the wiring multi-plug

connector

15.11B  Exterior handle retaining screw

access point in rear door

15.11A  Exterior handle retaining screws

4 Carefully prise free the control unit from the
trim, and where applicable, detach the wiring
connector from the adjuster (see illustration).
5 Support the mirror, undo the three retaining
screws, and remove the mirror from the door
(see illustration).
6 The motor can be removed if required by
undoing the three retaining screws (see
illustration).

Refitting

7 Refit in the reverse order of removal. Check
that the operation of the mirror adjuster is
satisfactory.

18 Interior mirror - 

removal and refitting

1

Removal

1 Using a length of strong thin cord or fishing
line, break the adhesive bond between the
base of the mirror and the glass. Have an
assistant support and remove the mirror as it
is released.
2 If the original mirror is to be refitted,
thoroughly clean its base with methylated
spirit and a lint-free cloth. Allow a period of
one minute for the spirit to evaporate. Clean
the windscreen black patch in a similar
manner.

Refitting

3 During the installation of the mirror, it is
important that the mirror base, windscreen
black patch and the adhesive patch are not
touched or contaminated in any way - poor
adhesion will result.
4 Prior to fitting the mirror, the temperature
inside the vehicle should ideally be around
20ºC. While this isn’t critical, it’s worth
ensuring that the inside of the vehicle is as
warm and dry as possible.
5 With the contact surfaces thoroughly
cleaned, remove the protective tape from one
side of the adhesive patch, and press it firmly
into contact with the mirror base.
6 If fitting the mirror to a new windscreen, the
protective tape must first be removed from
the windscreen black patch.

7 Warm the mirror base and the adhesive
patch for about 30 seconds to a temperature
of 50 to 70ºC. Peel back the protective tape
from the other side of the adhesive patch on
the mirror base, then align the mirror base and
the windscreen patch, and press the mirror
firmly into position. Hold the base of the mirror
firmly against the windscreen for a minimum
period of two minutes to ensure full adhesion.
8 Wait at least thirty minutes before adjusting
the mirror position.

19 Boot lid - 

removal, refitting and
adjustment

1

Removal

1 Open the boot lid, and mark the position of
the hinges with a pencil.
2 Where applicable, disconnect the wiring
multi-plug and the earth lead for the central
locking motor from the boot lid (see
illustration). Attach a suitable length of strong
cord to the end of the wire, then withdraw the
lead from the bootlid. Detach the cord and
leave it in position in the boot. This will then
act as an aid to guiding the wiring through the
lid when it is refitted.
3 Place cloth rags beneath each corner of the
boot lid to prevent damage to the paintwork.
4 With the help of an assistant, unscrew the
mounting bolts (see illustration) and lift the
boot lid from the car.

Refitting and adjustment

5 Refitting is a reversal of removal. Check
that the boot lid is correctly aligned with the
surrounding bodywork, with an equal
clearance around its edge. Adjustment is
made by loosening the hinge bolts and
moving the boot lid within the elongated
mounting holes. Check that the lock enters
the striker centrally when the boot lid is
closed, and if necessary adjust the striker’s
position within the elongated holes.

20 Boot lid lock components -

removal and refitting

1

Removal

Lock barrel

1 Open the boot and undo the screw
securing the barrel retaining clip, then remove
the clip.
2 Detach the barrel from the link rod, and
withdraw the lock from the boot lid.

Lock

3 Open the boot lid and remove the lock
barrel (see above for details).
4 Undo the three retaining screws, then
withdraw the lock from the boot lid.

Lock striker and remote release 

5 Open the boot, undo the two retaining
screws, and remove the trim from the rear
face of the luggage compartment.

Bodywork and fittings  11•11

17.6  Mirror motor and retaining screws

(arrowed)

17.5  Undo the three mirror retaining

screws

17.4  Detach the wiring multi-plug from the

mirror control unit

19.4  Boot lid hinge retaining bolt locations

(arrowed)

19.2  Multi-plug (A) and earth lead (B)

connection points in the boot lid

11