Ford Orion. Manual - part 58

6 Using a soft pencil, mark an outline around
the striker and the release unit, to act as a
guide for repositioning on refitting. Undo the
two Torx-type screws, and remove the lock
striker and the release unit. Detach the
operating cable from the release unit to
remove it.

Release cable

7 Remove the striker and release unit as
described above, then detach the release
cable from it.
8 Detach and remove the kick panel trim
beneath the front and rear doors on the
driver’s side. Fold back the carpet from
around the bootlid lock release handle.
9 Withdraw the outer cable from the slot in
the lever mounting plate, then detach the
inner cable from the lever.
10 Remove the appropriate side trim panels
from the rear of the vehicle on the side
concerned, to expose the cable routing.
Where the cable has to pass through cavities
in the body, tie a suitable length of cord to the
cable end before pulling the cable through
and removing it. The cord can be untied from
the cable, and left in situ in the vehicle. It will
then act as a “puller-guide” when the cable is
being refitted.

Refitting

11 Refitting is a reversal of removal. When
refitting the lock, check that the striker enters
the lock centrally when the boot lid is closed,
and if necessary re-position the striker by
loosening the mounting screws.

21 Tailgate - removal, refitting

and adjustment

Removal

1 Open the tailgate, then undo the seven
retaining screws and remove the trim panel
from the tailgate.
2 Using a soft pencil, mark the fitted position
outline around the tailgate hinges to act as a
guide for repositioning when refitting.
3 Prise free and remove the plug for access
to the washer jet, then detach the hose from
the jet. Attach a suitable length of strong cord
to the end of the hose to assist in guiding the
hose back through the aperture of the tailgate
when it is being refitted. Now prise free the
flexible grommet on the left-hand side, and
withdraw the washer jet hose from the
tailgate. Undo the cord from the hose, and
leave it in position in the tailgate.
4 Where applicable, detach the central
locking lead multi-connector and earth lead
from the tailgate (see illustration). Attach a
suitable length of strong cord to the end of the
wire, to assist in guiding the wiring back
through the aperture of the tailgate when it is
being refitted. Now prise free the flexible
grommet on the right-hand side, and
withdraw the central locking wires from the
tailgate. Undo the cord from the wire, and
leave it in position in the tailgate.
5 Have an assistant support the tailgate in the
open position, then prise open the support

strut balljoint securing clip, and detach the strut
each side from the tailgate (see illustration).
6 Unscrew and remove the hinge bolts, then
lift the tailgate clear of the vehicle (see
illustration).

Refitting and adjustment

7 Refitting is a reversal of removal, but check
that the tailgate 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
tailgate within the elongated mounting holes.
Adjust the rear height by turning the rubber
bump stop each side in the desired direction
(see illustration). Check that the striker enters
the lock centrally when the tailgate is closed,
and if necessary adjust the position of the
striker within the elongated holes.

22 Tailgate support strut -

removal and refitting

Removal

1 Support the tailgate in its open position. If
both struts are to be removed, the tailgate will
need to be supported by an alternative means.
2 Disconnect each end of the support strut
by prising out the spring clip retainers with a
small screwdriver and pulling the strut from
the ball mountings.

Refitting

3 Refitting is a reversal of removal, but note
that the piston end of the strut faces
downwards.

23 Tailgate lock components -

removal and refitting

Removal

Lock barrel

1 Open the tailgate, then remove the seven
screws and remove the inner trim panel from
the rear of the luggage area.
2 Depending on type, unscrew and remove
the lock barrel clip retaining screw, then
remove the clip or undo the two retaining nuts
(see illustration).

11•12 Bodywork and fittings

23.2 Tailgate lock barrel, operating rod

and retaining nuts

21.7 Tailgate bump stop

21.6 Tailgate hinge and retaining bolts

21.5 Tailgate strut and balljoint

21.4 Detach the wiring connector from the

tailgate

3 Disengage the operating rod and remove
the barrel.

Lock

4 Open the tailgate and remove the lock
barrel as described above.
5 Undo the three Torx-type retaining screws
and remove the lock. Where applicable,
detach the wiring in-line connector from the
lock (see illustrations).

Striker and release unit

6 Using a soft pencil, mark an outline around
the striker and the release unit to act as a
guide for repositioning on refitting. Undo the
two Torx-type screws (and where applicable,
the earth lead screw), then remove the lock
striker and release unit. Detach the operating
cable from the release unit to remove it (see
illustrations).

Release cable

Refitting

11 Refitting is a reversal of removal. When
refitting the lock, check that the striker enters
the lock centrally when the tailgate is closed,
and if necessary re-position the striker by
loosening the mounting screws.

24 Central locking system

control module -
removal and refitting

Removal

1 Disconnect the battery negative (earth) lead
(refer to Chapter 5, Section 1).
2 Remove the front footwell side cowl trim
panel from the driver’s side, as described in
Section 34.
3 Withdraw the central locking module from
its location bracket, and detach the multi-plug
wiring connections from it (see illustration).

Refitting

4 Refit in the reverse order of removal. Check
the operation of the system to complete.

25 Windscreen and fixed

windows -
removal and refitting

Removal

Windscreen and rear quarter and rear
window/tailgate glass

1 The windscreen, rear quarter and rear
window/tailgate glass are bonded in place
with special mastic. Special tools are required
to cut free the old glass and fit replacements,

Bodywork and fittings 11•13

23.6A Undo the retaining screws . . .

23.6B . . . withdraw the tailgate striker

plate and detach the release cable

23.5B . . . and withdraw the lock from the

tailgate

23.5A Undo the three retaining screws . . .

26.4 Initial securing points when fitting a

door weatherstrip

24.3 Central locking system control

module location

23.9 Tailgate release handle and operating

cable

Where the cable has to pass
through cavities in the body,
tie a suitable length of cord to
the cable end before pulling

the cable through and removing it. The
cord can be untied from the cable, and
left in situ in the vehicle. It will then act
as a “puller-guide” when the cable is
being refitted.

together with cleaning solutions and primers.
It is therefore recommended that this work is
entrusted to a Ford dealer or windscreen
replacement specialist.

Rear window(s) - Van models

2 Working from the inner face of the door
concerned, use a blunt-ended instrument to
push the inner lip of the weatherseal beneath
the window frame, starting at the top. Get an
assistant to support the window on the
outside during this operation.
3 With the weatherseal free, withdraw the
window from the door.

Rear window - Cabriolet models

4 Detach the heated rear window lead, and
withdraw the lead from the weatherstrip.
5 Arrange for an assistant to support the
glass from the outside, then wearing
protective gloves, press the window outwards
and remove it from its frame. Take care not to
apply undue strain to the hood material or the
hood frame as the window is pressed out.
6 Remove the weatherstrip from the glass.

Refitting

7 Clean the window and aperture in the
body/frame. Petrol or spirit-based solvents
must not be used for this purpose, as they are
harmful to the weatherstrip.
8 Fit the weatherseal on the window, then
insert a cord in the weatherseal groove so that
the ends project from the bottom of the
window and are overlapped by approximately
150 mm.
9 Locate the window on its location aperture,
and pass the ends of the cord inside the
vehicle. Have an assistant hold the window in
position.
10 Slowly pull one end of the cord (at right-
angles to the window frame, towards the
centre of the glass) so that the lip of the
weatherseal goes over the aperture. At the
same time, have the assistant press firmly on
the outside of the window. When the cord
reaches the middle top of the window, pull the
remaining length of cord to position the other
half of the weatherseal.
11 Reconnect the heated rear window lead,
and press it under the weatherstrip (Cabriolet
models).

26 Door and tailgate

weatherstrips -
removal and refitting

Removal

1 To remove a weatherstrip seal from its
aperture flange, grip the strip at its joint end,
and progressively pull it free, working around
the aperture to the other end of the strip.

Refitting

2 First check that the contact surfaces of the
weatherstrip and the aperture flange are
clean. Check around the aperture flange for

any signs of distortion, and rectify as
necessary.
3 To refit the weatherstrip, start by roughly
locating its ends midway along the base of the
aperture concerned, but do not press them
into position over the flange at this stage.
Proceed as follows, according to type.

Door weatherstrip

4 In the case of a door weatherstrip, press
the strip into position at the corners to initially
locate it (see illustration). Check that the
distances between each contact point are
such that the strip will fit smoothly around the
aperture (without distortion), then firmly press
the strip fully into position, starting at the top
edge and working down each side to finish at
the bottom joint. Check that the seal is
correctly located, then apply a suitable
sealant to the joint, to prevent the possibility
of water leakage through it caused by
capillary action.
5 Shut the door, and check it for fit. Adjust if
required by resetting the position of the striker
plate to suit.

Tailgate weatherstrip

6 Position the ends of the weatherstrip so
that they are centralised within 300 mm of the
tailgate striker plate. A new weatherstrip will
need to be measured and cut to length.
Progressively fit the weatherstrip around the
aperture flange, squeezing it closed over the
flange by hand to secure. When fitted, check
that it is not distorted, then close the tailgate
and check it for fit. Adjustment of the striker
plate and the tailgate bump stops may be
necessary to obtain a satisfactory fit and seal.

27 Body side-trim mouldings

and adhesive emblems -
removal and refitting

Removal

1 Insert a length of strong cord (fishing line is
ideal), between the moulding or emblem
concerned, and break the adhesive bond
between the moulding (or emblem) and the
panel.
2 Thoroughly clean all traces of adhesive
from the panel using methylated spirit, and
allow the moulding/emblem location to dry.

Refitting

3 Peel back the protective paper from the
rear face of the new moulding/emblem, and
then carefully fit it into position on the panel
concerned, but take care not to touch the
adhesive. When in position, apply a hand
pressure to the moulding/emblem for a short
period to ensure maximum adhesion to the
panel.

28 Roof moulding (Van models)

- removal and refitting

Removal

1 Prise free and lift the moulding up from the
roof at the front end, then pull the moulding
from its location channel in the roof.
2 Clean the contact faces of the moulding
and the roof channel before refitting the
moulding.

Refitting

3 Locate the moulding into position over the
channel, check that it is correctly realigned,
then progressively press it into place using the
palm of the hand.

29 Sunroof -

checking and adjustment

1 The sunroof should operate freely, without
sticking or binding, as it is opened and
closed. When in the closed position, check
that the panel is flush with the surrounding
roof panel, the maximum allowable gap at the
front edge being 1.0 mm.
2 If adjustment is required, open the sun
blind, then undo and remove the three lower
frame-to-glass panel retaining screws (see
illustration). Slide the lower frame back into
the roof.
3 Loosen off the central and front securing
screws, adjust the glass roof panel so that it is
flush at its front edge with the roof panel, then
retighten the securing screws (see
illustration).
4 Pull the lower frame forwards, insert and
tighten its retaining screws to complete.

11•14 Bodywork and fittings

29.3 Loosen off these screws (arrowed) to

adjust the sunroof glass panel

29.2 Sunroof lower frame-to-glass panel

retaining screws (arrowed)

30 Sunroof panel -

removal and refitting

Removal

1 Open the sun blind, unscrew and remove
the three screws securing the lower frame,
and slide the frame back into the roof.
2 Undo the three roof panel-to-sliding gear
screws, then push the panel up and out to
remove it from the vehicle. Have an assistant
lift the panel free from above as it is raised, to
avoid the possibility of the panel and/or the
surrounding roof from being damaged.

Refitting

3 Refit in the reverse order of removal. When
the panel is in position, adjust it as described
in the previous Section.

31 Sunroof weatherstrip -

removal and refitting

Removal

1 Wind the sunroof panel into the tilted open
position, then grip the ends of the
weatherstrip and pull it free from the flanged
periphery of the roof panel.
2 Clean the contact faces of the panel and
the weatherstrip (where the original strip is to
be used) before refitting.

Refitting

3 Refit in the reverse order of removal. Ensure
that the weatherstrip joint is located in the
middle of the rear face of the panel.

32 Seats -

removal and refitting

Removal

Front seat

Warning: On vehicles fitted with
seat belt pre-tensioning stalks,
be careful when handling the
seat, as the tensioning device

(“grabber”) contains a powerful spring,
which could cause injury if released in an
uncontrolled fashion. The tensioning
mechanism should be immobilised by
inserting a safety “transit clip” available
from Ford parts stockists.
1 If required, the front seat cushion can be
removed on its own by undoing the two
retaining screws on the underside of the seat
at the front, and sliding the cushion forwards.
To remove the complete seat, slide the seat
forwards to the full extent of its travel, then
unscrew and remove the rear mounting bolts
(one on the outer slide and two on the inner)
(see illustrations).
2 Now slide the seat fully to the rear, then
unscrew the front securing bolt each side (see

illustration). Lift the seat and remove it from
the vehicle.

Rear seat cushion

3 Prise free the blanking plugs, then unscrew
and remove the cushion hinge retaining screw
each side (see illustration). Remove the
cushion from the vehicle.

Rear seat backrest (Hatchback,
Saloon and Estate models)

4 Pivot the rear seat cushion forwards, then
fold the backrest down. Undo the two screws
retaining the hinge to the backrest each side,
and remove the backrest from the vehicle
(see illustration).

Rear seat backrest (Cabriolet models)

5 Raise the seat cushion, then unscrew and
remove the seat belt lower reel anchor bolts.
6 Unscrew and remove the screws (one each
side) securing the backrest upper section.
7 Pivot the seat backrest down (release knob
in boot), pull back the backrest cover, then
unscrew and remove the two screws each
side retaining the top section.
8 Detach the seat belt guide from the top of
the backrest, then lift the backrest and feed
the belt reel lower anchor plate through the
backrest to allow the backrest to be removed
from the car.
9 Unscrew the bolts securing the lower
backrest to the hinges on each side, and
remove the backrest lower section.

Refitting

10 Refitting is a reversal of the removal
procedure. Where applicable, tighten the seat
belt anchor bolts to the specified torque
wrench setting.

33 Seat belts -

removal and refitting

Removal

Warning: On vehicles fitted with
seat belt pre-tensioning stalks,
be careful when working on the
seat belts, as the tensioning

device (“grabber”) contains a powerful
spring, which could cause injury if

Bodywork and fittings 11•15

32.2 Front seat/runner forward mounting

bolt

32.1B Front seat/runner rear inboard

retaining bolts

32.1A Front seat/runner rear outboard

retaining bolt

32.4 Rear seat backrest-to-cushion hinge

screws

32.3 Rear seat cushion retaining screw

(Saloon)

Content .. 56 57 58 59 ..