FORD FIESTA 1989 Service Repair Manual

the special tool (see illustration) , then strike
the main body of the tool with a soft-faced
hammer to extract the lower hinge pin from its
location.
6 With the help of an assistant to support the
door, remove the upper hinge pin from its
location, in a similar manner to that used for
the lower hinge pin, and then remove the door
assembly.
Refitting
7 To refit, align the door hinge sections to the
hinge sections on the body, and insert both
hinge pins as far as possible, by hand.
Ensuring that the hinge pins have entered all
three sections of hinge, tap them gently
through, with a soft-faced hammer, until their
retaining clips can be fitted. New retaining
clips should be used. 8
Reconnect the multi-plug and insert it to its
body location on the A- pillar, ensuring that it
seats correctly.
9 Refit the door check arm to its body
location. Press the door aperture weatherseal
back into position on its flange.
10 There should be no need to adjust the
door striker, or check door alignment.
21 Side door inner trim panel -
removal and refitting
1
Removal
1 Using a screwdriver with a broad flat blade,
carefully prise up and remove the interior
weatherstrip from its location at the top of the
door trim panel. Be careful not to kink or bend
it as it is being removed. On front doors, pull the end of the weatherstrip out from under the
door mirror trim.
2
Detach the door interior release handle
bezel by removing its retaining screw (see
illustration) .
3 Using a small thin screwdriver, release the
window regulator handle (where fitted) by
releasing its spring clip from behind and pulling
it from the regulator shaft (see illustration).
Remove its bezel also. On models with electric
front window switches in the door trim panel,
disconnect the switch wiring multi-plugs as the
trim panel is withdrawn.
4 Detach the armrest/doorpull assembly from
the door. Some models are fitted with an
armrest/doorpull secured by three screws,
two of which are concealed behind a
removable panel. Certain lower specification
vehicles have the door pull secured with only
two screws. (see illustrations)
5 On front doors, remove the three screws
securing the door stowage pocket/speaker
grille moulding, then pull the moulding upper
edge away from the door, and disengage the
hook fixings on its base from their locations
(see illustration) .
6 Using a trim clip tool, release the retaining
clips around the base and the sides of the
panel, then raise it to free it from the door. If a
trim clip tool is unavailable, two thin flat-
bladed screwdrivers carefully inserted
between the trim panel and the door may
suffice. Place the screwdrivers on each side
of the clips and then apply gentle leverage.
11•10 Bodywork and fittings
21.4b Undoing armrest/doorpull retaining screws21.4a Detaching armrest/doorpullremovable panel
21.3 Window regulator handle. Inset shows removal
A Spring clip
B Rotate the tag to remove the knob
21.2 Removing the door interior release handle bezel (armrest/doorpull shown removed)
1595Ford Fiesta Remake
20.5 Door hinge pin removal using Ford special tools
A Hinge pin B Removal tool C Soft-faced hammer
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Refitting
7To refit, first align the trim panel to the door,
secure its upper edge into its hook fastenings,
then press into position to engage the trim
clips. Where electric window switches are
fitted, reconnect the switch wiring multi-plugs
before fitting the panel.
8 If necessary, refit the clip to the window
regulator handle, then refit the handle to the
regulator shaft by pushing it on. The clip
should engage positively, in the annular
groove on the shaft.
9 Refit the door stowage pocket/speaker
grille moulding, armrest/doorpull and door
interior release handle bezel, as applicable, by
reversing the method of removal.
10 Refit the interior weatherstrip to its
location, tapping it down into position, being
careful not to bend or kink it. On front doors, it
will be necessary to slide its forward edge
under the door mirror trim before tapping into
position.
22 Side door lock, lock cylinder
and handles - removal and
refitting
2
Exterior handle
Removal
1 Remove the door inner trim panel, as
described in Section 21.
2 Locally detach the PVC sheet from the door
to allow access into the door cavity. Do not
tear the sheet; cut closely around the clips, as
required.
3 Disconnect the handle operating rod from
the latch assembly, by twisting the clip and
withdrawing the rod, as applicable.
4 Remove the two screws securing the
handle then, from the outside, withdraw
the handle and rod, guiding the rod out
through the door skin as necessary (see
illustrations) . The handle and rod may be
disconnected as required.
Refitting
5 Refitting is a reversal of the removal
procedure. On completion, re-secure the PVC
sheet then refit the inner trim panel as
described in Section 21.
Door lock barrel
Removal
6 Remove the door inner trim panel, as
described in Section 21.
7 Locally detach the PVC sheet from the door
to allow access into the door cavity. Do not
tear the sheet; cut closely around the clips, as
required.
8 Drill out the rivets securing the door glass
guide above the lock barrel, and remove it.
9 Disconnect the lock barrel operating rod
from the latch assembly, by twisting the clip
and withdrawing the rod.
10 Release the lock barrel retaining clip by
withdrawing it upwards, then from the
outside, withdraw the lock barrel and rod,
guiding the rod out through the door skin. The
lock barrel and rod may be disconnected as
required.
Refitting
11 Refitting is a reversal of the removal
procedure. Ensure that the lock barrel gasket
is located correctly between the lock barrel
outer surround and the door skin, and that the door glass guide is riveted securely. Check
that the window operates smoothly and
correctly, by temporarily refitting the regulator
handle or operating the electric window
motor.
12
On completion, re-secure the PVC sheet
then refit the inner trim panel as described in
Section 21.
Door latch and interior release
handle
Removal
13 Remove the door inner trim panel, as
described in Section 21.
14 Locally detach the PVC sheet from the
door to allow access into the door cavity. Do
not tear the sheet; cut closely around the
clips, as required.
15 On rear doors fitted with central locking,
undo the two screws securing the rod guard
and remove it (see illustration) .
16 Disconnect the operating rods from the
latch assembly as necessary. On rear doors
with central locking, disconnect and release
the motor loom multi-plug assembly, and
withdraw the motor side of the loom back into
the door cavity. Undo the three screws
securing the motor assembly, disengage its
operating rod and remove it from the vehicle
(see illustration) .
Bodywork and fittings 11•11
22.4b Removing the door exterior handle,
guiding its operating rod out through the door skin (front door)22.4a Door exterior handle and lock barrelsecuring arrangements (front door)
A Handle screw locations
B Lock barrel retaining clip21.5 Disengaging the hook fixings on the
base of the door stowage pocket/speaker grille moulding
22.16 Central locking motor retainingscrews (A), and loom multi-plug
assembly (B) on rear door22.15 Rod guard securing screws
(arrowed) on rear doors with central
locking only
11
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17On front doors, vehicles fitted with central
locking have a latch with an integral motor. If
central locking is fitted, prise up and twist the
rearward clips securing the motor loom to the
door, to free the loom, disconnect the multi-
plugs and withdraw the loom (motor side)
back into the door cavity.
18 Remove the interior release handle
surround, then prise up the forward end of the
handle unit. Release the handle from its
rearward location by sliding it forward to
disengage the hooks (see illustration).
19 Detach the door interior release cable
from its retaining clips on the door panel.
20 Remove the latch securing screws from
the upper rear edge of the door, and with-
draw the latch and interior release mechanism
from the vehicle (see illustration) .
21 Remove the cable cover from the latch
assembly, then detach the cable from the
latch.
22 Peel the sponge pad from the reverse side
of the interior release handle, and remove the
outer cable from its abutment in the body of
the handle. Remove the inner cable core by
aligning the core with the slot by its end fixing,
then slide the end fixing out.
Refitting
23 Refitting is a reversal of the removal
procedure. On completion, re-secure the PVC
sheet then refit the inner trim panel as
described in Section 21.
23 Tailgate support strut -
removal and refitting
1
Removal
1 Open the tailgate and support it securely,
using a length of timber, or have an assistant
hold it open.
2 Detach the support strut by raising the
retaining clip and pulling the strut away from
its ball stud fixing on the tailgate. Do not raise
the clip more than 4.0 mm, or the support
strut will be damaged.
3 Repeat the operation on the other end of
the support strut.
Refitting
4 To refit, align the thicker (cylinder) end of
the support strut to the ball stud fixing on the
tailgate, then push until it snaps into
engagement.
5 Repeat the operation with the thinner
(piston) end of the support strut to the ball
stud fixing on the body.
24 Tailgate -
removal and refitting
1
Removal
1 Open the tailgate and mark around the
hinge positions on the tailgate panel itself.
2 Remove the central blanking plug from the
upper portion of the tailgate to expose the
washer jet, and disconnect the washer hose
from the jet base, as applicable. Free the
washer hose grommet and withdraw the hose
from the tailgate.
3 Disconnect the support strut from the
tailgate, as described in Section 23.
4 With the aid of an assistant, undo the four
bolts securing the tailgate to the vehicle body
and remove the tailgate.
Refitting
5 To refit, align the hinges on the body with
the marks made on the tailgate panel, then
refit and tighten the four bolts to secure. Refit
the support strut as described in Section 23.
6 The remainder of the refitting operation is a
reversal of the removal procedure.
7 Close the tailgate and check the alignment.
Adjust as necessary to obtain an even gap
between the tailgate and all adjacent panels.
25 Tailgate spoiler -
removal and refitting
2
Removal
1 Drill out the rivets securing the outer edges
of the spoiler to the tailgate. 2
Open the tailgate and remove the four
blanking plugs covering the spoiler retaining
nuts. Undo the nuts and remove the spoiler.
Refitting
3 To refit, first align the spoiler mounting
studs to their tailgate fixing holes, then rivet
the outer edges of the spoiler to the tailgate.
4 Refit the four retaining nuts and tighten to
the specified torque.
5 Refit the blanking plugs.
26 Tailgate inner trim panel -
removal and refitting
1
Removal
1 Open the tailgate then, using a screwdriver,
remove the seven plastic retaining screws
from the trim panel.
2 Remove the square plastic clip from the
trim panel.
3 Disengage the clips from the panel edge
nearest the window, and manoeuvre the panel
to release the hooks on the other panel edge.
Withdraw the trim panel from the vehicle.
Refitting
4 Refitting is a reversal of removal.
27 Tailgate lock components -
removal and refitting
2
Note: For vehicles equipped with remote
tailgate release, removal and refitting
procedures for the tailgate remote release
motor are contained in Chapter 12.
Removal
1 Remove the tailgate inner trim panel as
described in Section 26.
2 Remove the two Torx screws securing the
tailgate latch, then pull it down, disconnect its
operating rod and remove the latch from the
vehicle (see illustration) .
3 Remove the bolt securing the lock barrel
11•12 Bodywork and fittings
27.2 Tailgate latch and its Torx securing
screws (arrowed)
22.20 Removing the latch securing screws (arrowed)22.18 Detaching the interior door release handle
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retainer to the tailgate, then withdraw the
retainer (see illustration) .
4 Remove the lock assembly from the tailgate
by partially withdrawing the lock, twisting it so
that the lock rod can be removed, then fully
withdrawing.
Refitting
5 To refit, first ensure that the lock gasket is
in position, then partially insert the lock into
the tailgate and reconnect the lock rod. Fully
insert the lock and refit its retainer and
securing bolt.
6 Using an electrician’s thin screwdriver,
prise up the lever on the latch and fit the lock
rod to it, ensuring that it fully engages.
7 Align the latch with its location and refit its
two securing screws.
8 Check for correct lock operation before
refitting the tailgate interior trim panel as
described in Section 26.
28 Rear doors (Courier models) - removal and refitting
1
Removal
1Open the door and disconnect the wiring
leading to it; all connectors are accessible
from the openings inside the door frame. 2
Unclip the door check arm, and unscrew
the bottom hinge’s cap securing bolt (see
illustration) .
3 Lift the door off its hinges and withdraw it.
Refitting
4Refitting is the reverse of the removal
procedure; apply grease to the hinge pins,
and tighten the cap bolt securely.
5 The door hinges can be unbolted from the
door and frame; either remove the door first,
or support it carefully and remove the hinge
with it in place.
29 Rear door inner trim panels (Courier models) -
removal and refitting
1
Removal
1 Remove the interior handle bezel by
pushing it away from the door’s hinges until it
can be withdrawn.
2 Using either a trim clip releasing tool or a
screwdriver with a broad flat blade, and
protecting the paintwork and trim with a layer
of rag, extract the clips securing the panel and
withdraw it.
Refitting
3 Refitting is the reverse of the removal
procedure.
30 Rear door lock, catches and
handles (Courier models) -
removal and refitting
1
Interior handle
Removal
1 Remove the inner trim panel, as described
in Section 29.
2 Remove its four retaining screws, and
withdraw the complete latch assembly (see
illustrations) .
3 Disconnect the link rod and remove the
single retaining screw to withdraw the interior
handle.
Refitting
4 Refitting is the reverse of the removal
procedure.
Exterior handle and lock
assembly
Removal
5 Remove the inner trim panel, as described
in Section 29.
6 Remove its four retaining screws, and
withdraw the complete latch assembly.
7 Using pliers, rotate the exterior handle
locking ring anti-clockwise to release it, then
withdraw the handle with the inner and outer
gaskets (see illustrations) .
8 The lock assembly is secured by a circlip to
the handle.
Bodywork and fittings 11•13
30.2a Courier rear door latch assembly retaining screws (arrowed)28.2 Unscrewing the bottom hinge’s capsecuring bolt on Courier rear door27.3 Tailgate lock retention arrangement
A Lock barrel retainer securing bolt
B Lock barrel retainer
30.7b . . . to release Courier rear door exterior handle30.7a Release locking ring and withdraw gaskets . . .30.2b Latch assembly released -disconnect cables to withdraw
11
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Refitting
9Refitting is the reverse of the removal
procedure.
Upper and lower door catches
Removal
10 Remove the inner trim panel, as described
in Section 29.
11 Remove its four retaining screws, and
withdraw the complete latch assembly.
Disconnect the upper and lower catch cables from the latch assembly operating
mechanism.
12
Unbolt the catch and withdraw it from the
door (see illustration) . If the cables are
available separately (seek the advice of a Ford
dealer) they can be disconnected from each
catch by releasing the retaining clip.
Refitting
13 Refitting is the reverse of the removal
procedure; check the adjustment of the catch
before finally tightening the bolts.
14 The striker plates can be adjusted on their
slotted mounting bolt locations, if required.
31 Door window regulator -
removal and refitting
3
Manual front regulator
Removal
1 Remove the door inner trim panel, as
described in Section 21.
2 Locally detach the PVC sheet from the door
to allow access into the door cavity. Do not tear the sheet; cut closely around the clips, as
required.
3
Remove the door window glass, as
described in Section 32.
4 Drill the heads off the regulator securing
rivets and manoeuvre the regulator assembly
from the door (see illustration) . Lay the
regulator body in the bottom of the door, then
withdraw the gear mechanism and cable
followed by the rigid “pillar”.
Refitting
5 Refit the regulator by reversing the method
of removal, ensuring that it is securely riveted
to the door.
6 Refit the door window glass, as described
in Section 32.
7 Re-secure the PVC sheet then refit the door
inner trim panel as described in Section 21.
Electric front regulator
Removal
Note : For motor removal and refitting
procedure, refer to Chapter 12.
8 Remove the door inner trim panel, as
described in Section 21.
9 Locally detach the PVC sheet from the door
to allow access into the door cavity. Do not
tear the sheet; cut closely around the clips, as
required.
10 Remove the door window glass, as
described in Section 32.
11 Disconnect the multi-plug on the regulator
motor body, and remove the three nuts
securing the motor/winding mechanism
section of the assembly to the door.
12 Drill the heads off the regulator securing
rivets and manoeuvre the regulator assembly
from the door. Lay the regulator body in the
bottom of the door, then withdraw the gear
mechanism and cable followed by the rigid
“pillar”.
Refitting
13 To refit, first position the regulator
assembly in the door, and refit the three nuts
securing the motor/winding mechanism
section.
14 Re-rivet the pillar section of the regulator
assembly securely to door.
15 Reconnect the multi-plug to the regulator
motor body.
16 Refit the door window glass, as described
in Section 32.
17 Re-secure the PVC sheet then refit the
door inner trim panel as described in Sec-
tion 21.
Rear regulator
Removal
18 Remove the door inner trim panel, as
described in Section 21.
19 Locally detach the PVC sheet from the
door to allow access into the door cavity. Do
not tear the sheet; cut closely around the
clips, as required.
20 Drill the heads off the four regulator
securing rivets, and remove the two lower
11•14 Bodywork and fittings
31.4 Window regulator assembly (manual, front)
30.12 Courier rear door lower catch
removal
1595Ford Fiesta RemakeA Window glass lifting
channel
B Regulator assembly
C Rivets
D Screwsprocarmanuals.com
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window glass guide securing screws (see
illustration) .
21 Support the window glass then, having
pushed the regulator into the door cavity,
disconnect the regulator arm from it. Remove
the regulator assembly.
Refitting
22 Refitting is a reversal of the removal
procedure, ensuring that the window regulator
is securely riveted to the door. Check the
operation of the window regulator, by
temporarily refitting the regulator handle and,
if necessary, adjust the window glass guide to
ensure that the window glass does not stick
or judder.
23 Re-secure the PVC sheet then refit the
door inner trim panel as described in Sec-
tion 21.
32 Door window glass -
removal and refitting
3
Front side door glass
Removal
1 Remove the door inner trim panel, as
described in Section 21.
2 Locally detach the PVC sheet from the door
to allow access into the door cavity. Do not
tear the sheet; cut closely around the clips, as
required.
3 Remove the door belt weatherseal
moulding as described in Section 10.
4 Remove the two screws securing the
window glass lifting channel to the regulator
assembly, through either their upper or lower
access holes. Support the glass as the screws
are removed.
5 Remove the window glass by tilting it
forwards towards the hinge end of the door,
then withdraw it towards the latch end.
Refitting
6 To refit, position the window glass into the
door by reversing the method of removal.
7 Loosely refit the two screws to hold the
window glass lifting channel to the regulator assembly, but do not tighten them at this
stage.
8
Raise the window glass fully, then tighten
the retaining screws through their upper
access holes. This ensures correct positioning
of the window glass in its aperture.
9 Refit the door belt weatherseal moulding as
described in Section 10.
10 Re-secure the PVC sheet then refit the
door inner trim panel as described in Sec-
tion 21.
Rear side door sliding glass
Removal
11 Remove the door window regulator, as
described in Section 31, then fully lower the
window glass into the door.
12 Remove the door belt weatherseal
mouldings in a similar manner to that
described in Section 10.
13 Remove the remaining two window glass
guide securing screws from their location at
the top of the door, and disengage the top
of the guide.
14 Manoeuvre the fixed rear quarter window
glass forwards and out from its location, along
with the window glass guide. Lift out the
plastic strip.
15 Manoeuvre the door window glass up and
out of the door, from the exterior side of the
door.
Refitting
16 Refitting is a reversal of the removal
procedure, ensuring that the fixed rear quarter
window seats correctly in its location, and that
the window glass guide holds the window
glass correctly (refer to Section 31).
Rear side door fixed quarter
glass
17 The fixed rear quarter window glass is
removed and refitted in conjunction with the
rear side door sliding glass described
previously in this Section.
Rear door glass (Courier
models)
18 The rear door window glass on Courier
models is removed and refitted using the
same technique as for the fixed side window
glass described in Section 33.
33 Side window glass -
removal and refitting
3
Fixed side window glass
Removal
1 The lip of the weatherseal surrounding the
window glass must be released from the top
and sides of the body aperture flange, using a
suitable tool, before exerting pressure from
the inside of the vehicle to remove the glass.
Any surrounding interior trim should be
removed. It is important that an assistant helps and holds the glass from the outside as
it is pressed out from the inside.
2
With the assembly removed from the
vehicle, detach the weatherseal from the
window glass.
3 If the weatherseal is to be re-used it should
be cleaned. Do not use petrol, white spirit or
other similar substances, as they may cause
rapid rubber deterioration. Ensure that the
glass groove in the weatherseal is free from
any sealant or glass fragments.
4 Ensure that the body aperture flange is free
from any sealant also.
Refitting
5 Commence refitting by attaching the
weatherseal to the window glass, ensuring
that it is seated correctly.
6 Insert a length of nylon or terylene cord into
the body aperture flange groove of the
weatherseal, so that the cord ends emerge at
the top centre of the window, and overlap by
approximately 150.0 mm.
7 Offer the assembly to the body aperture,
and engage the lower lips of the weatherseal
over the body aperture flange. Ensure that the
engagement of the weatherseal lips is not
hampered in any way, and that the cord ends
are protruding inside the vehicle.
8 With an assistant applying a gentle even
pressure on the window glass from the
outside, pull one end of the cord at right-
angles to the glass. This will pull the inner lip
of the weatherseal over the body aperture
flange.
9 When the cord has been pulled halfway
around the aperture, repeat the procedure
with the other end of the cord. The cord
should release when the window glass is fully
fitted.
10 Refit any disturbed interior trim as
necessary.
Hinged side window glass
Removal
11 With an assistant standing outside ready
to take the window, unscrew the single screw
securing each hinge, then open the window
and unscrew the two screws securing the
catch to the body. Withdraw the window.
12 The weatherstrip can now be removed
and refitted, if required.
Refitting
13 To refit the window, have your assistant
stand outside and offer up the window so that
both hinge leaves enter their sockets, then
loosely refit the catch securing screws. Refit
the hinge securing screws, then adjust the
catch position to ensure that the window is
clamped evenly on to the weatherstrip over
the whole mating surface when the catch is
fastened. Tighten all screws securely.
Sliding side window and glass
Removal
14 To remove the complete sliding window
assembly on Courier Kombi models requires
special cutting equipment and supplies of
Bodywork and fittings 11•15
31.20 Regulator retaining rivets (A) and lower window glass guide securing screws (B) on rear door
11
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suitable adhesive; it is recommended that this
task be left to a Ford dealer or similar expert.
15To remove the window glass, remove their
retaining screws and withdraw the lock
assemblies, slide the front glass as far to the
rear as possible, then prise up and withdraw
the front glass guide; it will be necessary to
pull the last part of the guide from under the
glass.
16 Withdraw the vertical seal and two
support blocks from between the two glasses,
slide the seal to the front of the frame, and
withdraw it. Slide each glass in turn
to the front of the frame and withdraw it,
then prise up and withdraw the rear glass
guide.
Refitting
17 On refitting, check that the glass guides
are undamaged; renew them if necessary.
Ensure that the lock assemblies are removed
from both glasses.
18 Press the rear glass guide into place. Refit
first the rear glass, fitting it to the front of the
frame and sliding it to the rear, then the front
glass, in the same way.
19 To refit the vertical seal, sandwich it
between two strips of thin sheet metal and
install it, with its support blocks, first in the
front part of the frame, then push it into place.
This will require some effort as the glass is
reached, due to the distortion caused by the
location notch on the block. When the seal is
fully in place, withdraw the metal strips, and
check that the seal’s lips have not folded back
on themselves.
20 When refitting the front glass guide, locate
it first around the frame’s detent catch, then
slide it under the glass using soapy water as a
lubricant.
21 Refit the lock assemblies, clean the
glasses, and check the operation of the
windows and locks.
34 Windscreen and tailgate window glass -
removal and refitting
4
Note : The DIY mechanic is advised to leave
windscreen/tailgate window glass removal
and refitting to an expert. For those with the
necessary tools and equipment, the
following paragraphs are a guide to the
procedure.
Removal
1 Remove the windscreen/tailgate wiper arms
as described in Chapter 12.
2 If removing the windscreen, remove both A-
pillar trims, and release the front of the
headlining by removing the sun visors and
courtesy light. If a heated windscreen is fitted,
disconnect its electrical contacts at the
windscreen. If removing the tailgate window
glass, disconnect the wiring to the heating
element. 3
As a precautionary measure to prevent
damage to the paintwork, cover the
surrounding bodywork with an old blanket or
similar.
4 Using a suitable tool, release the
weatherseal from the top and sides of the
body aperture flange before exerting pressure
from the inside of the vehicle to remove the
assembly. It is strongly advised that an
assistant outside the vehicle is ready to
receive the glass as it is pushed out.
5 With the assembly removed from the
vehicle, detach the weatherseal from the
windscreen/tailgate glass.
Refitting
6 With reference to the procedures described
for the fixed side window glass in Section 33,
clean the weatherseal, then refit in
accordance with the rest of that Section.
7 Any trim and equipment removed during
preparation should now be refitted.
35 Sunroof panel -
removal and refitting
1
Removal
1 Open the sunroof fully using the handwheel.
2 Detach the sunroof from its rearward
mounting point by pressing in the red locking
bar on the handwheel, then raise it and
remove.
Refitting
3 To refit, engage the hinges in their
locations, in the forward edge of the sunroof
opening, then lower the sunroof. Allow the
handwheel to click into its safety lock.
4 Check that the safety lock mechanism
retains the panel securely.
5 Close the sunroof fully using the
handwheel.
36 Sunroof panel seal -
renewal
1
1 Remove the sunroof panel, as described in
Section 35, then lay the panel on a soft cloth.
2 Remove the two hinge plate assemblies
from the panel by undoing the hinge plate
retaining screws.
3 Pull the seal from the panel edge, noting the
position of its join.
4 Starting from the position of the original
join, press the seal into position, ensuring that
it sits evenly right around. Adjust as necessary
so that the ends butt tightly together.
5 Refit the two hinge plate assemblies to the
panel.
6 Refit the sunroof panel, as described in
Section 35.
37 Sunroof weatherseal -
removal and refitting
1
Removal
1 Remove the sunroof panel, as described in
Section 35.
2 Starting from the joint on the rearward
opening edge, pull the seal up and remove.
Refitting
3 Refitting is a reversal of the removal
procedure, ensuring that the weatherseal
does not deform at the corners, or split at the
joint.
38 Full-length sunroof -
general information
1 The full-length sunroof is electrically-
operated, the operating system consisting of
the motor and the roof-mounted switch. The
circuit is fed via fuses 18 and 28 from the
ignition switch; switch illumination is via
fuse 6.
2 All components are mounted in the roof of
the passenger compartment, above the
headlining at the front of the vehicle.
3 To open the sunroof, press the switch
lightly on the upper side; to close it, check
first that the opening is completely
unobstructed, and press the switch on the
lower side.
4 Maintenance is confined to checking for
freedom of action and a snug fit when shut.
Check that the seals are in good clean
condition and not scratched or damaged.
5 Owners must note the following to ensure
that the maximum trouble-free life from this
feature:
a) It is normal for the motor to slow down as
the sunroof approaches full opening.
b) If the sunroof stops before it is fully
opened in cold weather, this may be due
to the material being too hard to fold
correctly; do not force the sunroof open if
this is suspected.
c) If the material does not fold correctly on
opening at any time, close the sunroof
again, correct the folds by hand, and try
again.
d) Never open or close the sunroof with the
vehicle travelling at more than 70 mph
(120 km/h), and never allow passengers to
travel standing up or with any part of their
bodies in the opening.
e) Ensure that any collected water, snow or ice is removed from the sunroof before
opening it. Check that the deflector is
clear of water, particularly after washing
the vehicle; sponge it dry if necessary.
f) Never place heavy objects on the sunroof or its surrounds.
g) The sunroof should be cleaned frequently
11•16 Bodywork and fittings
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to avoid the material being stained by dirt.
Use a sponge, soft brush or soft cloth and
a neutral detergent, rinsing with a gentle
flow of clean water from directly above
until all traces of dirt and detergent are
removed. Neveruse a high-pressure jet,
pressure washer or similar, and do not
aim the jet from a hose at the joints of the
sunroof with the body (or water will enter
the passenger compartment). Neveruse
alcohol, petrol, thinners or similar
products to clean the material.
h) If the vehicle is parked in heavy rain, or if it is parked outside for long periods, a
proprietary car cover or tarpaulin should
be used to protect the roof and body. Do
not leave the sunroof open for long
periods; the material will stiffen in its folds,
with a consequent risk of tearing when the
sunroof is eventually operated again.
6 If the system fails with the sunroof open, it
can be closed in emergency by switching off
the ignition, prising out the access plug in
front of the switch, and using the crank
provided to rotate the motor shaft clockwise
until the roof is closed.
7 If the switch is thought to be at fault, it can
be removed after first disconnecting the
battery negative (earth) lead (refer to Chap-
ter 5, Section 1) ; the switch can then be
eased from its housing until the wires can be
disconnected. Refitting is the reverse of the
removal procedure.
8 If any other failure or problem is
encountered, the general inaccessibility of the
system’s components means that servicing
and fault-finding is beyond the capabilities of
most owners; the vehicle should be taken to a
Ford dealer for attention.
39 Front seat and slide assembly -
removal and refitting
1
Removal
Warning: On vehicles fitted with
mechanical 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.
You are strongly advised to seek the
advice of a Ford dealer as to the correct
use of the “transit clip” and the safety
implications before proceeding.
1 On pre-1994 models, slide the seat fully
rearwards to expose the two front slide
assembly to floorpan bolts. Remove all four
bolts securing the slides to the floorpan, and
remove the seat from the vehicle.
2 On later models, pull off the trim cover from
the outer slide. 3
On vehicles fitted with mechanical seat belt
pre-tensioning stalks, fit the safety “transit
clip”.
4 Slide the seat fully rearwards, remove the
inner slide trim cover then unscrew and
remove the front slide assembly to floorpan
bolts.
5 Now slide the seat fully forward, and
unscrew the rear slide securing bolts each
side. Lift the seat and remove it from the
vehicle.
Refitting
6 Position the seat in the vehicle, and align
the slide assemblies with their mounting bolt
locations in the floorpan. Refit the front
securing bolts first, followed by the
rear securing bolts, to ensure that the seat
runs smoothly in its slide mechanism. Tighten
the bolts to the specified torque. On later
models, remove the “transit clip” (where
applicable) and refit the trim covers.
40 Rear seat -
removal and refitting
1
Backrest and catch
Removal
1 To remove the backrest, release the
backrest catch/catches, then fold the
backrest forwards.
2 Remove the hinge-to-backrest securing
screws, then remove the backrest (see
illustration) .
3 The hinges may be removed at this stage if
required, by undoing the hinge-to-body
securing screws.
4 If desired, the rear seat backrest catch may
be removed by removing the catch retaining
bolts (see illustration) .
Refitting
5If removed, refit the backrest catch and
secure with the retaining bolts.
6 To install the backrest, align the hinges to
the body and backrest, then loosely refit the
securing screws. 7
Fold the backrest into its upright position
and engage the backrest catch/catches.
Adjust the alignment of the components then,
when correct, tighten the securing screws to
their specified torques.
8 Check for correct catch engagement.
Cushion
Removal
9To remove the cushion, remove the three
screws securing the forward edge of the seat
cushion to the raised floorpan section.
10 Push down and back on the cushion, to
disengage the hook and catch on the rear
underside of the seat.
11 Remove the seat from the vehicle after
guiding the seat belt clips through the slits in
the seat cushion.
Refitting
12 Refitting the cushion is a reversal of the
removal procedure.
Seat assembly (Courier Kombi
models)
Removal
13 The seats are secured by two bolts at
each forward hinge, visible once the seat has
been folded forwards. Unbolt the hinges and
withdraw the seat assembly.
Refitting
14 Refitting is the reverse of the removal
procedure.
41 Seat belts -
removal and refitting
3
Removal
Front seat belt (five-door models)
1 Remove the cover from the upper anchor
position and remove the anchor bolt.
2 Remove the lower anchor bolt from its
location on the floor by the base of the B-
pillar. Prevent the retractor unit from reeling in
too great a quantity of seat belt by attaching a
clothes peg, or similar item, to the seat belt.
Bodywork and fittings 11•17
40.4 Rear seat backrest catch retaining bolts (arrowed)40.2 Rear seat hinge arrangement
A Hinge-to-backrest screw locations
B Hinge-to-body screw locations (removed after backrest detached)
11
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3Remove the B-pillar trim and sill scuff plate
as described in Section 42.
4 Remove the bolt (two bolts on later models)
securing the seat belt retractor unit to its
location in the base of the B-pillar (see
illustration) , then remove the retractor unit
and the seat belt from the vehicle.
Front seat belt (three-door models)
5 Remove the rear quarter trim panel, as
described in Section 42.
6 Undo the bolt securing the seat belt
retractor unit to its location, then remove the
retractor unit and seat belt from the vehicle.
Front seat belt (Van models)
7 Remove the cover from the upper anchor
position and remove the anchor bolt.
8 Undo the bolt securing the retractor unit
and integral lower anchor position, then
remove the retractor unit and seat belt from
the vehicle.
Front seat belt stalk
Warning: On vehicles fitted with
mechanical seat belt pre-
tensioners, any work on the seat
belt stalk should be entrusted to
a Ford dealer. The following procedure is
therefore only applicable to models with conventional seat belt stalks which DO
NOT incorporate any form of pre-
tensioning device.
9
Remove the bolt securing the seat belt stalk
assembly to the floor, between the two front
seats, noting the arrangement of washers and
spacers (see illustration) . Remove the stalk
assembly from the vehicle.
Front seat belt height adjuster
Note : If a height adjuster mechanism is not
fitted, it is possible to lower the upper anchor
position from its production setting, by
removing the plug from the lower adjuster
plate hole and bolting the anchor into this (see
illustration 41.13) . The plug can then be fitted
to the production setting hole.
10 Remove the height adjuster knob by
carefully inserting a small screwdriver into the
aperture on the underside of the knob, and
gently levering it off.
11 Remove the anchor cover, again using a
screwdriver, then remove the anchor bolt and
anchor (see illustration) .
12 Remove the door aperture weatherseal(s)
around the B-pillar location, then remove the
B-pillar trim, as described in Section 42.
13 Remove the bolts securing the adjuster
plate to the B-pillar, noting washer fitment, then remove the adjuster plate from the
vehicle
(see illustration) .
Rear seat belts
14Remove the rear seat cushion, as
described in Section 40, then also remove the
parcel shelf.
15 Undo the bolt securing each seat belt
buckle assembly to its body location (see
illustration) , and remove the buckle
assemblies from the vehicle, as required.
16 Prevent the retractor units from reeling in
too much seat belt by attaching a clothes peg
or similar item to the belt, close to the
retractor unit.
17 Detach the seat belt lower anchor by
removing its retaining bolt.
18 Remove the upper anchor bolt cover and
undo the bolt securing the anchor to its
location. Detach the anchor, noting any
spacer fitment.
19 On vehicles fitted with a parcel shelf,
remove the seat belt guide from the parcel
shelf support/rear loudspeaker housing, then
pass the seat belt through it.
20 On vehicles without a parcel shelf as
standard, remove the trim panel covering the
seat belt retractor unit, where fitted, by
undoing its retaining screws. Remove the seat
belt guide from the trim panel, then pass the
seat belt through it.
21 Remove the bolt securing the seat belt
retractor unit to its body location, then
withdraw the retractor unit and the seat belt
from the vehicle.
Refitting
22 Refitting is a reversal of the removal
procedure, noting the following points. Ensure
that the tag on the retractor unit engages in its
body location and, in the case of the rear seat
belts, that it does not trap the wiring loom
between itself and the body. Having fitted the
upper anchor to its location, ensure that it can
rotate freely. The stalk assembly anchor(s)
must engage to the anti-rotation floorpin(s)
and, when refitting a rear centre lap
belt/buckle assembly, the lap belt must be
fitted to lie on the right-hand side of the
vehicle. Tighten all bolts to their specified
torque.
11•18 Bodywork and fittings
41.15 Rear seat belt and buckle securing
arrangements (rear seat cushion removed)
A Seat belt lower anchor retaining bolts
B Centre lap belt/single buckle assembly securing bolt
C Dual buckle assembly securing bolt41.13 Seat belt upper anchor position (fixed and adjustable)
A Adjuster plate securing bolt
B Anchor bolt position (production setting)
C Lower setting for fixed type (if required)
41.11 Removing a seat belt upper anchor cover41.9 Front seat belt stalk assembly
A Bolt
B Anti-rotation plate
C Stalk D Metal washers
E Paper washer
F Floorpin
41.4 Seat belt retractor unit location in
base of B-pillar (five-door models)
A Retractor unit locating tag
B Retractor unit securing bolt
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42 Interior trim panels-
removal and refitting
2
A-pillar trim
Removal
1 Remove the securing screw from the trim
panel, located near to the windscreen top
corner (see illustration) .
2 Detach the door aperture weatherseal from
around the trim panel, then pull the trim panel
from the pillar.
Refitting
3 To refit, align the trim fixing lugs to the pillar
and press into position. Refit the securing
screw then push the door aperture
weatherseal back onto its flange.
B-pillar trim
Removal
4 Remove the front seat belt height adjuster
knob, as applicable, by inserting a small
screwdriver into the aperture on the underside
of the knob and levering it off.
5 Remove the upper seat belt anchor bolt
cover, and remove the bolt, as required.
6 Open the doors and detach the door
aperture weatherstrip from the area around
the B-pillar trim. 7
Remove the securing screws and detach
the trim.
Refitting
8 Refitting is the reverse sequence to
removal, tightening the seat belt anchor bolt
to the specified torque. Ensure that the
anchor is free to rotate.
C-pillar trim
Removal
9 Open the tailgate, then detach the
loudspeaker from its location by
disconnecting its multi-plug connection,
removing its two retaining screws and
unhinging it.
10 Detach the tailgate weatherstrip from its
flange, around the trim panel.
11 Remove the parcel shelf, then slacken the
parcel shelf support/rear loudspeaker housing
retaining screws, and remove the single screw
from the base of the C-pillar trim (see
illustration) .
12 Remove the upper seat belt anchor bolt
cover, and remove the bolt and anchor, noting
any spacer fitment.
13 Remove the screw(s) from the top of the
C-pillar trim, then remove the trim from the
vehicle.
Refitting
14 To refit, position the base of the trim behind the parcel shelf support/rear
loudspeaker housing, then loosely refit the
upper and lower securing screws.
15
Refit the seat belt anchor, bolt, and
spacer, as applicable, tightening the bolt to
the specified torque. Refit the anchor bolt
cover, and ensure that the anchor is free to
rotate.
16 Tighten the trim and parcel shelf
support/rear loudspeaker housing screws,
then refit the parcel shelf.
17 Refit the loudspeaker by reversing the
method of removal, then press the tailgate
weatherstrip back into place.
Sill scuff plate
Removal
18 Remove the front seat adjacent to the
scuff plate to be removed (see Section 39).
19 Detach the door aperture weatherstrip(s)
from around the scuff plate location.
20 Remove the B-pillar trim, as applicable.
21 Remove the lower seat belt anchor bolt on
five-door models, and detach the anchor from
its location.
22 On three-door models, remove the bolt
securing the forward end of the seat belt slide
bar, then manoeuvre the slide bar to free it
from its rear location.
23 Remove the plastic screws securing the
sill scuff plate, then slip the seat belt through
its slot on five-door models, and remove the
sill scuff plate from the vehicle (see
illustration) . Should the soft plastic screws
round off during attempts to remove them,
force an electrician’s thin screwdriver into the
body of the screw and try again, fitting a new
screw upon reassembly.
Refitting
24 Refitting is a reversal of the removal
procedure, tightening the seat belt anchor
bolts to the specified torque.
Rear quarter trim panel
Removal
25 Detach the door aperture weatherstrip
from around the trim location.
26 Remove the rear seat cushion, as
described in Section 40.
27 Remove the screw from the upper rear
corner of the trim panel.
28 Remove the plastic stud from the lower
rear corner of the trim panel.
29 Detach the seat belt slide bar by removing
the bolt from its forward end then
manoeuvring it to free it from its rear location
(see illustration) . Remove the seat belt from
the slide bar.
30 Release the trim clips from the front and
top edges of the panel using a trim clip tool.
This may be achieved by carefully inserting
two thin flat-bladed screwdrivers between the
panel and the body - one each side of the clip
being released, and applying gentle leverage,
if a trim clip tool is not available.
Bodywork and fittings 11•19
42.11 C-pillar trim fixings
A Screw locations
B Parcel shelf support/rear loudspeaker housing location42.1 A-pillar trim retaining screw (A),
heated windscreen live wire (B) and heated windscreen earth wire (C)
42.29 Seat belt lower slide bar anchorarrangement (three-door models)
A Bush location B Anchor bolt42.23 B-pillar trim being removed to
expose seat belt removal/refitting slot in sill scuff plate (arrowed)
11
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