four wheel drive FORD SIERRA 1985 1.G Bodywork And Fittings Workshop Manual

Removal
1Open the tailgate and prise out the trim
panel using a wide-bladed screwdriver(see
illustration).
2Remove the lock barrel retaining clip, and
where applicable disconnect the operating
lever from the central locking solenoid/motor,
then withdraw the lock barrel (see
illustration). Central locking solenoid/motor
removal and refitting is covered in Chapter 13.
3Remove the two securing screws and
detach the lock barrel support bracket from
the tailgate.
4Where applicable, disconnect the battery
negative lead, the earth lead from the tailgate
and the “tailgate ajar” sensor wiring plug.
Unclip the luggage compartment light switch
from the lock assembly, where applicable.
5Remove the securing screws and withdraw
the lock assembly.
Refitting
6Refitting is a reversal of removal, but do not
tighten the lock barrel support bracket screws
until the lock barrel has been fitted.
Removal
1Support the tailgate in the open position
using a prop, or with the aid of an assistant.
2Disconnect the strut from the tailgate by
prising out the retaining clip. Do not remove
the clip completely, just raise it by a maximum
of 4.0 mm (0.16 in) and then pull the strut off
its mounting.
3Pull the strut from the pivot stud on the
body.
Refitting
4Refitting is a reversal of removal.
Removal
1Operate the control lever to open the
tailgate/boot lid and the fuel filler flap (see
illustration).
2Remove the driver’s side centre pillar lower
trim panel and the sill trim panel.
3Withdraw the cover from the control lever.
4Unscrew the two securing bolts, and
detach the control lever assembly from the
body panel. Detach the cable from the control
assembly.
5Fold the rear seat cushion forwards or
remove it, as applicable, and remove the rear
seat side cushion for access to the wheel arch
trim panel.
6Detach the trim panel from the wheel arch
by removing the two securing screws from the
parcel shelf bracket. Free the cable up to the
wheel arch.
7Working inside the luggage compartment,
remove the trim panels for access to the
petrol flap lock and tailgate/boot lid lock.
8Disengage the petrol flap catch from the
housing by twisting and pulling out (see
illustration). Carefully pull the cable through into
the luggage compartment, noting its routing.
9Remove the securing screws, and withdraw
the tailgate/boot lid lock striker from the bodypanel. Withdraw the striker and cable
assembly.
Refitting
10Commence refitting by installing the
tailgate/boot lid striker and cable assembly.
Secure the cable to the body with tape.
11Route the cable back to the petrol flap
housing, and refit the petrol flap catch.
12Route the cable into the interior of the
vehicle, and refit the luggage compartment
trim panels.
13Route the cable to the control lever,
securing the cable with tape to the body, then
refit the wheel arch trim panel, and refit the
seat cushions.
14Reconnect the cable to the control lever
assembly, then refit the assembly.
15Refit the control lever cover and the trim
panels.
Models up to 1990
1Open the tailgate/boot lid.
2Prise the four screw covers from the
spoiler, then remove the screws, and
withdraw the spoiler.
3Refitting is a reversal of removal.
Models from 1990
4Open the tailgate/boot lid.
5Remove the inner tailgate/boot lid trim
panel for access to the spoiler securing nuts.
6Unscrew the central spoiler securing nut,
then unscrew the four outer securing nuts
(two on each side), and withdraw the spoiler.
7Refitting is a reversal of removal.
Front door
1On models with electric mirrors, electric
windows, central-locking, door-mounted
speakers, or “door ajar” sensors, remove the
trim panel and disconnect the wiring inside
the door. Withdraw the wiring loom(s) through
the grommet(s) in the front edge of the door.
16Door - removal and refitting
15Tailgate/boot lid spoiler -
removal and refitting
14Tailgate/boot lid/fuel filler
flap release cable - removal
and refitting
13Tailgate strut (Hatchback
and Estate models) - removal
and refitting
12Tailgate lock (Hatchback and
Estate models) - removal and
refitting
12•6Bodywork and fittings
14.1 Tailgate/boot lid/fuel filler flap control
lever assembly14.8 Disengaging the petrol flap catch
from the housing
12.2 Tailgate lock assembly - Hatchback
and Estate models
A Lock barrel support
bracket
B Lock barrel
retaining clipC Lock barrel
D Torx screw
E Lock assembly
F Screws
12.1 Tailgate trim panel fixings -
Hatchback and Estate models

New bumpers are supplied without the trim
moulding fitted. Special primer and adhesive
tape are specified by the manufacturer to
retain the moulding: it is suggested that a
Ford dealer is consulted for further details.
A damaged moulding can be removed by
prising it from the bumper using a screwdriver.
Models up to 1987
1With the bonnet raised, remove the four
grille panel securing screws from the top of
the front panel.
2Lift the grille panel from its lower mounting
bushes, and withdraw it from the vehicle.
3Refitting is a reversal of removal, but ensure
that the lower mounting lugs are correctly
located in their bushes.
Models from 1987
4With the bonnet raised, remove the two
grille panel securing screws from the front
face of the panel.
5Release the upper and lower grille retaining
clips, and withdraw the grille panel from the
vehicle (see illustrations).
6Refitting is a reversal of removal, but align
the grille panel carefully before tightening the
securing screws.
Models from 1990
7With the bonnet raised, remove the two
securing screws from the top of the grille
panel.
8Slide the panel towards the driver’s side of
the vehicle, then pull the panel forwards to
release the retaining clips (see illustration).
9Refitting is a reversal of removal.
Removal
1Open the bonnet and disconnect the
windscreen washer hose at the T-piece
connector.
2Remove both windscreen wiper arm
assemblies.
3Remove the single securing screw from
each end of the cowl panel.
4On models up to 1987, prise out the screw
covers and remove the eight plastic screws
securing the cowl panel to the body.
Withdraw the panel.
5On models from 1987, prise out the screw
covers and remove the plastic securing
screws. Pull the front edge of the cowl panel
upwards to disengage the front fixing clips,
then move the panel to the left and then to the
right to disengage the hooks on the panel
underside. Withdraw the panel.
Refitting
6Refitting is a reversal of removal.1Remove the interior rear pillar trim panel.
2Unscrew the three now exposed securing
nuts and withdraw the exterior trim panel (see
illustration).
3Refitting is a reversal of removal, but do not
overtighten the securing nuts, as this may
result in damage to the rubber seals.
1Remove the cab interior side trim panel.
2Working inside the cab, remove the two
rubber grommets from the rear pillar, then
unscrew the two now exposed nuts, and
withdraw the air vent panel.
3Refitting is a reversal of removal.
1Where fitted, the wheel arch liners may be
retained by self-tapping screws, plastic clips,
or a combination of both.
2To remove a liner, simply unscrew the
retaining screws, or where plastic clips are
fitted, release them by turning with a
screwdriver (see illustration).
3Refitting is a reversal of removal.
Removal
1Open the filler flap and the tailgate or boot
lid, as applicable.
2Remove the fuel filler cap and then remove
the screw securing the filler housing to the
fuel tank neck (see illustration).
3Working inside the luggage compartment,
depress the filler housing retaining tangs, and
push the assembly out through the body
panel. Recover the gasket.
37Fuel filler flap - removal and
refitting
36Wheel arch liners - renewal
35Cab air vent panel (P100
models) - renewal
34Exterior rear pillar trim panel
(Saloon models) - renewal
33Windscreen cowl panel -
removal and refitting
32Radiator grille panel -
removal and refitting
31Bumper trim moulding -
renewal
12•14Bodywork and fittings
32.8 Removing the later type front grille
panel36.2 Releasing a wheel arch liner plastic
clip34.2 Exterior rear pillar trim panel securing
nut locations (arrowed) - Saloon models
A Heated rear window wiring plug
32.5b Radiator grille panel lower retaining
clip - models from 198732.5a Radiator grille panel upper retaining
clip - models from 1987

4Unscrew the upper seat belt anchor nut,
noting the fitted positions of any washers and
spacers so that they can be refitted in their
original positions.
5Remove the two securing screws, and
withdraw the upper trim panel.
6Remove the two or three securing screws
as applicable, and withdraw the lower trim
panel, passing the seat belt webbing through
the panel as it is removed.
7Refitting is a reversal of removal.
Rear pillar
Saloon models
8Remove the rear seat cushion.
9Unbolt the lower seat belt anchor.
10On models with fixed rear seats, remove
the backrest.
11On models with folding rear seats, remove
the side cushion.
12Remove the two securing screws from the
base of the pillar trim panel, then pull the trim
panel from the pillar, passing the seat belt
webbing through the panel as it is removed.
13Refitting is a reversal of removal.
Hatchback models
14Remove the rear seat side cushion.
15Remove the rear parcel shelf, and where
applicable unbolt the rear seat belt upper
anchor and spacer.
16On “high specification” models, lift the
seat catch release lever, push out the pin
securing the link rod to the lever and
disconnect the link rod.
17Remove the securing screws from the rear
parcel shelf support (nine screws on models
up to 1987, eight screws from 1987 onwards)
and on “high specification” models remove
the two bolts securing the rear seat catch
assembly to the wheel arch, then withdraw
the catch assembly. Remove the rear parcel
shelf support.
18Remove the five securing screws and
detach the rear pillar trim panel.
19Refitting is a reversal of removal, but
where applicable check the operation of the
rear seat catch on completion.
P100 models
20Remove the cover from the seat belt
upper anchor, then unscrew the anchor,
noting the fitted positions of any washers and
spacers so that they can be refitted in their
original positions.
21Remove the three securing screws from
the upper trim panel, and withdraw the panel
(see illustration).
22Remove the three securing screws from
the lower trim panel, then pull the panel away
from the pillar and pass the seat belt webbing
through the slot.
23Withdraw the trim panel by disengaging it
from the seat belt inertia reel mounting
bracket.
24Refitting is a reversal of removal.
Side trim panel
1Remove the rear pillar trim panel.
2Remove the side trim panel by prising out
the four expander pins from the clips, then
pulling out the clips and withdrawing the
panel.
3Refitting is a reversal of removal.
Upper rear trim panel
4Remove the side trim panels from both
sides of the cab as previously described in
this Section.
5Remove the cab rear window.
6Prise out the four expander pins from the
trim panel clips beneath the rear window
aperture, then pull out the clips (see
illustration).
7Remove the blanking covers, then remove
the three securing screws from the rear of the
headlining.
8Lower the rear of the headlining and
remove the trim panel.
9Refitting is a reversal of removal.
Lower rear trim panel
10Remove the side trim panels from both
sides of the cab as previously described in
this Section.
11Prise out the four expander pins from the
trim panel clips beneath the rear window
aperture, then pull out the clips.
12Pull the jack handle from its two retaining
clips, then remove the clips.
13Prise out the two expander pins from the
trim panel lower clips, then pull out the clips.
14Pull the bottom edge of the trim panel
away from the rear of the cab, and slide the
panel out from under the upper trim panel.
15Refitting is a reversal of removal.
Models up to 1992
1Note the locations of the facia panel
securing screws (see illustration).
Disconnect the battery negative lead.
Driver’s side lower facia panel
2Remove the two securing screws and
withdraw the side trim panel from the right-
hand side of the footwell (see illustration).
3Remove the securing screws and unclip the
lower and upper steering column shrouds.
43Facia panels - removal and
refitting
42Cab interior trim panels
(P100 models) - removal and
refitting
12•16Bodywork and fittings
42.6 Cab interior rear panel fixings - P100
models
A Upper and lower trim panel fixings
B Jack handle retaining clips
C Lower trim panel fixings
41.21 Interior rear pillar trim panel fixings
(arrowed) - P100 models
A Upper trim panelB Lower trim panel
41.1 Interior pillar trim panel fixings - Hatchback models
A Front pillar trim panel
B1 Centre pillar upper trim panelB2 Centre pillar lower trim panel
C Rear pillar trim panel

Rear seat armrest
26Fold the rear seat backrest forwards, and
remove the three armrest securing screws.
27Remove the armrest by prising out the
trim clips securing the cover material to the
seat backrest.
28Refitting is a reversal of removal.
Saloon models
1Working in the luggage compartment,
release the seat catch by pulling the release
knob, or if the cable is broken, use a
screwdriver to release the catch itself.
2Fold the backrest forwards into the
passenger compartment and remove the two
screws shown (see illustration).
3Detach the cover and then remove the
catch from the body.
4Disconnect the release cable and sheath
from the catch.
5Refitting is a reversal of removal, but on
completion check the catch for correct
operation, and if necessary adjust the position
of the striker on the seat backrest to achieve
satisfactory engagement with the catch.
Hatchback and Estate models
Low specification
6Release the seat catch by pulling the
release knob, and fold the backrest forwards
into the passenger compartment.7Unscrew the release knob from the top of
the seat backrest.
8Carefully pull the edge of the seat cover
from the flange on the seat backrest, then pull
the backrest cushion away from the seat
panel to gain access to the catch (see
illustration).
9Remove the catch assembly by unscrewing
the two securing bolts.
10Refitting is a reversal of removal, but on
completion check the catch for correct
operation, and if necessary adjust the position
of the striker to achieve satisfactory
engagement with the catch.
High specification
11Release the seat catch and fold the
backrest forwards into the passenger
compartment.
12Remove the rear parcel shelf for improved
access, then remove the screws and withdraw
the cover for access to the catch.
13Unscrew the two bolts securing the catch
to the bracket on the rear wheel arch (see
illustration).
14Using a small screwdriver, push out the
pin securing the link rod to the catch, then
withdraw the catch.
15If required, lift the release lever, push out
the securing pin and remove the link rod. The
lever can be removed by drilling out the two
securing rivets from the parcel shelf support.
16Refitting is a reversal of removal, but
where applicable fit new rivets using a hand
riveter to secure the release lever. Oncompletion check the operation of the catch
and if necessary adjust the position of the
striker to achieve satisfactory engagement
with the catch.
Complete assembly - removal and
refitting
1Remove the seat.
2Straighten the seat back cover retaining
tangs, and pull the cover upwards to expose
the air cushion.
3Cut through the four securing rings (see
illustration)and remove the two screws
securing the metal air tube to the side of the
seat, then withdraw the assembly from the
seat frame.
4Refitting is a reversal of removal, using new
cushion securing rings.
Air inflator ball - renewal
5Remove the seat.
6Remove the two screws securing the metal
air tube to the side of the seat (see
illustration), then cut through the plastic hose
as close to the end of the metal tube as
possible. Discard the old tube and the inflator
ball.
49Front seat air cushion
assembly - removal and
refitting
48Rear seat catch - removal and
refitting
12•20Bodywork and fittings
48.8 Pull back the seat cover to expose the
rear seat catch securing bolts - “low
spec.” Hatchback and Estate models
49.3 Front seat air cushion securing rings
(arrowed)
49.6 Front seat air cushion tube and
inflator ball
A Air tube securing screws
B Hose cutting point48.13 Rear seat catch assembly - “high
specification” Hatchback model
48.2 Rear seat catch fixings - Saloon
models
A Remove the securing screws
B Withdraw the cover and catch47.24 Rear seat side cushion removed
exposing upper fixing hook