ABS FORD SIERRA 1987 2.G Body Electrical System Workshop Manual

Removal
1Disconnect the battery negative lead.
2For improved access, remove the securing
screws and unclip the lower and upper
steering column shrouds.
3Insert the ignition key and turn to position
“I”, then, working through the access hole,
depress the spring clip using a suitable tool
and pull the key to withdraw the lock barrel
and cylinder from the ignition switch housing.
The spring clip access hole is shown (see
illustration). Note that, on certain models, the
spring clip must be released by inserting the
tool through a small circular hole at the top of
the switch housing, above the rectangular slot
shown. Slight movement of the key may be
necessary to allow removal of the barrel and
cylinder.
4To remove the lock barrel from the cylinder
insert the key fully into the barrel and remove
the retaining circlip, taking care not to
damage the circlip location, then withdraw the
key approximately 5.0 mm (0.2 in) to retract
the lock barrel securing lug, and withdraw the
barrel from the cylinder.
5To remove the ignition switch, disconnect
the wiring plug, then remove the two grub
screws and withdraw the switch.
Refitting
6Refitting is a reversal of removal, bearing in
mind the following points.
7Note that the lock barrel can only be fitted
to the cylinder in one position, and check with
the key fully inserted that the barrel can be
turned from position “O” to “Ill” satisfactorily.
8The open jaws of the lock barrel retaining
circlip must align with the keyway register on
the cylinder, and the cylinder retaining circlip
must locate in the slot in the ignition switch
housing.
9On completion, check the operation of the
steering lock and ignition switch in all
positions.
1Disconnect the battery negative lead.
2Remove the securing screws and unclip the
lower and upper steering column shrouds.
3Remove the two securing screws and
disconnect the two wiring plugs, then
withdraw the switch from the steering column.
4Refitting is a reversal of removal.
1Disconnect the battery negative lead.2The relay is located on a bracket above the
steering column. Access is gained either by
removing the driver’s side lower facia panel or
the instrument panel.
3Unclip the relay from the bracket, and
disconnect the wiring plug (see illustration).
4Refitting is a reversal of removal. Check for
correct operation before refitting the facia
panel or instrument panel.
The procedure is identical to that described
for the direction indicator switch, except for
the additional removal and refitting of an earth
lead (see illustration).
1For automatic transmission models, refer to
Chapter 7, PartB. For manual gearbox
models, proceed as follows:
2Disconnect the battery negative lead.
3Apply the handbrake, jack up the front of
the vehicle and support on axle stands (see
“Jacking and Vehicle Support”).
4Working underneath the vehicle,
disconnect the wiring plug, then unscrew the
switch from the gearbox extension housing.
5Refitting is a reversal of removal, but make
sure that the wiring is routed clear of the
exhaust system.1Disconnect the battery negative lead.
Rocker switches and push button
switches
2Using a thin-bladed screwdriver, carefully
prise the switch from the facia panel.
3Disconnect the wiring plug and withdraw
the switch.
4Refitting is a reversal of removal.
Instrument panel illumination and
intermittent wipe rheostats
5Proceed as described in paragraphs 2 to 4.
Heater blower switch
6Carefully pull off the switch knob, using
pliers with padded jaws if necessary.
7Using a thin-bladed screwdriver, prise out
the switch front plate from the facia panel.
8Squeeze the switch retaining tabs, then
withdraw the switch and disconnect the wiring
plug (see illustration).
9Refitting is a reversal of removal.
Loudspeaker balance joystick
10Using a thin-bladed screwdriver, carefully
prise the joystick front plate from the facia
panel.
11Twist the joystick assembly retaining ring
anti-clockwise and remove the ring.
12Working behind the facia panel,
disconnect the wiring plug and slide out the
joystick assembly.
9Facia panel switches - removal
and refitting
8Reversing lamp switch -
renewal
7Lighting and wash/wipe
switch assembly - renewal
6Direction indicator/hazard
warning flasher relay - renewal
5Direction indicator and hazard
warning flasher switch
assembly - renewal
4Ignition switch and lock barrel
- removal and refitting
13•4Body electrical system
4.3 Ignition switch lock barrel spring clip
location (arrowed)
7.1 Lighting and wash/wipe switch
assembly earth lead securing screw
(arrowed)9.8 Heater blower switch removal. Switch
retaining tabs arrowed
6.3 Direction indicator/hazard warning
flasher relay location (arrowed)

10Remove the headlamp securing bolt and
the two nuts, then release the anchor spring
and withdraw the direction indicator !amp unit
(see illustrations).
11Pull the headlamp forwards, then swivel it
and remove it sideways.
12If required, the headlamp lens can be
removed by releasing the spring clips around
its edge.
13Refitting is a reversal of removal.
14On completion, check the headlamp
alignment.
1It is recommended that the headlamp
alignment is carried out by a Ford dealer using
specialist beam setting equipment. However,
in an emergency the following procedure will
provide an acceptable light pattern.
2With the vehicle unladen, with a full tank of
fuel, and with the tyres correctly inflated,
position the vehicle approximately 10 metres(33 feet) in front of, and at right-angles to, a
wall or garage door.
3Draw a vertical line on the wall
corresponding to the centre line of the car.
The position of the line can be ascertained by
marking the centre of the front and rear
screens with crayon then viewing the wall
from the rear of the car.
4Complete the lines shown (see
illustration).
5Switch the headlamps on dipped beam and
adjust them as necessary using the knobs
located behind the headlamps (see
illustration). Cover the headlamp not being
checked with cloth.
1Disconnect the battery negative lead.
Saloon and Hatchback models
2Working inside the luggage compartment,
press the plastic retaining tab and remove thebulbholder assembly.
3Disconnect the wiring plug from the
bulbholder.
4Unscrew the securing nuts, and withdraw
the rear lamp unit from outside the vehicle.
Recover the gasket.
5Refitting is a reversal of removal.
Estate models
6Working inside the luggage compartment,
turn the retaining tabs a quarter-turn and
remove the rear side trim panel cover.
7Push out the retaining tabs and withdraw
the bulbholder.
8Disconnect the wiring plug from the
bulbholder.
9Unscrew the four securing nuts, and
withdraw the rear lamp unit from outside the
vehicle. Recover the gasket.
10Refitting is a reversal of removal.
43Rear lamp unit - removal and
refitting
42Headlamps - alignment
13•14Body electrical system
41.8 Disconnect the headlamp wiring plug
- models from 198741.10b . . . the upper securing nut . . .
42.5 Adjusting the headlamp alignment
42.4 Headlamp alignment chart
A Distance between headlamp centres
B Light/dark boundary
C Centre of dipped beam
D Dipped beam patternH Height of headlamp centre from ground
X = 160.0 mm (6.3 in) for all models up to 1987
120.0 mm (4.7 in) for all models from 1987
41.10c . . . and the side securing nut -
models from 1987
41.10a Remove the headlamp rear
securing bolt . . .

P100 models
11Remove the two securing screws and
detach the rear lamp wiring cover from the
side of the cargo area(see illustration).
12Working through the cargo area aperture,
unscrew the two wing nuts and remove the
rear lamp cover.
13Disconnect the wiring plug from the back
of the lamp unit.
14Unscrew the four securing nuts and
withdraw the lamp unit from outside the cargo
area. Recover the gasket.
15Refitting is a reversal of removal, but
ensure that the plastic washer between the
wiring plug and the lamp unit is seated
correctly, and make sure that the wiring
protective sheath is seated correctly in the
opening in the lamp cover.
1Disconnect the battery negative lead.
Models up to 1987
Low specification
2Push the lamp unit rearwards into the
bumper until the plastic retaining tang is heard
to click in the locked position.
3Withdraw the lamp unit from the front of the
bumper and disconnect the wiring plug (see
illustration).
4Commence refitting by reconnecting the
wiring plug.
5Release the retaining tang, then refit the
lamp unit to the bumper, ensuring that the
pivot on the lamp unit engages with the slot in
the bumper. Reconnect the battery.
High specification
6Press the release lever at the top of the
lamp unit upwards, and withdraw the unit
from the bumper. Disconnect the wiring plug.
7To refit, reconnect the wiring plug, then
push the lamp unit into the bumper until it
locates securely. Reconnect the battery.
All models from 1987
8Working in the engine compartment,
unhook the lamp unit anchor spring from itsanchorage next to the headlamp, then
withdraw the lamp unit sideways from its
recess (see illustrations). Disconnect the
bulbholder by twisting it anti-clockwise.
9Refitting is a reversal of removal, but ensure
that the locating pins on the lamp unit engage
with the corresponding holes in the headlamp
mounting panel.
1Disconnect the battery negative lead.
Models up to 1987
2To improve access, turn the steering onto
full lock.
3Remove the relevant wheel arch liner.
4Working under the wheel arch, depress the
retaining tabs and withdraw the lamp through
the outside of the wing (see illustration).
Disconnect the bulbholder by twisting it anti-
clockwise.
5Refitting is a reversal of removal.
Models from 1987
6To improve access, turn the steering onto
full lock.
7Working in the engine compartment,
disconnect the wiring plug.
8Remove the relevant wheel arch liner.
9Working under the wheel arch, twist the
lamp clockwise and withdraw it through theoutside of the wing. Feed the wiring through
the holes in the wing panels.
10Refitting is a reversal of removal.
1Disconnect the battery negative lead.
Models up to 1987
2Remove the relevant front direction
indicator lamp unit.
3Release the retaining catch on the inside
edge of the lamp, then withdraw the lamp
from the bumper and disconnect the wiring
plug (see illustration).
4Refitting is a reversal of removal.
46Front foglamps - removal and
refitting
45Front direction indicator side
repeater lamp - removal and
refitting
44Front direction indicator
lamp unit - removal and
refitting
Body electrical system 13•15
13
44.8a Unhook the front direction indicator
lamp unit anchor spring . . .
46.3 Front foglamp removal -
models up to 1987
A Retaining catch45.4 Withdrawing a front direction
indicator side repeater lamp -
models up to 1987
44.8b . . . and withdraw the lamp unit
44.3 Withdrawing a front direction
indicator lamp unit - “low specification”
models up to 198743.11 Rear lamp wiring cover (A) and rear
lamp cover (B) - P100 models

12Disconnect the wiring from the bulb, then
release the spring clip and withdraw the bulb.
Do not touch the bulb glass.
13Refitting is a reversal of removal.
Front direction indicator lamps
Models up to 1987
14Remove the lamp unit.
15Twist the bulbholder anti-clockwise and
withdraw it from the rear of the lamp. The bulb
is a bayonet fit in the bulbholder (see
illustration).
16Refitting is a reversal of removal.
Models from 1987
17Remove the lamp unit.
18Release the bulbholder by pressing it and
turning clockwise, then withdraw the bulb
from the bulbholder (see illustration).
19Refitting is a reversal of removal.
Front direction indicator side
repeater lamps
Models up to 1987
20To improve access, turn the steering onto
full lock.
21Remove the relevant wheel arch liner.
22Working under the wheel arch, twist the
bulbholder anti-clockwise and withdraw it
from the lamp. The bulb is a push-fit in the
bulbholder.
23Refitting is a reversal of removal.
Models from 1987
24Remove the lamp unit. 25Twist the bulbholder anti-clockwise to
remove it from the lamp. The bulb is a push-fit
in the bulbholder.
26Refitting is a reversal of removal.
Front foglamps
27Remove the foglamp.
28On models up to 1987, remove the bulb
cover from the rear of the lamp, then release
the two spring clips, disconnect the wiring and
withdraw the bulb. Do not touch the bulb glass.
29On models from 1987, release the spring
clip and pull the bulb from the bulbholder. Do
not touch the bulb glass (see illustration).
30Refitting is a reversal of removal.
Rear lamp unit
Saloon and Hatchback models
31Working inside the luggage compartment,
press the plastic retaining tab and remove the
bulbholder assembly. The bulbs are a bayonet
fit in the bulbholder (see illustrations).
32Refitting is a reversal of removal.
Estate models
33Working inside the luggage compartment,
turn the retaining tabs a quarter-turn and
remove the rear side trim panel cover.
34Push out the retaining tabs and withdraw
the bulbholder. The bulbs are a bayonet fit in
the bulbholder.
35Refitting is a reversal of removal.
P100 models
36Remove the two securing screws and
detach the rear lamp wiring cover from the
side of the cargo area. 37Working through the cargo area aperture,
unscrew the two wing nuts and remove the
rear lamp cover.
38Twist the relevant bulbholder anti-
clockwise to remove it from the lamp. The
bulb is a bayonet fit in the bulbholder.
39Refitting is a reversal of removal, but
ensure that the wiring protective sheath is
seated correctly in the opening in the lamp
cover.
Rear number plate lamp
Saloon, Hatchback and Estate models
40Remove the lamp unit.
41Twist the bulbholder anti-clockwise to
remove it from the lamp. The bulb is a push-fit
in the bulbholder (see illustration).
42Refitting is a reversal of removal.
Body electrical system 13•17
13
48.15 Removing a front direction indicator
lamp bulb - models up to 1987
48.31b Removing a bulb from the rear lamp
bulbholder - Saloon and Hatchback
models48.31a Press the plastic retaining tab to
release the rear lamp bulbholder assembly
- Saloon and Hatchback models48.29 Front foglamp bulb retaining spring
clip - models from 1987
48.18 Removing a front direction indicator
lamp bulb - models from 1987
48.11 Auxiliary driving lamp bulb location -
models from 198748.9 Withdraw the auxiliary driving lamp
bulb from the headlamp unit -
models up to 1987