ESP FORD SIERRA 1987 2.G Bodywork And Fittings Workshop Manual

8Position the crane with the lifting arm
diagonally over the centre of the cargo area,
and attach the cradle. Carefully lift the cargo
area from the chassis. Note that the lip of the
cargo area rear panel fits over the rear chassis
crossmember, therefore the cargo area must
be pulled rearwards as it is removed to
disengage it from the crossmember.
Refitting
9Refitting is a reversal of removal, but ensure
that the insulators are in place between the
cargo area and the chassis. Before finally
tightening the securing bolts, adjust the
position of the cargo area to give an equal
clearance on both sides of the vehicle
between the cab rear panel and the cargo
area front panel.
Removal
1Lower the tailboard to the open position.
2Detach the rear lamp wiring cover on one
side of the vehicle by removing the two
securing screws (see illustration).
3Remove the four rear lamp securing nuts,
and withdraw the rear lamp assembly.
Disconnect the wiring plug.
4Raise the tailboard by approximately 20º,
lift the centre pivot of one of the support arms,
and when the bolt head on the tailboard is
aligned with the slot in the support arm, pull
the support arm clear. Repeat this procedure
for the remaining support arm, and lower the
tailboard to the vertical position.
5On the side of the vehicle from which the
rear lamp has been removed, remove the two
screws securing the tailboard hinge to the
cargo area.
6Close the tailboard and lever out the hinge.
7Pull the free end of the tailboard away from
the cargo area, and carefully prise the
remaining end from its hinge. Withdraw the
tailboard from the vehicle.
8If required, the pivot bushes can be
removed from the tailboard for renewal.
Refitting
9Refitting is a reversal of removal.
Removal
1With the exception of the cab rear window
on P100 models, all fixed glass panels are
direct glazed to the body using a special
adhesive. Special tools are required to
remove the old glass and to fit the new glass,
therefore the work is best entrusted to a
dealer or replacement glass specialist.
2The cab rear window on P100 models can
be removed as follows, although it is
advisable to entrust the work to a specialist.
3Remove the six Torx bolts and nut/washer
assemblies, and withdraw the safety grille
from the rear of the cab.
4Prise out one end of the trim insert from the
window rubber, then pull out the remainder of
the trim.
5With the aid of an assistant, carefully push
the glass and rubber into the passenger
compartment.
6Remove all traces of old sealer from the
glass, rubber and cab aperture.
Refitting
7Commence refitting by pushing the window
rubber into the aperture, ensuring that the trim
panel and body panel engage in their
respective grooves in the rubber.
8Working from outside the cab, enter the
bottom edge of the glass into the rubber, and
hold the glass against the rubber while an
assistant working from inside the passenger
compartment pushes the rubber over the
glass.
9The trim insert must now be refitted to the
rubber, preferably using a suitable windscreen
trim insert tool. If no special tool is available,
the trim can be refitted by prising open the
rubber lips and pressing the trim into its
groove, although this is likely to prove difficult
and time consuming.
10Refit the safety grille to the rear of the cab
on completion.
Removal
1Remove the rear pillar interior trim panel.
2Remove the two screws securing the
window catch to the body (see illustration).
3Prise the two screw covers from the hinges.
Support the glass, and remove the two hinge
screws, then lift out the glass (see
illustration).
4If a new window is to be fitted, transfer the
catch to it.
Refitting
5Refitting is a reversal of removal.
Front door
1Remove the door inner trim panel.
2Where necessary for access, peel back the
waterproof plastic sheet from the door.
3Remove the door mirror.
4Remove the window channel extension
screw from the bottom rear corner of the
door, and withdraw the channel through the
lower door aperture.
5Lower the window until the lower support
channel is visible through the lower door
aperture. Prise the regulator arms from the
sockets in the support channel, then lower the
window to the bottom of the door.
6Carefully prise the weatherstrip from the
rear edge of the window aperture, then tilt the
window forwards and lift it outwards through
the aperture.
7Refitting is a reversal of removal, but
position the rear window channel extension
screw to allow approximately 5.0 mm (0.2 in)
fore and aft movement of the window. Check
to ensure that the window does not tip as it is
raised, and that the regulator effort is
acceptable (check that the motor is not being
27Door window - removal and
refitting
26Opening rear quarter window
- removal and refitting
25Windscreen, rear window and
fixed rear quarter windows -
removal and refitting
24Tailboard (P100 models) -
removal and refitting
Bodywork and fittings 12•11
12
26.3 Opening the rear quarter window
hinge
A Cap
B Screw
C Hinge
D SpacerE Grommet
F Retainer
G Cap
H Screw
26.2 Opening the rear quarter window
catch
A Cap
B Retainer
C GrommetD Spacer
E Catch
F Screw (one of two)
24.2 Rear lamp wiring cover screws (A)
and tailboard hinge screws (B)