battery FORD SIERRA 1993 2.G Bodywork And Fittings Workshop Manual

Models up to 1987
1Working in the engine compartment,
disconnect the cable from the bonnet lock by
pulling the cable sheath end fitting from its
bracket, then releasing the end fitting from the
lock lever.
2Remove the three securing screws and
withdraw the lock from the front panel.
3Refitting is a reversal of removal.
Models from 1987
4Remove the radiator grille panel.
5Disconnect the cable from the bonnet lock
by pulling the cable sheath end fitting from its
bracket, then releasing the end fitting from the
lock lever.
6Detach the bracing strut from the lock by
removing the screw, then remove the two
securing screws and withdraw the lock from
the front panel.
7Refitting is a reversal of removal.
Removal
1Open the boot lid, and place protective
covers (old rags or cardboard) beneath the
corners of the lid, and over the rear wings to
prevent damage to the paintwork.
2Where applicable, disconnect the wiring
from the lock solenoid and “boot lid ajar”
sensor, after disconnecting the battery
negative lead.
3Release the wiring loom grommets, taking
care not to lose them, then tie string to the
wiring loom(s), and pull the loom(s) through
the boot lid. Leave the string(s) in position in
the boot lid to aid refitting of the loom(s).
4Mark the location of the hinges on the
underside of the lid using a soft pencil or
masking type, then loosen the four hinge bolts.5With the help of an assistant, remove the
bolts and lift the boot lid from the vehicle.
Refitting
6Refitting is a reversal of removal, bearing in
mind the following points.
7Adjust the hinges to their original marked
positions before tightening the bolts.
8On completion, check that the boot lid is
central within its aperture and aligned with the
surrounding bodywork. Re-adjust the hinges
to give satisfactory alignment if necessary.
9Check that the lock striker engages fully in
the lock, and if necessary adjust the position
of the lock striker.
Removal
1With the boot lid raised, remove the lock
barrel retaining clip.
2Where applicable, disconnect the operating
lever from the central locking solenoid/motor,
then withdraw the lock barrel.
3Remove the three retaining screws from the
lock assembly, if necessary loosening the
reinforcing plate (see illustration).
4Where applicable, disconnect the battery
negative lead, the earth lead from the bootlid
and the “boot lid ajar” sensor wiring plug.
Unclip the luggage compartment light switch
from the lock assembly, where applicable.
5Withdraw the lock assembly from the boot
lid.
Refitting
6Commence refitting by inserting the lock
assembly and loosely refitting the retaining
screws.
7Insert the lock barrel, where applicable
reconnecting the operating lever to the
solenoid, and refit the retaining clip.
8Tighten the lock assembly retaining screws,
and where applicable reconnect the earth
lead and “boot lid ajar” sensor wiring plug,
and the battery negative lead.
9If the reinforcing plate was loosened during
removal, tighten the retaining screws.Note: On Hatchback models made before
1990 with an integral heated rear
window/radio aerial, note that the radio aerial
lead is routed through different openings to
that of other models in the rear bodywork and
the tailgate. If a new, later-specification
tailgate is to be fitted to an earlier vehicle, a
new opening must be made in the bodywork
for the aerial lead. Ideally, this work should be
carried out by a Ford dealer, who will have the
necessary template available to ensure that
the opening is positioned accurately.
Removal
1Disconnect the battery negative lead.
2Open the tailgate and prise out the trim
panel using a wide-bladed screwdriver.
3Disconnect the wiring from the heated rear
window, rear wash/wipe, interior light, lock
solenoid and “tailgate ajar” sensor, as
applicable. Disconnect the washer fluid hose
where applicable; be prepared for fluid
spillage.
4Release the wiring loom/hose grommet(s)
taking care not to lose it/them, then tie string
to the wiring loom(s)/hose, and pull the
loom(s)/hose through the tailgate. Leave the
string(s) in position in the tailgate to aid
refitting of the loom(s)/hose.
5Have an assistant support the tailgate, then
disconnect the support struts by prising out
the retaining clips. Do not remove the clips
completely, just raise them by a maximum of
4.0 mm (0.16 in) and then pull the struts off
their mountings (see illustration).
6Prise out the hinge fixing covers from the
headlining, unscrew the hinge nuts and
washers, and with the aid of the assistant,
withdraw the tailgate from the vehicle (see
illustration).
Refitting
7Refitting is a reversal of removal, but do not
fully tighten the hinge nuts until the tailgate is
positioned centrally in its aperture. If
necessary, adjust the position of the lock
striker so that it engages fully in the lock.
11Tailgate (Hatchback and
Estate models) - removal and
refitting
10Boot lid lock (Saloon models)
- removal and refitting
9Boot lid (Saloon models) -
removal and refitting
8Bonnet lock - removal and
refitting
Bodywork and fittings 12•5
12
11.6 Tailgate hinge assembly - Hatchback
and Estate models
11.5 Prising out a tailgate strut retaining
clip10.3 Boot lid lock - Saloon models
A Lock retaining
screws
B Earth leadC Reinforcing plate
screws

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

3Remove the securing screw from the
interior door handle surround, lift the handle,
and withdraw the surround and grip (see
illustrations).
4Remove the two securing screws and
withdraw the door pocket (see illustration).
5If working on the driver’s side of models
fitted with electric mirrors, first disconnect the
battery negative lead, then prise the mirror
switch assembly from the door trim panel and
disconnect the wiring plug.
6The trim panel can now be prised from the
door. To prevent damage to the panel, only
prise under the retaining clips (see
illustration). It is advisable to use a forked
tool similar to that shown (see illustration)to
prise around the retaining clips, but failing
this, use a wide-bladed screwdriver. If a clip
will not release, sever it with a chisel or sharp
knife, taking care not to damage the trim
panel, and renew the clip on reassembly.7Refitting is a reversal of removal, but ensure
that all the retaining clips are correctly aligned
before pressing them into the door, and make
sure that the upper lip of the trim panel
locates under the mirror trim panel.
Models from 1987
8Proceed as described in paragraph 1.
9Remove the securing screw from the
interior door handle surround, lift the handle,
and withdraw the surround (see illustration).
10Prise out the armrest trim panel, remove
the three securing screws, and withdraw the
armrest (see illustrations).
11On models with manually-operated
mirrors, unscrew the bezel from the adjuster
knob, then prise off the mirror trim panel.
12When working on the driver’s side of
models with electric mirrors, prise the
securing screw cover from the mirror control
panel, then remove the screw and withdraw
the control panel. Disconnect the wiring plug
after disconnecting the battery negative lead
(see illustrations).
13When working on the passenger side of
models with electric mirrors, the mirror trim
panel can simply be prised off.14Remove the now exposed door trim panel
securing screw.
15Remove the two trim panel securing
screws from each side of the door, and the
four securing screws from the door pocket,
12•8Bodywork and fittings
17.4 Withdraw the door pocket
17.6b Trim panel retaining clip removal
tool
17.12a Prise the securing screw cover
from the mirror control panel . . .17.10b . . . and remove the armrest
securing screws17.10a Prise out the armrest trim panel . . .
17.9 Remove the interior door handle
surround securing screws17.6a Door inner trim panel retaining clip
locations (arrowed)
17.3a Remove the securing screw . . .17.3b . . . and withdraw the handle
surround and door grip17.2 Withdraw the trim panel from behind
the door grip

then lift the trim panel to disengage it from the
top retaining clips, and withdraw the panel
from the door (see illustrations).
16Refitting is a reversal of removal.
Rear door
Models up to 1987
17Proceed as shown in paragraphs 1 to 3.
18On models fitted with electric windows,
disconnect the battery negative lead, then
prise the switch from the armrest and
disconnect the wiring plug.
19Proceed as described in paragraph 6.
20Refitting is a reversal of removal, but
ensure that all the retaining clips are correctly
aligned before pressing them into the door.
Models from 1987
21Proceed as described in paragraph 1.
22Remove the securing screw from the
interior door handle, then pull out the ashtray,
and remove the two now exposed screws.23Lift the interior door handle, and withdraw
the handle/ashtray surround.
24Prise out the armrest trim panel, remove
the three securing screws and withdraw the
armrest.
25Remove the two trim panel securing
screws from each side of the door, then lift the
trim panel to disengage it from the top
retaining clips, and withdraw the panel from
the door.
26Refitting is a reversal of removal.
Removal
1Remove the door inner trim panel.
2Where necessary for improved access, peel
back the waterproof plastic sheet from the
door.
3Remove the two securing screws in the
case of models up to 1987, or the single
securing screw on models from 1987, and
slide the handle assembly from the door
aperture, if necessary unclipping the remote
control rods from their guides (see
illustrations).
4Disconnect the remote control rods from
the handle assembly, and withdraw the
handle assembly.
Refitting
5Refitting is a reversal of removal, but check
that the remote control rods are correctly
located in their guides (see illustration).
Removal
1Remove the door inner trim panel.
2Where necessary for improved access, peel
back the waterproof plastic sheet from the door.
3If working on a front door, remove the
window channel extension screw from the
bottom rear corner of the door, and withdraw
the channel through the lower door aperture
(see illustration).
4Disconnect the handle operating rod at the
lock.
5Remove the two handle securing screws
and withdraw the handle and operating rod
from the door.
Refitting
6Refitting is a reversal of removal, but if
working on a front door, ensure that the
window channel extension is correctly
located.
Removal
1Remove the door inner trim panel.
2Where necessary for access, peel back the
waterproof plastic sheet from the door.
20Door lock barrel - removal
and refitting
19Door exterior handle -
removal and refitting
18Door interior handle - removal
and refitting
Bodywork and fittings 12•9
12
18.5 Remote control rods correctly located
in their guides
19.3 Front door window channel extension
A Remove the retaining screw (arrowed)
B Withdraw the channel through the lower
door aperture18.3b . . . and slide the handle assembly
from the door aperture
18.3a Remove the securing screws . . .
17.15b Trim panel securing screw at top
edge of door pocket17.15a Trim panel securing screw at
bottom rear edge of door17.12b . . . and withdraw the mirror control
panel

3Remove the window channel extension
screw from the bottom rear corner of the
door, and withdraw the channel through the
lower door aperture.
4Working inside the door aperture, pull out
the lock barrel retaining clip using pliers, then
unhook the lock operating rod from the barrel,
and withdraw the barrel from outside the door
(see illustration).
Refitting
5Refitting is a reversal of removal.
Models up to 1990
1Remove the door inner trim panel.
2Where necessary for improved access, peel
back the waterproof plastic sheet from the
door.
3Withdraw the window channel extension
through the lower rear door aperture after
removing the single securing screw if working
on a front door or the two securing screws if
working on a rear door.
4Remove the three securing screws from the
rear edge of the door, then reach inside the
door and turn the lock to disconnect it from
the control rods.
5Where applicable, disconnect the “door
ajar” sensor wiring plug and the central
locking component wiring plug(s). Central
locking component removal and refitting is
covered in Chapter 13.
6Withdraw the lock from inside the door.
7Refitting is a reversal of removal, but ensure
that the window channel extension is correctly
located.
Models from 1990
8From 1990, cable-operated door locks have
been fitted to all Sierra models. To remove the
later type of lock, proceed as follows. Do not
bend or stretch the cable during removal and
refitting, as the operation of the lock will be
impaired.
9Remove the door inner trim panel.
10Where necessary for improved access,
peel back the waterproof plastic sheet from
the door.11Remove the securing screw, and
withdraw the window channel extension
through the door’s lower aperture.
12Disconnect the door outer handle and the
lock barrel (front doors) operating rods at the
lock assembly.
13Disconnect the battery negative lead, and
disconnect the door lock motor and the alarm
system wiring plugs (where applicable).
14Remove the screw securing the door
interior handle to the door panel.
15Remove the three lock securing screws
from the rear edge of the door, then withdraw
the lock assembly complete with the
operating cable and the door interior handle.
16To disconnect the cable from the lock,
proceed as follows.
17Carefully prise the cover plate from the
lock, using a screwdriver(see illustration).
18Using a suitable pair of pliers, carefully
remove the outer cable from the groove in the
lock assembly casing.
19Extend the inner cable until the flats on
the plastic end piece align with the guide, then
withdraw the cable (see illustration).
20Commence reassembly and refitting as
follows.
21Align the flats on the inner cable end piece
with the cable guide, and refit the inner cable.
22Using a suitable pair of pliers, carefully
refit the outer cable to the groove in the lock
assembly casing.
23Refit the lock cover plate.
24Insert the lock, cable and interior handle
into the door, and refit the three lock securing
screws. 25Push the interior handle assembly
towards the lock to adjust the cable, and
when adjustment is correct, refit and tighten
the interior handle securing screw.
26Further refitting is a reversal of removal,
ensuring that the window channel extension is
correctly located.
Removal
1Remove the door inner trim panel.
2Unscrew and remove the bolt securing the
check arm to the body pillar.
3Unscrew and remove the two bolts
securing the check arm to the door, and
withdraw the check arm from inside the door.
Peel back the waterproof plastic sheet where
necessary for improved access.
Refitting
4Refitting is a reversal of removal.
Note: A suitable lifting crane and tackle will be
required for this operation.
Removal
1Disconnect the battery negative lead.
2Remove the fuel filler cap, then drain the
fuel tank.
3Remove the two securing screws and
detach the fuel filler pipe from the cargo area.
4Disconnect the number plate lamp and the
rear lamp wiring plugs, and release the wiring
from the cargo area.
5Disconnect the earth lead from the right-
hand front cargo area mounting bracket
underneath the vehicle.
6Working underneath the vehicle, remove
the three Torx bolts on each side securing the
cargo area to the chassis (see illustration).
7Make up a cradle to lift the cargo area from
the chassis, using suitable ropes or chains
attached to the tonneau tie-down points.
23Cargo area (P100 models) -
removal and refitting
22Door check arm - removal
and refitting
21Door lock - removal and
refitting
12•10Bodywork and fittings
21.17 Prising the cover plate from a cable-
operated door lock
23.6 Cargo area-to-chassis Torx bolt
locations (arrowed) - one side shown for
clarity
21.19 Disconnecting the operating cable
from a cable-operated door lock
A Removing outer cable
B Disconnecting inner cable
20.4 Door lock barrel location. Retaining
clip arrowed

overloaded on models with electric windows).
Adjust the channel extension screw if
necessary.
Rear door
8Proceed as shown in paragraphs 1 and 2.
9On Saloon and Hatchback models, prise
the interior quarter trim panel from the rear of
the door, then remove the now exposed
screw and withdraw the exterior trim panel.
10Remove the three window channel
extension screws from the rear of the door,
and withdraw the channel through the lower
door aperture.
11Lower 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.
12Carefully prise the weatherstrip from the
front edge of the window aperture, then tilt the
window rearwards and lift it outwards through
the aperture.
13Refitting is as described in paragraph 7.
Removal
1Remove the door inner trim panel.
2Where necessary for improved access, peel
back the waterproof plastic sheet from the
door.
3Lower 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 (see
illustration).
4Drill out the four rivets securing the
regulator assembly to the inner door skin, and
if working on a front door, drill out the two
rivets securing the regulator guide (see
illustration).
5On models with electric windows,
disconnect the motor wiring plug after
disconnecting the battery negative lead.
Removal and refitting of the motor is
described in Chapter 13.
6Withdraw the regulator assembly through
the lower door aperture.
Refitting
7Refitting is a reversal of removal, but fit new
rivets, using a hand riveter.
Manually-operated mirror
1On remote-control type mirrors, unscrew
the bezel from the adjuster knob (see
illustration).
2Prise the mirror trim panel from the door
(see illustration).
3Remove the three mirror securing screws,
and withdraw the mirror by tilting its rear edge
outwards and disengaging its front edge from
under the window surround. Where
applicable, withdraw the mirror control cable
through the door.
4To remove the mirror glass, proceed as
follows according to model. 5On “high specification” models with fixed
(ie not remote control) mirrors, lever the glass
assembly outwards to disengage it from the
balljoint on the mirror glass mounting.
6On “low specification” models with fixed (ie
not remote control) mirrors, unclip the cover,
then remove the securing screw and withdraw
the glass assembly (see illustration).
29Door mirror - removal and
refitting
28Door window regulator -
removal and refitting
12•12Bodywork and fittings
29.2 . . . and prise the mirror trim panel
from the door to reveal the 3 mirror
securing screws (2 arrowed)29.6 Fixed door mirror assembly
29.1 Unscrew the bezel from the adjuster
knob . . .
28.4 Door window regulator
fixings
A Front door
B Rear door
C Regulator assembly securing
rivets
D Regulator guide rivets
28.3 Front door window lower support
channel and regulator arms

7On models with remote control mirrors,
insert a thin screwdriver through the hole in
the bottom of the mirror assembly, and whilst
supporting the glass, release the locking ring
(see illustration).
8Refitting is a reversal of removal, but ensure
that the front edge of the mirror is correctly
located under the window surround.
Electric mirror
9Disconnect the battery negative lead.
10If working on the driver’s side of models
up to 1987, prise the mirror switch assembly
from the door trim panel and disconnect the
wiring plug.
11If working on the driver’s side of models
from 1987, prise the securing screw cover
from the mirror control panel, then remove the
screw and withdraw the control panel.
Disconnect the wiring plug.
12On models up to 1987, and when working
on the passenger side of models from 1987,
prise out the mirror trim panel.
13Remove the three mirror securing screws,
and withdraw the mirror by tilting its rear edge
outwards and disengaging its front edge from
under the window surround. Withdraw the
wiring through the door.
14To remove the mirror glass proceed as
described in paragraph 7.
15Refitting is a reversal of removal, but
ensure that the front edge of the mirror is
correctly located under the window surround.
Front bumper
Models up to 1987
1Remove the radiator grille panel.
2Disconnect the battery negative lead, then
disconnect the wiring plugs from the
indicators, and where applicable the
foglamps.
3Working under the front wing, release the
single bumper fastener from each side of the
vehicle by turning the plastic clip through 90º
(quarter of a turn).
4On Ghia models, unclip the support strap
between each front wing and the bumper.
5Unscrew the single bolt securing each
bumper fixing bracket to the body front panel,
then pull the bumper forwards away from the
body, disengaging the retaining pegs from the
clips in each wing.
6Refitting is a reversal of removal; ensure that
all fixings are correctly located and secure.
Models from 1987
7If foglamps are fitted, disconnect the
battery negative lead, then disconnect the
wiring plugs from the foglamps.
8Working under the front wings, unscrew the
single bolt from each side of the bumper.
9Release the plastic retaining screws and
pull the wheel arch liners away from the ends
of the bumper.
10Pull the bumper forwards away from the
body, releasing the front mounting spigots
from their sockets.11Refitting is a reversal of removal, but
ensure that the reinforcing plate and O-ring are
located on the right-hand mounting spigot.
12The bumper height can be adjusted by
turning the adjusters located on the front
mounting spigots using a suitable Torx
screwdriver with a length of at least 150.0 mm
(6.0 in) (see illustrations).
Rear bumper - Saloon, Hatchback
and Estate models
13Disconnect the battery negative lead, then
prise the number plate lamps from the bumper,
and disconnect the wiring plugs. Withdraw the
wiring through the bumper assembly.
14Working inside the luggage compartment,
unscrew the two bumper securing bolts.
15Working under the rear wings, release the
single bumper fastener from each side of the
vehicle by turning the plastic clip through 90º
(quarter of a turn) (see illustration).
16Pull the bumper rearwards away from the
body, disengaging the retaining pegs from the
clips in each wing.
17Refitting is a reversal of removal, but
ensure that all fixings are correctly located
and secure.
18On some later models, the bumper height
can be adjusted by means of the adjusters
located on the mounting brackets - see
paragraph 12 (see illustration).
Rear bump stop - P100 models
19Working underneath the vehicle, unscrew
the two securing nuts and washers from the
bump stop studs, and withdraw the bump
stop (see illustration).
20Refitting is a reversal of removal.
30Bumper - removal and refitting
Bodywork and fittings 12•13
12
30.15 Rear bumper plastic fastener30.19 Rear bump stop securing nut
locations (arrowed) - P100 models30.18 Adjusting the height of a rear
bumper
30.12b Front bumper height adjusting
screw - models from 198730.12a Adjusting the height of a front
bumper - models from 198729.7 Manual remote control and electric
door mirror glass removal
A Locking operation
B Unlocking
operationC Locating pegs
D Locking slots
E Locking ring

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

20On models with an adjustable steering
column, fully extend and lower the steering
column before attempting to remove any of
the panels on the driver’s side.
21The steering column shrouds are secured
by six screws - five through the lower shroud,
and one through the upper shroud.
22If necessary, remove the centre console.
23The driver’s side lower facia panel is
secured by five screws.
24The passenger’s side lower facia panel is
secured by eight screws.
25On models with an alarm, the alarm warning
light must be disconnected and removed before
removing the upper facia panel.
Models up to 1990
Full length console
1Where applicable, prise the electric window
switches from the front upper console panel
and disconnect the wiring.
2Remove the three securing screws from the
front upper console panel, then withdraw the
panel over the gear selector lever, at the same
time releasing the rubber gaiter where
applicable.
3On “high specification” models, where
applicable prise the electric window switches
from the rear upper console panel and
disconnect the wiring. Remove the five
securing screws and withdraw the rear upper
console panel (see illustrations).
4On “low specification” models, remove the
two securing screws and release the single
rear clip, then withdraw the rear upper
console panel.
5Where applicable, remove the two screws
securing the lower console centre bracket to
the transmission tunnel, and remove the
bracket.
6Remove the six screws securing the lower
console panel, and withdraw the panel (see
illustrations).
7Refitting is a reversal of removal.
Short console
8Prise out the blanking plug, and remove the
rear console securing screw.9On automatic transmission models, lift out
the console tray mat and remove the front two
console securing screws.
10On manual gearbox models, prise out the
blanking plugs and remove the front two
console securing screws.
11Withdraw the console over the gear
selector lever, at the same time releasing the
rubber gaiter where applicable.
Models from 1990
12Remove the switch assembly (after
disconnecting the battery negative lead), or
remove the blanking plate from the gear lever
surround, as applicable.
13Remove the securing screw from the gearlever surround, and withdraw the gear lever
surround from the console by releasing the
two securing clips.
14Remove the seven console securing
screws (see illustration).
15Chock the rear wheels, then release the
handbrake lever.
16Jack up the vehicle and support it on axle
stands (see “Jacking and Vehicle Support”).
Disconnect the handbrake equaliser from the
linkage on the underbody.
17Raise the handbrake lever fully, and lift the
console over the handbrake lever.
18Refitting is a reversal of removal, but on
completion, check the handbrake/cable
adjustment.
44Centre console - removal and
refitting
12•18Bodywork and fittings
44.3b Rear upper console panel rear
retaining screws (arrowed)
44.6b . . . centre securing screw . . .
44.14 Centre console components - models from 1990
A Screw
B Screw coverC Gear lever surround
D Blanking plateE Centre console
44.6c . . . and rear securing screw
44.6a Removing a lower console panel
front securing screw . . .44.3a Removing a rear upper console
panel front retaining screw - “high
specification” model

Removal
1Disconnect the battery negative lead.
2Open the sunroof.
3On models with a manually-operated
sunroof, remove the sunroof handle securing
screw, then withdraw the handle and trim plate.
4On models with an electric sunroof, remove
the operating switch.
5Remove the courtesy lamp, if necessary,
then remove the two screws from the front of
the console (see illustration).
6Remove the two screws securing the rear of
the console to the sunroof flange, and
withdraw the console.
Refitting
7Refitting is a reversal of removal.
Saloon, Hatchback and Estate
models
1On Saloons, remove the rear seat back.
2Loosen the upper screws of all the pillar
trim panels touching the headlining.
3Prise off the covers and remove the screws
from the passenger grab handles. Withdraw
the grab handles. Similarly, prise off the
blanking covers and remove the headlining
securing screws from the driver’s position.
4Disconnect the battery negative lead, then
prise the courtesy light(s) from the headlining
or overhead console. Disconnect the wiring
and remove the courtesy light(s).
5Where applicable, remove the two securing
screws and withdraw the overhead console.
6Remove the sunroof (where fitted). The
headlining is folded around the sunroof
aperture flange and is held in place with
adhesive tape and a moulding which must be
removed.
7Support the headlining, then remove the
screws and withdraw the sun visors and clips.
Where applicable, disconnect the wiring from
the vanity mirror lamp.
8On Estate models, remove the two plastic
fasteners from the headlining between the
rear door and tailgate pillars.
9Remove the two plastic fasteners from the
rear of the headlining, and withdraw the
headlining through the luggage compartment.
10Refitting is a reversal of removal.
P100 models
11Loosen the front pillar trim panel upper
securing screws.
12Prise off the covers and remove the
screws from the passenger grab handle.
Withdraw the grab handle.13Prise off the blanking cover and remove
the headlining securing screw from the
driver’s side.
14Disconnect the battery negative lead, then
prise the courtesy light from the headlining.
Disconnect the wiring and remove the
courtesy light.
15Support the headlining, then remove the
screws and withdraw the sun visors and clips.
16Remove the blanking covers, and the
three securing screws from the rear of the
headlining, then withdraw the headlining
through one of the door apertures.
17Refitting is a reversal of removal.
Front seat
1Slide the seat fully forwards, and on seats
with height adjustment unhook the tension
spring from the rear crosstube. Where
applicable, disconnect the wiring from the
seat heating pad(s).
2Unscrew and remove the two bolts from the
inner rear seat mounting bracket and the
single bolt from the outer rear seat mounting
bracket (see illustration).
3Slide the seat fully rearwards, then unscrew
and remove the single bolt from each front
seat mounting bracket. Withdraw the seat
from the vehicle.
4Refitting is a reversal of removal, but when
fitting the front and rear mounting bolts,tighten the inner bolts first in each case.
Where applicable locate the height
adjustment tension spring between the weld
pips on the crosstube.
Rear seat cushion
5Remove the single screw from each side,
securing the cushion to the heel kick panel.
6Pull the cushion forwards and remove it
from the vehicle.
7Refitting is a reversal of removal.
Rear seat backrest
Fixed rear seats
8Remove the seat cushion as described in
paragraphs 5 to 7.
9Remove the three now exposed Torx
screws from the base of the backrest.
10Working inside the luggage compartment,
remove the three nuts securing the backrest
to the body.
11Pull the backrest forwards into the
passenger compartment and remove it from
the vehicle. Where applicable, feed the rear
seat belt straps and buckles around the edges
of the backrest.
12Refitting is a reversal of removal.
Folding rear seats
13Release the catch and fold the seat
backrest forwards.
14Remove the two Torx screws from each
backrest hinge.
15Pull the backrest forwards into the
passenger compartment and remove it from
the vehicle. Where applicable, feed the rear
seat belt straps and buckles around the edges
of the backrest.
16Refitting is a reversal of removal, but
where necessary adjust the position of the
seat catch striker to achieve correct operation
of the catch.
Rear seat side cushion
Saloon models
17Working in the luggage compartment,
remove the nut from the side cushion stud.
18Working in the passenger compartment,
remove the rear seat cushion as described in
paragraphs 5 and 6.
19Expose the seat backrest hinge bolt by
removing the cover, then remove the bolt.
20Pull the top of the side cushion forwards
to disengage the stud from the body.
21Straighten the metal retaining tangs at the
base of the side cushion, then withdraw the
cushion.
22Refitting is a reversal of removal.
Hatchback and Estate models
23Fold down the rear seat backrest.
24Carefully bend back the side cushion
lower retaining tangs, then unhook the
cushion from the upper fixing on the rear
parcel shelf support (see illustration).
25Refitting is a reversal of removal.
47Seats - removal and refitting
46Headlining - removal and
refitting
45Overhead console - removal
and refitting
Bodywork and fittings 12•19
12
47.2 Front seat inner rear mounting
45.5 Overhead console securing screws (A)