battery location 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

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

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

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