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

Torque wrench settingsNm lbf ft
Front seat belt stalk-to-seat bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 to 28 18 to 22
Seat belt anchor bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 to 41 22 to 30
Seat belt inertia reel securing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 to 41 22 to 30
Seat mounting bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 to 32 18 to 24
Cab safety grille securing bolts (P100 models) . . . . . . . . . . . . . . . . . . . 20 to 27 15 to 20
Rear bump stop securing nuts (P100 models) . . . . . . . . . . . . . . . . . . . . 8 to 11 6 to 8
Cargo area-to-chassis bolts (P100 models) . . . . . . . . . . . . . . . . . . . . . . 40 to 50 29 to 37
Tailboard hinge securing screws (P100 models) . . . . . . . . . . . . . . . . . . 20 to 25 15 to 18
Chapter 12
Bodywork and fittings
Bonnet - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Bonnet lock - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Bonnet lock release cable - removal and refitting . . . . . . . . . . . . . . . .7
Boot lid (Saloon models) - removal and refitting . . . . . . . . . . . . . . . . .9
Boot lid lock (Saloon models) - removal and refitting . . . . . . . . . . . . .10
Bumper - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Bumper trim moulding - renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Cab air vent panel (P100 models) - removal and refitting . . . . . . . . .35
Cab interior trim panels (P100 models) - removal and refitting . . . . .42
Cargo area (P100 models) - removal and refitting . . . . . . . . . . . . . . .23
Centre console - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .44
Door - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Door check arm - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .22
Door exterior handle - removal and refitting . . . . . . . . . . . . . . . . . . . .19
Door inner trim panel - removal and refitting . . . . . . . . . . . . . . . . . . .17
Door interior handle - removal and refitting . . . . . . . . . . . . . . . . . . . .18
Door lock - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Door lock barrel - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .20
Door mirror - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Door window - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .27
Door window regulator - removal and refitting . . . . . . . . . . . . . . . . . .28
Exterior rear pillar trim panel (Saloon models) - removal and refitting .34
Facia panels - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . .43
Front seat air cushion assembly - removal and refitting . . . . . . . . . .49
Fuel filler flap - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .37
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1Headlining - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Inner gutter weatherstrip (Saloon, Hatchback and Estate models)-
removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Interior pillar trim panels - removal and refitting . . . . . . . . . . . . . . . . .41
Interior trim panels - general information . . . . . . . . . . . . . . . . . . . . . .40
Maintenance - bodywork, underside and fittings . . . . . . . . . . . . . . . . .2
Maintenance - upholstery and carpets . . . . . . . . . . . . . . . . . . . . . . . . .3
Major body damage - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Minor body damage - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Overhead console - removal and refitting . . . . . . . . . . . . . . . . . . . . .45
Opening rear quarter window - removal and refitting . . . . . . . . . . . . .26
Radiator grille panel - removal and refitting . . . . . . . . . . . . . . . . . . . .32
Rear seat catch - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .48
Seats - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Seat belts - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Sunroof - removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . .39
Tailboard (P100 models) - removal and refitting . . . . . . . . . . . . . . . .24
Tailgate/boot lid/fuel filler flap release cable - removal and refitting .14
Tailgate/boot lid spoiler - removal and refitting . . . . . . . . . . . . . . . . .15
Tailgate (Hatchback and Estate models) - removal and refitting . . . .11
Tailgate lock (Hatchback and Estate models) - removal and refitting . .12
Tailgate strut (Hatchback and Estate models) - removal and refitting .13
Wheel arch liners - removal and refitting . . . . . . . . . . . . . . . . . . . . . .36
Windscreen cowl panel - removal and refitting . . . . . . . . . . . . . . . . .33
Windscreen, rear window and fixed rear quarter windows - removal
and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
12•1
Specifications Contents
12
Easy,suitable for
novice with little
experienceFairly easy,suitable
for beginner with
some experienceFairly difficult,
suitable for competent
DIY mechanic
Difficult,suitable for
experienced DIY
mechanicVery difficult,
suitable for expert
DIY or professional
Degrees of difficulty

The model range includes 4-door Saloon, 3
and 5-door Hatchback, 5-door Estate, and 2-
door Pick-up body styles.
Each body is of all-steel welded energy-
absorbing monocoque construction, with a
separate load-bearing rear chassis frame on
P100 Pick-up models. Corrosion protection is
applied to all new vehicles, and includes zinc
phosphate dipping of the body panels, and
wax injection of box sections and doors.
All models have flush direct-glazed fixed glass
panels, and integrated polycarbonate bumpers.
All body panels are welded, including the
front wings, so it is recommended that major
body damage repairs are entrusted to a dealer.
A wide range of interior equipment and trim
options are available depending on model.
The procedures given in this Chapter apply to
original equipment fitments, and do not cover
after-market products.
The general condition of a vehicle’s
bodywork is the one thing that significantly
affects its value. Maintenance is easy but
needs to be regular. Neglect, particularly after
minor damage, can lead quickly to further
deterioration and costly repair bills. It is
important also to keep watch on those parts of
the vehicle not immediately visible, for instance
the underside, inside all the wheel arches and
the lower part of the engine compartment.
The basic maintenance routine for the
bodywork is washing - preferably with a lot of
water, from a hose. This will remove all the
loose solids which may have stuck to the
vehicle. It is important to flush these off in
such a way as to prevent grit from scratching
the finish. The wheel arches and underframe
need washing in the same way to remove any
accumulated mud which will retain moisture
and tend to encourage rust. Oddly enough,
the best time to clean the underframe and
wheel arches is in wet weather when the mud
is thoroughly wet and soft. In very wet
weather the underframe is usually cleaned of
large accumulations automatically and this is
a good time for inspection.
Periodically, except on vehicles with a wax-
based underbody protective coating, it is a
good idea to have the whole of the underframe
of the vehicle steam cleaned, engine
compartment included, so that a thorough
inspection can be carried out to see what
minor repairs and renovations are necessary.
Steam cleaning is available at many garages
and is necessary for removal of the
accumulation of oily grime which sometimes is
allowed to become thick in certain areas. If
steam cleaning facilities are not available,
there are one or two excellent grease solvents
available, which can be brush applied. The dirt
can then be simply hosed off. Note that thesemethods should not be used on vehicles with
wax-based underbody protective coating or
the coating will be removed. Such vehicles
should be inspected annually, preferably just
prior to winter, when the underbody should be
washed down and any damage to the wax
coating repaired using a proprietry brand
undershield. Ideally, a completely fresh coat
should be applied. It would also be worth
considering the use of such wax-based
protection for injection into door panels, sills,
box sections, etc, as an additional safeguard
against rust damage where such protection is
not provided by the vehicle manufacturer.
After washing paintwork, wipe off with a
chamois leather to give an unspotted clear
finish. A coat of clear protective wax polish, will
give added protection against chemical
pollutants in the air. If the paintwork sheen has
dulled or oxidised, use a cleaner/polisher
combination to restore the brilliance of the
shine. This requires a little effort, but such
dulling is usually caused because regular
washing has been neglected. Care needs to be
taken with metallic paintwork, as special non-
abrasive cleaner/polisher is required to avoid
damage to the finish. Always check that the
door and ventilator opening drain holes and
pipes are completely clear so that water can be
drained out. Bright work should be treated in
the same way as paint work. Windscreens and
windows can be kept clear of the smeary film
which often appears by the use of a proprietary
glass cleaner. Never use any form of wax or
other body or chromium polish on glass.
At the specified intervals, check the
operation of the door locks and check straps
and lubricate the hinges with a little oil. Also
lubricate the hinges of the bonnet and boot lid
or tailgate, as applicable, and the bonnet
release mechanism.
Mats and carpets should be brushed or
vacuum cleaned regularly to keep them free of
grit. If they are badly stained remove them
from the vehicle for scrubbing or sponging and
make quite sure they are dry before refitting.
Seats and interior trim panels can be kept
clean by wiping with a damp cloth and a
proprietry wax polish. If they do become
stained (which can be more apparent on light
coloured upholstery) use a little liquid
detergent and a soft nail brush to scour the
grime out of the grain of the material. Do not
forget to keep the headlining clean in the same
way as the upholstery. When using liquid
cleaners inside the vehicle do not over-wet the
surfaces being cleaned. Excessive damp
could get into the seams and padded interior
causing stains, offensive odours or even rot. If
the inside of the vehicle gets wet accidentally it
is worthwhile taking some trouble to dry it out
properly, particularly where carpets are
involved. Do not leave oil or electric heaters
inside the vehicle for this purpose.Repair of minor scratches in
bodywork
If the scratch is very superficial, and does not
penetrate to the metal of the bodywork, repair is
very simple. Lightly rub the area of the scratch
with a paintwork renovator, or a very fine cutting
paste, to remove loose paint from the scratch
and to clear the surrounding bodywork of wax
polish. Rinse the area with clean water.
Apply touch-up paint to the scratch using a
fine paint brush; continue to apply fine layers
of paint until the surface of the paint in the
scratch is level with the surrounding
paintwork. Allow the new paint at least two
weeks to harden: then blend it into the
surrounding paintwork by rubbing the scratch
area with a paintwork renovator or a very fine
cutting paste. Finally, apply a good wax polish.
Where the scratch has penetrated right
through to the metal of the bodywork, causing
the metal to rust, a different repair technique is
required. Remove any loose rust from the
bottom of the scratch with a penknife, then
apply rust inhibiting paint, to prevent the
formation of rust in the future. Using a rubber or
nylon applicator fill the scratch with bodystopper
paste. If required, this paste can be mixed with
cellulose thinners to provide a very thin paste
which is ideal for filling narrow scratches. Before
the stopper-paste in the scratch hardens, wrap
a piece of smooth cotton rag around the top of a
finger. Dip the finger in cellulose thinners; and
then quickly sweep it across the surface of the
stopper-paste in the scratch; this will ensure that
the surface of the stopper-paste is slightly
hollowed. The scratch can now be painted over
as described earlier in this Section.
Repair of dents in bodywork
When deep denting of the vehicle’s
bodywork has taken place, the first task is to
pull the dent out, until the affected bodywork
almost attains its original shape. There is little
point in trying to restore the original shape
completely, as the metal in the damaged area
will have stretched on impact and cannot be
reshaped fully to its original contour. It is better
to bring the level of the dent up to a point which
is about 1/8 in (3 mm) below the level of the
surrounding bodywork. In cases where the dent
is very shallow anyway, it is not worth trying to
pull it out at all. If the underside of the dent is
accessible, it can be hammered out gently from
behind, using a mallet with a wooden or plastic
head. Whilst doing this, hold a suitable block of
wood firmly against the outside of the panel to
absorb the impact from the hammer blows and
thus prevent a large area of the bodywork from
being “belled-out”.
Should the dent be in a section of the
bodywork which has a double skin or some
other factor making it inaccessible from
behind, a different technique is called for. Drill
several small holes through the metal inside
the area particularly in the deeper section.
4Minor body damage - repair
3Maintenance - upholstery and
carpets
2Maintenance - bodywork,
underside and fittings
1General information
12•2Bodywork and fittings

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

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)