tailgate 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

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

New bumpers are supplied without the trim
moulding fitted. Special primer and adhesive
tape are specified by the manufacturer to
retain the moulding: it is suggested that a
Ford dealer is consulted for further details.
A damaged moulding can be removed by
prising it from the bumper using a screwdriver.
Models up to 1987
1With the bonnet raised, remove the four
grille panel securing screws from the top of
the front panel.
2Lift the grille panel from its lower mounting
bushes, and withdraw it from the vehicle.
3Refitting is a reversal of removal, but ensure
that the lower mounting lugs are correctly
located in their bushes.
Models from 1987
4With the bonnet raised, remove the two
grille panel securing screws from the front
face of the panel.
5Release the upper and lower grille retaining
clips, and withdraw the grille panel from the
vehicle (see illustrations).
6Refitting is a reversal of removal, but align
the grille panel carefully before tightening the
securing screws.
Models from 1990
7With the bonnet raised, remove the two
securing screws from the top of the grille
panel.
8Slide the panel towards the driver’s side of
the vehicle, then pull the panel forwards to
release the retaining clips (see illustration).
9Refitting is a reversal of removal.
Removal
1Open the bonnet and disconnect the
windscreen washer hose at the T-piece
connector.
2Remove both windscreen wiper arm
assemblies.
3Remove the single securing screw from
each end of the cowl panel.
4On models up to 1987, prise out the screw
covers and remove the eight plastic screws
securing the cowl panel to the body.
Withdraw the panel.
5On models from 1987, prise out the screw
covers and remove the plastic securing
screws. Pull the front edge of the cowl panel
upwards to disengage the front fixing clips,
then move the panel to the left and then to the
right to disengage the hooks on the panel
underside. Withdraw the panel.
Refitting
6Refitting is a reversal of removal.1Remove the interior rear pillar trim panel.
2Unscrew the three now exposed securing
nuts and withdraw the exterior trim panel (see
illustration).
3Refitting is a reversal of removal, but do not
overtighten the securing nuts, as this may
result in damage to the rubber seals.
1Remove the cab interior side trim panel.
2Working inside the cab, remove the two
rubber grommets from the rear pillar, then
unscrew the two now exposed nuts, and
withdraw the air vent panel.
3Refitting is a reversal of removal.
1Where fitted, the wheel arch liners may be
retained by self-tapping screws, plastic clips,
or a combination of both.
2To remove a liner, simply unscrew the
retaining screws, or where plastic clips are
fitted, release them by turning with a
screwdriver (see illustration).
3Refitting is a reversal of removal.
Removal
1Open the filler flap and the tailgate or boot
lid, as applicable.
2Remove the fuel filler cap and then remove
the screw securing the filler housing to the
fuel tank neck (see illustration).
3Working inside the luggage compartment,
depress the filler housing retaining tangs, and
push the assembly out through the body
panel. Recover the gasket.
37Fuel filler flap - removal and
refitting
36Wheel arch liners - renewal
35Cab air vent panel (P100
models) - renewal
34Exterior rear pillar trim panel
(Saloon models) - renewal
33Windscreen cowl panel -
removal and refitting
32Radiator grille panel -
removal and refitting
31Bumper trim moulding -
renewal
12•14Bodywork and fittings
32.8 Removing the later type front grille
panel36.2 Releasing a wheel arch liner plastic
clip34.2 Exterior rear pillar trim panel securing
nut locations (arrowed) - Saloon models
A Heated rear window wiring plug
32.5b Radiator grille panel lower retaining
clip - models from 198732.5a Radiator grille panel upper retaining
clip - models from 1987

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)