wiring FORD SIERRA 1993 2.G Bodywork And Fittings Workshop Manual
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Page 4 of 22
compatible with the type of plastic used. At one
time the use of a universal paint was not
possible owing to the complex range of plastics
encountered in body component applications.
Standard paints, generally speaking, will not
bond to plastic or rubber satisfactorily.
However, it is now possible to obtain a plastic
body parts finishing kit which consists of a pre-
primer treatment, a primer and coloured top
coat. Full instructions are normally supplied with
a kit, but basically the method of use is to first
apply the pre-primer to the component
concerned and allow it to dry for up to 30
minutes. Then the primer is applied and left to
dry for about an hour before finally applying the
special coloured top coat. The result is a
correctly coloured component where the paint
will flex with the plastic or rubber, a property
that standard paint does not normally possess.
Where serious damage has occurred or large
areas need renewal due to neglect, it means
certainly that completely new sections or panels
will need welding in and this is best left to
professionals. If the damage is due to impact, it
will also be necessary to completely check the
alignment of the bodyshell structure. Due to the
principle of construction, the strength and shape
of the whole car can be affected by damage to
one part. In such instances the services of a
Ford agent with specialist checking jigs are
essential. If a body is left misaligned, it is first of
all dangerous as the car will not handle properly,
and secondly uneven stresses will be imposed
on the steering, engine and transmission,
causing abnormal wear or complete failure. Tyre
wear may also be excessive.
Removal
1Support the bonnet in its open position,
and place protective covers (old rags or
cardboard) beneath the corners of the bonnet,
and over the front wings to prevent damage to
the paintwork.
2Remove the screw and disconnect the earth
strap from the rear left-hand edge of the bonnet
(see illustration). Where applicable, disconnect
the wiring from the underbonnet lamp.
3Mark the location of the hinges on the sides
of the bonnet with a soft pencil or masking
tape, then loosen the four hinge bolts.
4With the help of an assistant, remove the
bolts and lift the bonnet from the vehicle (see
illustration).
5If required, the underbonnet insulation can
be removed by prising out the two-piece
plastic securing clips.
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 bonnet is
central within its aperture and aligned with the
surrounding bodywork. Re-adjust the hinges
to give satisfactory alignment if necessary.
9Check that the bonnet lock striker engages
fully in the lock, and if necessary adjust the
position of the lock striker and/or the height of
the bonnet rubber bump stops (see
illustration).
Removal
1Working inside the vehicle, remove the
three retaining screws, and withdraw the
lower steering column shroud.
2Remove the retaining screw, and withdraw
the release cable bracket from the steering
column.
3Working in the engine compartment, pull
the cable sheath end fitting from its bracket,
and release the cable end fitting from the lock
lever (see illustration).
4Release the cable from the clips in the
engine compartment.
5Pull the cable through the bulkhead into the
passenger compartment, taking care not to
lose the bulkhead grommet.
Refitting
6Refitting is a reversal of removal, but ensure
that the grommet is correctly located in thebulkhead, and that the cable is free from
sharp bends and kinks. There should be a
small amount of free play at the lock end of
the cable if necessary re-route the cable to
achieve this condition.
7Note that should the release cable snap
while the bonnet is shut, the bonnet may be
opened as follows.
8Apply the handbrake, jack up the front of
the vehicle and support on axle stands (see
“
Jacking and Vehicle Support”).
9Using an inspection lamp or torch, look up
between the radiator and the radiator grille
panel and locate the circular hole below the
bonnet lock (see illustration).
10Insert a screwdriver through the hole so
that it passes to the right of the lock striker.
Twist or lever the lock sliding plate to the right
until the striker is released. The bonnet can
now be opened.
7Bonnet lock release cable -
removal and refitting
6Bonnet - removal and refitting
5Major body damage - repair
12•4Bodywork and fittings
6.2 Remove the screw and disconnect the
bonnet earth cable
6.9 Adjustable bonnet rubber bump stop
7.9 Access hole (arrowed) below bonnet
lock7.3 Bonnet lock release cable end fittings -
models up to 1987
6.4 Lifting the bonnet from the vehicle
Page 5 of 22
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
Page 6 of 22
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
Page 7 of 22
2Unscrew and remove the bolt securing the
check arm to the body pillar (see illustration).
3Remove the two securing screws, and
withdraw the side trim panel from the footwell.
4If working on the driver’s side, remove the
lower facia panels and disconnect the face
level vent hose.
5If working on the passenger side, remove
the face level vent cover.
6Support the door on blocks of wood.
7Working through the body pillar aperture,
unscrew the two securing nuts and remove
the reinforcing plate from the lower hinge.
Repeat the procedure for the upper hinge
(see illustration).
8Withdraw the door from the vehicle.
9Refitting is a reversal of removal, but do not
fully tighten the hinge bolts until the door is
positioned centrally in the body aperture and
aligned with the surrounding bodywork. If
necessary, remove the lock striker from the
body centre pillar before adjusting the door,
then refit it and adjust its position so that the
lock operates correctly.
Rear door
10On models equipped with electric
windows, central-locking, 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.11Unscrew and remove the bolt securing
the check arm to the body centre pillar.
12Remove the centre pillar trim panel.
13Proceed as described in paragraphs 6 to
9 inclusive.
Rear door (late model Estate)
14The door internal components have been
modified on later Estate models. If a new,
later-specification rear door is to be fitted to
an earlier vehicle, the door panels must be
modified as follows to enable refitting of the
original components.
15Remove all the serviceable components
and fasteners from the original door.
16Working on the new door, use a small
round file to elongate the door interior handle
mounting hole “A” (see illustration)vertically
downwards so that it will align with the
mounting hole in the handle/ashtray bezel.
Refit the original retaining clip.17The earlier type of trim fasteners (located
at “B”) are no longer used, and must be
replaced with the latest type of fasteners,
available from a Ford dealer.
Front door
Models up to 1987
1On models with manually-operated
windows, prise the cover from the window
regulator handle, note the position of the
handle with the window fully shut, then
remove the securing screw and withdraw the
handle and bezel (see illustrations).
2Remove the securing screw and withdraw
the trim panel from behind the door grip (see
illustration).
17Door inner trim panel -
removal and refitting
Bodywork and fittings 12•7
12
16.16 Later-type rear door -
Estate models
A Internal handle mounting hole
B Early-type ashtray/handle mounting holes
C Revised mounting holes17.1a Prise the cover from the window
handle, remove the securing screw . . .17.1b . . . then withdraw the window handle
and bezel (arrowed)
16.2 Remove the door check arm-to-body
pillar bolt (arrowed)
1 Nut
2 Reinforcing plate3 Hinge pin
4 Bush5 Hinge assembly
16.7 Exploded view of the front door hinge (A) and rear door hinge (B)
Page 8 of 22
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
Page 9 of 22
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
Page 10 of 22
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
Page 11 of 22
8Position the crane with the lifting arm
diagonally over the centre of the cargo area,
and attach the cradle. Carefully lift the cargo
area from the chassis. Note that the lip of the
cargo area rear panel fits over the rear chassis
crossmember, therefore the cargo area must
be pulled rearwards as it is removed to
disengage it from the crossmember.
Refitting
9Refitting is a reversal of removal, but ensure
that the insulators are in place between the
cargo area and the chassis. Before finally
tightening the securing bolts, adjust the
position of the cargo area to give an equal
clearance on both sides of the vehicle
between the cab rear panel and the cargo
area front panel.
Removal
1Lower the tailboard to the open position.
2Detach the rear lamp wiring cover on one
side of the vehicle by removing the two
securing screws (see illustration).
3Remove the four rear lamp securing nuts,
and withdraw the rear lamp assembly.
Disconnect the wiring plug.
4Raise the tailboard by approximately 20º,
lift the centre pivot of one of the support arms,
and when the bolt head on the tailboard is
aligned with the slot in the support arm, pull
the support arm clear. Repeat this procedure
for the remaining support arm, and lower the
tailboard to the vertical position.
5On the side of the vehicle from which the
rear lamp has been removed, remove the two
screws securing the tailboard hinge to the
cargo area.
6Close the tailboard and lever out the hinge.
7Pull the free end of the tailboard away from
the cargo area, and carefully prise the
remaining end from its hinge. Withdraw the
tailboard from the vehicle.
8If required, the pivot bushes can be
removed from the tailboard for renewal.
Refitting
9Refitting is a reversal of removal.
Removal
1With the exception of the cab rear window
on P100 models, all fixed glass panels are
direct glazed to the body using a special
adhesive. Special tools are required to
remove the old glass and to fit the new glass,
therefore the work is best entrusted to a
dealer or replacement glass specialist.
2The cab rear window on P100 models can
be removed as follows, although it is
advisable to entrust the work to a specialist.
3Remove the six Torx bolts and nut/washer
assemblies, and withdraw the safety grille
from the rear of the cab.
4Prise out one end of the trim insert from the
window rubber, then pull out the remainder of
the trim.
5With the aid of an assistant, carefully push
the glass and rubber into the passenger
compartment.
6Remove all traces of old sealer from the
glass, rubber and cab aperture.
Refitting
7Commence refitting by pushing the window
rubber into the aperture, ensuring that the trim
panel and body panel engage in their
respective grooves in the rubber.
8Working from outside the cab, enter the
bottom edge of the glass into the rubber, and
hold the glass against the rubber while an
assistant working from inside the passenger
compartment pushes the rubber over the
glass.
9The trim insert must now be refitted to the
rubber, preferably using a suitable windscreen
trim insert tool. If no special tool is available,
the trim can be refitted by prising open the
rubber lips and pressing the trim into its
groove, although this is likely to prove difficult
and time consuming.
10Refit the safety grille to the rear of the cab
on completion.
Removal
1Remove the rear pillar interior trim panel.
2Remove the two screws securing the
window catch to the body (see illustration).
3Prise the two screw covers from the hinges.
Support the glass, and remove the two hinge
screws, then lift out the glass (see
illustration).
4If a new window is to be fitted, transfer the
catch to it.
Refitting
5Refitting is a reversal of removal.
Front door
1Remove the door inner trim panel.
2Where necessary for access, peel back the
waterproof plastic sheet from the door.
3Remove the door mirror.
4Remove the window channel extension
screw from the bottom rear corner of the
door, and withdraw the channel through the
lower door aperture.
5Lower the window until the lower support
channel is visible through the lower door
aperture. Prise the regulator arms from the
sockets in the support channel, then lower the
window to the bottom of the door.
6Carefully prise the weatherstrip from the
rear edge of the window aperture, then tilt the
window forwards and lift it outwards through
the aperture.
7Refitting is a reversal of removal, but
position the rear window channel extension
screw to allow approximately 5.0 mm (0.2 in)
fore and aft movement of the window. Check
to ensure that the window does not tip as it is
raised, and that the regulator effort is
acceptable (check that the motor is not being
27Door window - removal and
refitting
26Opening rear quarter window
- removal and refitting
25Windscreen, rear window and
fixed rear quarter windows -
removal and refitting
24Tailboard (P100 models) -
removal and refitting
Bodywork and fittings 12•11
12
26.3 Opening the rear quarter window
hinge
A Cap
B Screw
C Hinge
D SpacerE Grommet
F Retainer
G Cap
H Screw
26.2 Opening the rear quarter window
catch
A Cap
B Retainer
C GrommetD Spacer
E Catch
F Screw (one of two)
24.2 Rear lamp wiring cover screws (A)
and tailboard hinge screws (B)
Page 12 of 22
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
Page 13 of 22
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