1983 FORD SIERRA fuel

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

Removal
1Open the tailgate and prise out the trim
panel using a wide-bladed screwdriver(see
illustration).
2Remove the lock barrel retaining clip, and
where applicable disconnect the operating
lever from the central locking solenoid/motor,
then withdraw the lock barrel (see
illustration). Central locking solenoid/motor
removal and refitting is covered in Chapter 13.
3Remove the two securing screws and
detach the lock barrel support bracket from
the tailgate.
4Where applicable, disconnect the battery
negative lead, the earth lead from the tailgate
and the “tailgate ajar” sensor wiring plug.
Unclip the luggage compartment light switch
from the lock assembly, where applicable.
5Remove the securing screws and withdraw
the lock assembly.
Refitting
6Refitting is a reversal of removal, but do not
tighten the lock barrel support bracket screws
until the lock barrel has been fitted.
Removal
1Support the tailgate in the open position
using a prop, or with the aid of an assistant.
2Disconnect the strut from the tailgate by
prising out the retaining clip. Do not remove
the clip completely, just raise it by a maximum
of 4.0 mm (0.16 in) and then pull the strut off
its mounting.
3Pull the strut from the pivot stud on the
body.
Refitting
4Refitting is a reversal of removal.
Removal
1Operate the control lever to open the
tailgate/boot lid and the fuel filler flap (see
illustration).
2Remove the driver’s side centre pillar lower
trim panel and the sill trim panel.
3Withdraw the cover from the control lever.
4Unscrew the two securing bolts, and
detach the control lever assembly from the
body panel. Detach the cable from the control
assembly.
5Fold the rear seat cushion forwards or
remove it, as applicable, and remove the rear
seat side cushion for access to the wheel arch
trim panel.
6Detach the trim panel from the wheel arch
by removing the two securing screws from the
parcel shelf bracket. Free the cable up to the
wheel arch.
7Working inside the luggage compartment,
remove the trim panels for access to the
petrol flap lock and tailgate/boot lid lock.
8Disengage the petrol flap catch from the
housing by twisting and pulling out (see
illustration). Carefully pull the cable through into
the luggage compartment, noting its routing.
9Remove the securing screws, and withdraw
the tailgate/boot lid lock striker from the bodypanel. Withdraw the striker and cable
assembly.
Refitting
10Commence refitting by installing the
tailgate/boot lid striker and cable assembly.
Secure the cable to the body with tape.
11Route the cable back to the petrol flap
housing, and refit the petrol flap catch.
12Route the cable into the interior of the
vehicle, and refit the luggage compartment
trim panels.
13Route the cable to the control lever,
securing the cable with tape to the body, then
refit the wheel arch trim panel, and refit the
seat cushions.
14Reconnect the cable to the control lever
assembly, then refit the assembly.
15Refit the control lever cover and the trim
panels.
Models up to 1990
1Open the tailgate/boot lid.
2Prise the four screw covers from the
spoiler, then remove the screws, and
withdraw the spoiler.
3Refitting is a reversal of removal.
Models from 1990
4Open the tailgate/boot lid.
5Remove the inner tailgate/boot lid trim
panel for access to the spoiler securing nuts.
6Unscrew the central spoiler securing nut,
then unscrew the four outer securing nuts
(two on each side), and withdraw the spoiler.
7Refitting is a reversal of removal.
Front door
1On models with electric mirrors, electric
windows, central-locking, door-mounted
speakers, or “door ajar” sensors, remove the
trim panel and disconnect the wiring inside
the door. Withdraw the wiring loom(s) through
the grommet(s) in the front edge of the door.
16Door - removal and refitting
15Tailgate/boot lid spoiler -
removal and refitting
14Tailgate/boot lid/fuel filler
flap release cable - removal
and refitting
13Tailgate strut (Hatchback
and Estate models) - removal
and refitting
12Tailgate lock (Hatchback and
Estate models) - removal and
refitting
12•6Bodywork and fittings
14.1 Tailgate/boot lid/fuel filler flap control
lever assembly14.8 Disengaging the petrol flap catch
from the housing
12.2 Tailgate lock assembly - Hatchback
and Estate models
A Lock barrel support
bracket
B Lock barrel
retaining clipC Lock barrel
D Torx screw
E Lock assembly
F Screws
12.1 Tailgate trim panel fixings -
Hatchback and Estate models

3Remove the 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

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

4Immerse the housing assembly in a
container of hot water for approximately ten
minutes, then prise the hinge cover from the
housing, and using a screwdriver, prise the
filler flap hinge legs out of the sockets in the
housing.
Refitting
5Commence refitting by warming the filler
flap and housing, as during removal, then
push the flap hinge legs into the housing.
6Further refitting is a reversal of removal,
ensuring that the housing gasket and retaining
tangs are correctly located.
Removal
1Open both the front and rear doors to
expose the relevant weatherstrip.
2Carefully pull the weatherstrip from the
base of the front pillar, taking care to release
the flap which is stuck to the pillar with
adhesive.
3Pull the remainder of the weatherstrip from
its flange.
4Carefully clean the old adhesive from the
base of the front pillar using methylated
spirits.
Refitting
5Commence refitting by pushing the
weatherstrip onto its flange at the top corner
of the rear pillar, running it for approximately
200 mm (8.0 in) along the horizontal flange.
6Align the flap on the front pillar, and apply a
thin bead of rubber-based adhesive to the
flap. Refit the flap to the front pillar, ensuring
that it lies naturally. Should the flap not lie
naturally, or start to lift, temporarily secure it in
position with adhesive tape.
7Refit the remainder of the weatherstrip,
starting at the front pillar and working
rearwards, then close the doors and allow the
adhesive to dry for at least an hour.
Glass panel - removal and
refitting
1Open the sunblind and remove the three
screws and clips shown (see illustration)
then slide the lower frame rearwards into the
roof.
2Remove the six screws securing the glass
panel to the sliding gear (see illustration)
then push the glass panel upwards and
remove it from outside of the vehicle, taking
care not to damage the paintwork.
3Commence refitting by securing the glass
panel to the sliding gear with the six screws.
4Adjust the sunroof as described in
paragraphs 10 and 12 to 14 inclusive, but
note that there is no need to open and close
the roof before checking adjustment.
5Refit the three clips to the glass panel, then
pull the lower frame forwards and secure it to
the glass panel with the three screws. Tighten
the screws in the order shown.
Complete assembly - removal and
refitting
6Fully open the sliding roof panel, then
remove the screw securing the roof operating
handle and detach the handle.
7Remove the four screws on each side and
the two screws at the front securing the
sliding roof assembly to the roof tray.
8Lift the front rail and carefully withdraw the
assembly forwards from the roof tray, taking
care not to damage the paintwork.
9Refitting is a reversal of removal, but on
completion, adjust the sunroof as described in
paragraph 10 onwards, and if necessary
adjust the position of the roof operating
handle so that with the roof in its closed
position, the handle can fold into its recess.
Adjustment
10Fully open and close the sliding roof, then
check that the front edge of the glass panel is
flush with, or a maximum of 2.0 mm (0.08 in)
below the adjacent roof panel. The rear edge
of the glass panel should be flush with, or amaximum of 2.0 mm (0.08 in) above the
adjacent roof panel.
11If adjustment is necessary, remove the
three screws securing the glass panel to the
lower frame, then slide the lower frame
rearwards into the roof.
12To adjust the front edge of the glass
panel, loosen the front and centre screws
securing the glass panel to the sliding gear.
13To adjust the rear edge of the glass panel,
loosen the rear and centre screws securing
the glass panel to the sliding gear (see
illustration 39.1).
14On completion of adjustment, tighten the
glass panel-to-sliding gear securing screws.
15Pull the lower frame forwards and secure
it to the glass panel with the three screws.
Tighten the screws in the order shown.
1The method of removal and refitting for
most interior trim panels is self-explanatory.
The panels are fixed in place either by screws,
which may be concealed by plastic blanking
plugs in some cases, or by clips on the rear of
the panel.
2When removing a panel secured by clips,
prise the panel as close as possible to each
clip, using a forked tool similar to that shown
(see illustration, 17.6b) or a wide-bladed
screwdriver to prevent damage to the panel.
3Refer to the relevant Sections of this
Chapter for removal and refitting details of the
major trim panels.
Front pillar
1Remove the two trim panel securing screws
and withdraw the panel(see illustration)..
2Refitting is a reversal of removal.
Centre pillar
3Where applicable, lever the seat belt height
adjuster button downwards and detach the
button by removing the two securing screws.
41Interior pillar trim panels -
removal and refitting
40Interior trim panels - general
information
39Sunroof - removal, refitting
and adjustment
38Inner gutter weatherstrip
(Saloon, Hatchback and
Estate models) - removal and
refitting
Bodywork and fittings 12•15
12
39.2 Sunroof glass panel-to-sliding gear
securing screws (one side shown for
clarity)39.1 Sunroof lower frame-to-glass panel
securing screws and clips (arrowed)
Tighten screws in the order shown when
refitting37.2 Fuel filler housing securing screw
(arrowed)