1985 FORD SIERRA height

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

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

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)

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)

7Fit a new hose clamp over the plastic hose,
and warm the end of the hose in hot water
until it is pliable. Push the metal tube into the
plastic hose, ensuring an overlap of at least
20.0 mm (0.8 in).
8Crimp the new clamp onto the hose to
ensure an airtight seal.
9Refit the two screws securing the tube to
the side of the seat.
10Refit the seat.
Front seat belt stalk
1Remove the front seat.
2Detach the seat belt stalk from the seat by
removing the two Torx screws.
3Refitting is a reversal of removal.
Front seat belt assembly
4Where applicable, prise out the cover from
the height adjuster using a small coin or
similar implement, and detach the adjuster by
removing the two screws(see illustration).
5Unscrew the seat belt upper anchor nut,
noting the fitted positions of any washers and
spacers so that they can be refitted in their
original positions.
6Remove the centre pillar trim panels.
7On 3-door models, remove the waist-level
seat belt webbing guide, and remove the bolt
securing the belt slider bar to the body.
Disengage the slider bar from the heel kick
panel, and slide off the belt webbing loop.
8Unscrew the bolt securing the inertia reel
unit to the centre pillar, noting the fitted
positions of any washers and spacers so that
they can be refitted in their original positions.9Refitting is a reversal of removal, taking
care to install the belt without twists in the
webbing, and refitting any washers and
spacers in their original positions.
Rear seat belt assembly
Saloon models
10Remove the rear seat cushion.
11Unbolt the relevant belt anchor(s) from the
floor (see illustration), noting the fitted
positions of any washers and spacers so that
they can be refitted in their original positions.
The central lap strap and buckle assemblies
can be withdrawn after unbolting the anchors.
12To remove a side belt and inertia reel
assembly, proceed as follows.
13Remove the rear pillar trim panel.
14Unscrew the upper belt anchor (see
illustration), noting the fitted positions of any
washers and spacers so that they can be
refitted in their original positions.
15Unscrew the bolt securing the inertia reel
unit to the rear pillar, again noting the
positions of any washers and spacers.
16Refitting is a reversal of removal, taking
care to install the belt(s) without twists in the
webbing, and refitting any washers and
spacers in their original positions.
Hatchback and Estate models
17Remove the rear seat cushion.
18Unbolt the relevant belt anchor(s) from the
floor (see illustration), noting the fitted
positions of any washers and spacers so that
they can be refitted in their original positions.
19To remove the central lapstrap and buckle
assemblies, disconnect the buckle(s) from the
elasticated straps by withdrawing the
retaining dowel(s). To prevent the strap(s)
from moving into the interior of the seat, inserta length of wire through the strap loop(s).
20To remove a side belt and inertia reel
assembly, proceed as follows.
21Unbolt the upper left anchor, noting the
position of any washers and spacers, and
allow the webbing to pass into the inertia reel
unit.
22On Hatchback models, pull back the
inertia reel cover in the luggage compartment,
and unbolt the inertia reel from the body,
noting the position of any washers and
spacers. Prise out the belt guide from the rear
parcel shelf support, and push the guide,
upper and lower anchors, and buckle plate
through the aperture.
23On Estate models, remove the luggage
compartment side trim panel then unbolt the
inertia reel unit, noting the position of any
washers and spacers, and withdraw the belt
assembly.
24Refitting is a reversal of removal, taking
care to install the belt(s) without twists in the
webbing, and refitting any washers and
spacers in their original positions. Ensure that
the cut-outs in the lower anchor brackets are
correctly located around the raised dimples in
the floor.
50Seat belts - removal and
refitting
Bodywork and fittings 12•21
1250.18 Rear seat belt twin buckle assembly
lower anchor bracket - Hatchback and
Estate models
A Elasticated strap retaining dowels
B Anchor belt
C Floor dimple
50.14 Rear seat belt upper anchor (A) and
inertia reel securing bolt (B) - Saloon
models50.11 Rear seat belt lower anchors
A Inertia reel belt lower anchors
B Static belt and buckle
C Twin buckle assembly50.4 Front seat belt upper anchor fixings
A Adjuster securing screws
B Anchor nut