1990 FORD SIERRA belt

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

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)

4Unscrew the upper seat belt anchor nut,
noting the fitted positions of any washers and
spacers so that they can be refitted in their
original positions.
5Remove the two securing screws, and
withdraw the upper trim panel.
6Remove the two or three securing screws
as applicable, and withdraw the lower trim
panel, passing the seat belt webbing through
the panel as it is removed.
7Refitting is a reversal of removal.
Rear pillar
Saloon models
8Remove the rear seat cushion.
9Unbolt the lower seat belt anchor.
10On models with fixed rear seats, remove
the backrest.
11On models with folding rear seats, remove
the side cushion.
12Remove the two securing screws from the
base of the pillar trim panel, then pull the trim
panel from the pillar, passing the seat belt
webbing through the panel as it is removed.
13Refitting is a reversal of removal.
Hatchback models
14Remove the rear seat side cushion.
15Remove the rear parcel shelf, and where
applicable unbolt the rear seat belt upper
anchor and spacer.
16On “high specification” models, lift the
seat catch release lever, push out the pin
securing the link rod to the lever and
disconnect the link rod.
17Remove the securing screws from the rear
parcel shelf support (nine screws on models
up to 1987, eight screws from 1987 onwards)
and on “high specification” models remove
the two bolts securing the rear seat catch
assembly to the wheel arch, then withdraw
the catch assembly. Remove the rear parcel
shelf support.
18Remove the five securing screws and
detach the rear pillar trim panel.
19Refitting is a reversal of removal, but
where applicable check the operation of the
rear seat catch on completion.
P100 models
20Remove the cover from the seat belt
upper anchor, then unscrew the anchor,
noting the fitted positions of any washers and
spacers so that they can be refitted in their
original positions.
21Remove the three securing screws from
the upper trim panel, and withdraw the panel
(see illustration).
22Remove the three securing screws from
the lower trim panel, then pull the panel away
from the pillar and pass the seat belt webbing
through the slot.
23Withdraw the trim panel by disengaging it
from the seat belt inertia reel mounting
bracket.
24Refitting is a reversal of removal.
Side trim panel
1Remove the rear pillar trim panel.
2Remove the side trim panel by prising out
the four expander pins from the clips, then
pulling out the clips and withdrawing the
panel.
3Refitting is a reversal of removal.
Upper rear trim panel
4Remove the side trim panels from both
sides of the cab as previously described in
this Section.
5Remove the cab rear window.
6Prise out the four expander pins from the
trim panel clips beneath the rear window
aperture, then pull out the clips (see
illustration).
7Remove the blanking covers, then remove
the three securing screws from the rear of the
headlining.
8Lower the rear of the headlining and
remove the trim panel.
9Refitting is a reversal of removal.
Lower rear trim panel
10Remove the side trim panels from both
sides of the cab as previously described in
this Section.
11Prise out the four expander pins from the
trim panel clips beneath the rear window
aperture, then pull out the clips.
12Pull the jack handle from its two retaining
clips, then remove the clips.
13Prise out the two expander pins from the
trim panel lower clips, then pull out the clips.
14Pull the bottom edge of the trim panel
away from the rear of the cab, and slide the
panel out from under the upper trim panel.
15Refitting is a reversal of removal.
Models up to 1992
1Note the locations of the facia panel
securing screws (see illustration).
Disconnect the battery negative lead.
Driver’s side lower facia panel
2Remove the two securing screws and
withdraw the side trim panel from the right-
hand side of the footwell (see illustration).
3Remove the securing screws and unclip the
lower and upper steering column shrouds.
43Facia panels - removal and
refitting
42Cab interior trim panels
(P100 models) - removal and
refitting
12•16Bodywork and fittings
42.6 Cab interior rear panel fixings - P100
models
A Upper and lower trim panel fixings
B Jack handle retaining clips
C Lower trim panel fixings
41.21 Interior rear pillar trim panel fixings
(arrowed) - P100 models
A Upper trim panelB Lower trim panel
41.1 Interior pillar trim panel fixings - Hatchback models
A Front pillar trim panel
B1 Centre pillar upper trim panelB2 Centre pillar lower trim panel
C Rear pillar trim panel

Removal
1Disconnect the battery negative lead.
2Open the sunroof.
3On models with a manually-operated
sunroof, remove the sunroof handle securing
screw, then withdraw the handle and trim plate.
4On models with an electric sunroof, remove
the operating switch.
5Remove the courtesy lamp, if necessary,
then remove the two screws from the front of
the console (see illustration).
6Remove the two screws securing the rear of
the console to the sunroof flange, and
withdraw the console.
Refitting
7Refitting is a reversal of removal.
Saloon, Hatchback and Estate
models
1On Saloons, remove the rear seat back.
2Loosen the upper screws of all the pillar
trim panels touching the headlining.
3Prise off the covers and remove the screws
from the passenger grab handles. Withdraw
the grab handles. Similarly, prise off the
blanking covers and remove the headlining
securing screws from the driver’s position.
4Disconnect the battery negative lead, then
prise the courtesy light(s) from the headlining
or overhead console. Disconnect the wiring
and remove the courtesy light(s).
5Where applicable, remove the two securing
screws and withdraw the overhead console.
6Remove the sunroof (where fitted). The
headlining is folded around the sunroof
aperture flange and is held in place with
adhesive tape and a moulding which must be
removed.
7Support the headlining, then remove the
screws and withdraw the sun visors and clips.
Where applicable, disconnect the wiring from
the vanity mirror lamp.
8On Estate models, remove the two plastic
fasteners from the headlining between the
rear door and tailgate pillars.
9Remove the two plastic fasteners from the
rear of the headlining, and withdraw the
headlining through the luggage compartment.
10Refitting is a reversal of removal.
P100 models
11Loosen the front pillar trim panel upper
securing screws.
12Prise off the covers and remove the
screws from the passenger grab handle.
Withdraw the grab handle.13Prise off the blanking cover and remove
the headlining securing screw from the
driver’s side.
14Disconnect the battery negative lead, then
prise the courtesy light from the headlining.
Disconnect the wiring and remove the
courtesy light.
15Support the headlining, then remove the
screws and withdraw the sun visors and clips.
16Remove the blanking covers, and the
three securing screws from the rear of the
headlining, then withdraw the headlining
through one of the door apertures.
17Refitting is a reversal of removal.
Front seat
1Slide the seat fully forwards, and on seats
with height adjustment unhook the tension
spring from the rear crosstube. Where
applicable, disconnect the wiring from the
seat heating pad(s).
2Unscrew and remove the two bolts from the
inner rear seat mounting bracket and the
single bolt from the outer rear seat mounting
bracket (see illustration).
3Slide the seat fully rearwards, then unscrew
and remove the single bolt from each front
seat mounting bracket. Withdraw the seat
from the vehicle.
4Refitting is a reversal of removal, but when
fitting the front and rear mounting bolts,tighten the inner bolts first in each case.
Where applicable locate the height
adjustment tension spring between the weld
pips on the crosstube.
Rear seat cushion
5Remove the single screw from each side,
securing the cushion to the heel kick panel.
6Pull the cushion forwards and remove it
from the vehicle.
7Refitting is a reversal of removal.
Rear seat backrest
Fixed rear seats
8Remove the seat cushion as described in
paragraphs 5 to 7.
9Remove the three now exposed Torx
screws from the base of the backrest.
10Working inside the luggage compartment,
remove the three nuts securing the backrest
to the body.
11Pull the backrest forwards into the
passenger compartment and remove it from
the vehicle. Where applicable, feed the rear
seat belt straps and buckles around the edges
of the backrest.
12Refitting is a reversal of removal.
Folding rear seats
13Release the catch and fold the seat
backrest forwards.
14Remove the two Torx screws from each
backrest hinge.
15Pull the backrest forwards into the
passenger compartment and remove it from
the vehicle. Where applicable, feed the rear
seat belt straps and buckles around the edges
of the backrest.
16Refitting is a reversal of removal, but
where necessary adjust the position of the
seat catch striker to achieve correct operation
of the catch.
Rear seat side cushion
Saloon models
17Working in the luggage compartment,
remove the nut from the side cushion stud.
18Working in the passenger compartment,
remove the rear seat cushion as described in
paragraphs 5 and 6.
19Expose the seat backrest hinge bolt by
removing the cover, then remove the bolt.
20Pull the top of the side cushion forwards
to disengage the stud from the body.
21Straighten the metal retaining tangs at the
base of the side cushion, then withdraw the
cushion.
22Refitting is a reversal of removal.
Hatchback and Estate models
23Fold down the rear seat backrest.
24Carefully bend back the side cushion
lower retaining tangs, then unhook the
cushion from the upper fixing on the rear
parcel shelf support (see illustration).
25Refitting is a reversal of removal.
47Seats - removal and refitting
46Headlining - removal and
refitting
45Overhead console - removal
and refitting
Bodywork and fittings 12•19
12
47.2 Front seat inner rear mounting
45.5 Overhead console securing screws (A)

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