1991 FORD SIERRA Bodywork And Fittings Workshop Manual

4Unclip the trim panel from the lower edge of
the lower facia panel.
5Remove the four securing screws and
withdraw the lower facia panel. Where
applicable, disconnect the loudspeaker
wiring.
6Refitting is a reversal of removal.
Passenger side lower facia panel
7Remove the two securing screws and
withdraw the side trim panel from the left-
hand side of the footwell.
8Remove the centre console to gain access
to the lower facia panel securing screws.
9Unclip the trim panel from the lower edge of
the lower facia panel.
10Unscrew the seven securing screws and
withdraw the lower facia panel. Disconnect
the wiring from the loudspeaker, glovebox
lamp, ashtray lamp, heater switch, cigarette
lighter, radio/cassette player, and
loudspeaker balance control, as applicable. It
is advisable to label the wiring plugs to assist
refitting in the correct positions.
11Refitting is a reversal of removal.
Upper facia panel
12Remove the lower facia panels as
described previously in this Section.13Remove the instrument panel (Chapter 13).
14Where applicable, remove the trip
computer and “door ajar” monitor.
15Remove the heater control panel.
16Prise out the front and rear foglamp, heated
rear window and heated windscreen switches
and the instrument light and intermittent wiper
rheostats, as applicable, from the upper facia
panel, and disconnect their wiring plugs. It is
advisable to label the wiring plugs to assist
refitting in the correct positions.
17Remove the five securing screws and
withdraw the upper facia panel through the
passenger door aperture. Disconnect the
heater vent hoses, and ensure that any
remaining wiring is disconnected and where
applicable unclipped from the facia panel.
18Refitting is a reversal of removal.
Models from 1992
19A restyled facia is fitted from 1992. The
procedures for removal and refitting of the
various panels are essentially as described
above, noting the following points(see
illustration).
Bodywork and fittings 12•17
1243.19 Facia components and securing screw locations (arrowed) - models from 1992
A Upper facia panel
B Passenger’s side lower facia panel
C Driver’s side lower facia panel
D Heater fan control cover and bezel
E Clock/auxiliary warning system displayF Instrument panel surround and screw covers
G Clock/auxiliary warning system display
surround
H Instrument cluster
J Instrument cluster surround
A Upper facia panel
B Passenger side lower facia panelC Driver’s side lower facia panel
43.1 Facia panel securing screw locations (arrowed)
43.2 Withdraw the side trim panel from the
footwell

20On models with an adjustable steering
column, fully extend and lower the steering
column before attempting to remove any of
the panels on the driver’s side.
21The steering column shrouds are secured
by six screws - five through the lower shroud,
and one through the upper shroud.
22If necessary, remove the centre console.
23The driver’s side lower facia panel is
secured by five screws.
24The passenger’s side lower facia panel is
secured by eight screws.
25On models with an alarm, the alarm warning
light must be disconnected and removed before
removing the upper facia panel.
Models up to 1990
Full length console
1Where applicable, prise the electric window
switches from the front upper console panel
and disconnect the wiring.
2Remove the three securing screws from the
front upper console panel, then withdraw the
panel over the gear selector lever, at the same
time releasing the rubber gaiter where
applicable.
3On “high specification” models, where
applicable prise the electric window switches
from the rear upper console panel and
disconnect the wiring. Remove the five
securing screws and withdraw the rear upper
console panel (see illustrations).
4On “low specification” models, remove the
two securing screws and release the single
rear clip, then withdraw the rear upper
console panel.
5Where applicable, remove the two screws
securing the lower console centre bracket to
the transmission tunnel, and remove the
bracket.
6Remove the six screws securing the lower
console panel, and withdraw the panel (see
illustrations).
7Refitting is a reversal of removal.
Short console
8Prise out the blanking plug, and remove the
rear console securing screw.9On automatic transmission models, lift out
the console tray mat and remove the front two
console securing screws.
10On manual gearbox models, prise out the
blanking plugs and remove the front two
console securing screws.
11Withdraw the console over the gear
selector lever, at the same time releasing the
rubber gaiter where applicable.
Models from 1990
12Remove the switch assembly (after
disconnecting the battery negative lead), or
remove the blanking plate from the gear lever
surround, as applicable.
13Remove the securing screw from the gearlever surround, and withdraw the gear lever
surround from the console by releasing the
two securing clips.
14Remove the seven console securing
screws (see illustration).
15Chock the rear wheels, then release the
handbrake lever.
16Jack up the vehicle and support it on axle
stands (see “Jacking and Vehicle Support”).
Disconnect the handbrake equaliser from the
linkage on the underbody.
17Raise the handbrake lever fully, and lift the
console over the handbrake lever.
18Refitting is a reversal of removal, but on
completion, check the handbrake/cable
adjustment.
44Centre console - removal and
refitting
12•18Bodywork and fittings
44.3b Rear upper console panel rear
retaining screws (arrowed)
44.6b . . . centre securing screw . . .
44.14 Centre console components - models from 1990
A Screw
B Screw coverC Gear lever surround
D Blanking plateE Centre console
44.6c . . . and rear securing screw
44.6a Removing a lower console panel
front securing screw . . .44.3a Removing a rear upper console
panel front retaining screw - “high
specification” model

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)

Rear seat armrest
26Fold the rear seat backrest forwards, and
remove the three armrest securing screws.
27Remove the armrest by prising out the
trim clips securing the cover material to the
seat backrest.
28Refitting is a reversal of removal.
Saloon models
1Working in the luggage compartment,
release the seat catch by pulling the release
knob, or if the cable is broken, use a
screwdriver to release the catch itself.
2Fold the backrest forwards into the
passenger compartment and remove the two
screws shown (see illustration).
3Detach the cover and then remove the
catch from the body.
4Disconnect the release cable and sheath
from the catch.
5Refitting is a reversal of removal, but on
completion check the catch for correct
operation, and if necessary adjust the position
of the striker on the seat backrest to achieve
satisfactory engagement with the catch.
Hatchback and Estate models
Low specification
6Release the seat catch by pulling the
release knob, and fold the backrest forwards
into the passenger compartment.7Unscrew the release knob from the top of
the seat backrest.
8Carefully pull the edge of the seat cover
from the flange on the seat backrest, then pull
the backrest cushion away from the seat
panel to gain access to the catch (see
illustration).
9Remove the catch assembly by unscrewing
the two securing bolts.
10Refitting is a reversal of removal, but on
completion check the catch for correct
operation, and if necessary adjust the position
of the striker to achieve satisfactory
engagement with the catch.
High specification
11Release the seat catch and fold the
backrest forwards into the passenger
compartment.
12Remove the rear parcel shelf for improved
access, then remove the screws and withdraw
the cover for access to the catch.
13Unscrew the two bolts securing the catch
to the bracket on the rear wheel arch (see
illustration).
14Using a small screwdriver, push out the
pin securing the link rod to the catch, then
withdraw the catch.
15If required, lift the release lever, push out
the securing pin and remove the link rod. The
lever can be removed by drilling out the two
securing rivets from the parcel shelf support.
16Refitting is a reversal of removal, but
where applicable fit new rivets using a hand
riveter to secure the release lever. Oncompletion check the operation of the catch
and if necessary adjust the position of the
striker to achieve satisfactory engagement
with the catch.
Complete assembly - removal and
refitting
1Remove the seat.
2Straighten the seat back cover retaining
tangs, and pull the cover upwards to expose
the air cushion.
3Cut through the four securing rings (see
illustration)and remove the two screws
securing the metal air tube to the side of the
seat, then withdraw the assembly from the
seat frame.
4Refitting is a reversal of removal, using new
cushion securing rings.
Air inflator ball - renewal
5Remove the seat.
6Remove the two screws securing the metal
air tube to the side of the seat (see
illustration), then cut through the plastic hose
as close to the end of the metal tube as
possible. Discard the old tube and the inflator
ball.
49Front seat air cushion
assembly - removal and
refitting
48Rear seat catch - removal and
refitting
12•20Bodywork and fittings
48.8 Pull back the seat cover to expose the
rear seat catch securing bolts - “low
spec.” Hatchback and Estate models
49.3 Front seat air cushion securing rings
(arrowed)
49.6 Front seat air cushion tube and
inflator ball
A Air tube securing screws
B Hose cutting point48.13 Rear seat catch assembly - “high
specification” Hatchback model
48.2 Rear seat catch fixings - Saloon
models
A Remove the securing screws
B Withdraw the cover and catch47.24 Rear seat side cushion removed
exposing upper fixing hook

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

12•22Notes