1991 FORD SIERRA roof rack

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

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)