Ford Sierra Manual

Headlamp unit - removal and refitting
Body electrical system / Headlamp unit - removal and refitting


1 Disconnect the battery negative lead.

2 Remove the radiator grille panel.

Models up to 1987
3 Disconnect the headlamp wiring plug(s) see illustration).

41.3 Disconnect the headlamp wiring plug - models up to 1987
41.3 Disconnect the headlamp wiring plug - models up to 1987

4 Remove the three or four headlamp securing bolts, as applicable, and the lower sliding clamp bracket bolt on the rear of the headlamp, then withdraw the headlamp (see illustrations).

41.4a Remove the upper headlamp securing bolts (arrowed) . . .
41.4a Remove the upper headlamp securing bolts (arrowed) . . .

41.4b . . . the rear securing bolt . . .
41.4b . . . the rear securing bolt . . .

41.4c . . . and the lower sliding clamp bracket bolt . . .
41.4c . . . and the lower sliding clamp bracket bolt . . .

41.4d . . . then withdraw the headlamp unit - models up to 1987
41.4d . . . then withdraw the headlamp unit - models up to 1987

5 If required, the headlamp lens can be removed by releasing the spring clips around its edge.

6 Refitting is a reversal of removal, but the headlamp securing bolts should not be tightened until the headlamp is aligned with the front grille panel.

7 On completion, check the headlamp alignment.

Models from 1987
8 Disconnect the headlamp wiring plug(s) (see illustration).

41.8 Disconnect the headlamp wiring plug - models from 1987
41.8 Disconnect the headlamp wiring plug - models from 1987

9 Where applicable, remove the headlamp wiper motor.

10 Remove the headlamp securing bolt and the two nuts, then release the anchor spring and withdraw the direction indicator !amp unit (see illustrations).

41.10a Remove the headlamp rear securing bolt . . .
41.10a Remove the headlamp rear securing bolt . . .

41.10b . . . the upper securing nut . . .
41.10b . . . the upper securing nut . . .

41.10c . . . and the side securing nut - models from 1987
41.10c . . . and the side securing nut - models from 1987

11 Pull the headlamp forwards, then swivel it and remove it sideways.

12 If required, the headlamp lens can be removed by releasing the spring clips around its edge.

13 Refitting is a reversal of removal.

14 On completion, check the headlamp alignment.


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