Door lock - removal and refitting

Models up to 1990
1 Remove the door inner trim panel.

2 Where necessary for improved access, peel back the waterproof plastic sheet from the door.

3 Withdraw 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.

4 Remove 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.

5 Where 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.

6 Withdraw the lock from inside the door.

7 Refitting is a reversal of removal, but ensure that the window channel extension is correctly located.

Models from 1990
8 From 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.

9 Remove the door inner trim panel.

10 Where necessary for improved access, peel back the waterproof plastic sheet from the door.

11 Remove the securing screw, and withdraw the window channel extension through the doors lower aperture.

12 Disconnect the door outer handle and the lock barrel (front doors) operating rods at the lock assembly.

13 Disconnect the battery negative lead, and disconnect the door lock motor and the alarm system wiring plugs (where applicable).

14 Remove the screw securing the door interior handle to the door panel.

15 Remove 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.

16 To disconnect the cable from the lock, proceed as follows.

17 Carefully prise the cover plate from the lock, using a screwdriver (see illustration).

21.17 Prising the cover plate from a cableoperated door lock
21.17 Prising the cover plate from a cableoperated door lock

18 Using a suitable pair of pliers, carefully remove the outer cable from the groove in the lock assembly casing.

19 Extend the inner cable until the flats on the plastic end piece align with the guide, then withdraw the cable (see illustration).

21.19 Disconnecting the operating cable from a cable-operated door lock
21.19 Disconnecting the operating cable from a cable-operated door lock

A Removing outer cable B Disconnecting inner cable

20 Commence reassembly and refitting as follows.

21 Align the flats on the inner cable end piece with the cable guide, and refit the inner cable.

22 Using a suitable pair of pliers, carefully refit the outer cable to the groove in the lock assembly casing.

23 Refit the lock cover plate.

24 Insert the lock, cable and interior handle into the door, and refit the three lock securing screws.

25 Push the interior handle assembly towards the lock to adjust the cable, and when adjustment is correct, refit and tighten the interior handle securing screw.

26 Further refitting is a reversal of removal, ensuring that the window channel extension is correctly located.

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