Freelander 1998 Body Repair Manual

FREELANDER
Body Repair Manual
Carrosserie
reparatiehandboek
Manuel de réparation
de carrosserie
Karosseriereparaturanleitung
Manuale delle operazioni di
riparazione della carrozzeria
Manual de reparaciones
de carrocería
Manual de reparações
da carroçaria
INTRODUCTION
GENERAL INFORMATION
INFORMATION
RESTRAINT SYSTEMS
BODY
PANEL REPAIRS
FREELANDER
BODY REPAIR
MANUAL
Publication Part No. LRL 0154ENG
Published by Rover Technical Communication
 1998 ROVER GROUP LIMITED
INTRODUCTION
CONTENTS
Page
INTRODUCTION
INTRODUCTION ...................................................................................................... 1
REPAIRS AND REPLACEMENTS ........................................................................... 2
SPECIFICATION ...................................................................................................... 2
INTRODUCTION
INTRODUCTION
References
How to use this Manual
References to the LH or RH side given in this
Manual are made when viewing the vehicle from the
rear.
This Body Repair Manual is designed to provide the
experienced Body Shop technician with the
information required to carry out efficient and
cost-effective repairs.
For ease of use, this Manual is structured to display
the section title at the top of each page and the
relevant sub-section at the bottom of each page. In
addition, a section icon is displayed at the top outer
corner of right-hand pages.
Each major section is preceded by a contents page,
which lists titles of the topics and procedures
contained in the relevant sub-sections.
Technical data is subject to change; to facilitate the
periodic revision of technical information, each
sub-section is numbered from page 1 so that revised
sub-sections can be replaced if required.
The individual steps of procedures are to be
performed in the sequence in which they appear.
Where item numbers appear in the Figure of a
procedure, those items are referred to in the text.
Cross references may be made to sections not
included in this manual. In these cases, refer to the
relevant Workshop Manual for the referenced
information.
Operations covered in this Manual do not include
instructions for testing the vehicle after repair. It is
essential that work is inspected and tested after
completion and if necessary a road test of the
vehicle should be conducted.
WARNING: It is particularly important to
test a vehicle after repairs to safety related
items have been performed.
Dimensions
The dimensions quoted are to design engineering
specification with service limits where applicable.
WARNINGS, CAUTIONS and NOTES have the
following meanings:
WARNING: Procedures which must be
followed precisely to avoid the possibility
of injury.
CAUTION: Calls attention to procedures
which must be followed to avoid damage
to components.
NOTE: Gives helpful information.
INTRODUCTION
1
INTRODUCTION
REPAIRS AND REPLACEMENTS
When replacement parts are required it is essential
that only Land Rover recommended parts are used.
The following points concerning repairs and the
fitting of replacement parts and accessories is
emphasised:
• Safety features and corrosion prevention
treatments embodied in the vehicle may be
impaired if other than Land Rover recommended
parts are fitted.
• In certain territories, legislation prohibits the
fitting of parts which are not compliant with the
manufacturer’s specification.
• Torque figures shown in this Manual should be
used where specified.
• Locking devices (circlips, split pins etc.) must be
fitted where specified.
• If a locking device is damaged during removal, or
its efficiency is impaired, it must be renewed.
• Owners purchasing accessories while travelling
abroad should ensure that the accessory and its
installation or application conform to the legal
requirements of the territory.
• The Terms of the vehicle Warranty may be
invalidated by the fitting of other than Land Rover
recommended parts.
• All Land Rover recommended parts are covered
under the terms of the vehicle Warranty.
• Land Rover Dealers are obliged to supply only
Land Rover recommended parts.
SPECIFICATION
Land Rover are constantly seeking to improve the
specification, design and production of their vehicles
and alterations take place accordingly. While every
effort has been made to ensure the accuracy of this
Manual, it should not be regarded as an infallible
guide to current specifications of any particular
vehicle.
This Manual does not constitute an offer for sale of
any particular vehicle. Land Rover Dealers are not
agents of Land Rover and have no authority to bind
the manufacturer by any expressed or implied
undertaking or representation.
2
INTRODUCTION
GENERAL INFORMATION
CONTENTS
Page
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS
GENERAL PRECAUTIONS ...................................................................................... 1
Dangerous substances ............................................................................................. 1
Engine oils ................................................................................................................ 2
Health Protection Precautions .................................................................................. 2
Environmental Protection Precautions ...................................................................... 2
SAFETY INSTRUCTIONS ........................................................................................ 3
GENERAL FITTING INSTRUCTIONS ...................................................................... 4
BALL AND ROLLER BEARINGS .............................................................................. 6
OIL SEALS ............................................................................................................... 7
JOINTS AND JOINT FACES .................................................................................... 8
LOCKING DEVICES ................................................................................................. 8
SCREW THREADS .................................................................................................. 9
BOLT IDENTIFICATION ........................................................................................... 9
NUT IDENTIFICATION ........................................................................................... 10
FLEXIBLE HYDRAULIC PIPES AND HOSES ........................................................ 11
SERVICE TOOLS AND GARAGE EQUIPMENT .................................................... 12
DYNAMOMETER TESTING - NON ANTI-LOCK BRAKE VEHICLES .................... 12
DYNAMOMETER TESTING - VEHICLES WITH ANTI-LOCK BRAKES (ABS) ...... 13
FUEL HANDLING PRECAUTIONS
FUEL HANDLING PRECAUTIONS .......................................................................... 1
ELECTRICAL PRECAUTIONS
ELECTRICAL PRECAUTIONS ................................................................................. 1
SRS PRECAUTIONS
SUPPLEMENTARY RESTRAINT SYSTEM PRECAUTIONS .................................. 1
COMPONENT REPLACEMENT POLICY ................................................................ 9
AIR CONDITIONING PRECAUTIONS
AIR CONDITIONING SYSTEM PRECAUTIONS ......................................................
REMEDIAL ACTIONS ...............................................................................................
SERVICE PRECAUTIONS .......................................................................................
PRECAUTIONS FOR REFRIGERANT RECOVERY, RECYCLING AND
RECHARGING ..........................................................................................................
1
2
3
5
VEHICLE IDENTIFICATION NUMBER
VEHICLE IDENTIFICATION NUMBER .................................................................... 1
IDENTIFICATION NUMBER LOCATIONS ............................................................... 2
GENERAL INFORMATION
GENERAL PRECAUTIONS
Synthetic rubber
Dangerous substances
WARNING: Many ’O’ rings, seals, hoses,
flexible pipes and other similar items
which appear to be natural rubber, are in
fact, made of synthetic materials called
Fluoroelastomers.
Under normal operating conditions this material
is safe and does not present a health hazard.
However, if the material is damaged by fire or
excessive heating, it can break down and
produce highly corrosive Hydrofluoric acid
which can cause serious burns on contact with
skin.
WARNING: Many liquids and other
substances used in motor vehicles are
poisonous and should not be consumed
under any circumstances.
As far as possible, try to prevent skin contact
with any potentially harmful materials.
Substances to be treated with particular caution
include (but is not limited to): acid, anti-freeze,
asbestos, brake fluid, fuel, windscreen washer
additives, lubricants, refrigerant and various
adhesives.
Always read the instructions printed on labels or
stamped on components carefully.
Such instructions should be strictly complied
with; they are included to ensure your health and
personal safety is not compromised through the
incorrect use of the materials to which they
relate.
If skin contact does occur:
• Remove any contaminated clothing immediately.
• Irrigate effected area of skin with a copious
amount of cold water or limewater for 15 to 60
minutes.
• Obtain medical assistance immediately
Should any material be in a burnt or over-heated
condition, handle with extreme caution and wear
protective clothing (seamless industrial gloves,
protective apron etc.).
Decontaminate and dispose of gloves immediately
after use.
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS
1
GENERAL INFORMATION
Engine oils
• Do not use petrol, kerosene, diesel fuel, gas,
oil, thinners or solvents for cleaning skin.
WARNING: Prolonged and repeated
contact with mineral oil can result in the
removal of natural fats from the skin; this
may cause dryness, irritation and dermatitis.
• If skin disorders develop, obtain medical
advice without delay.
In particular, used engine oil contains potentially
harmful carcinogenic contaminants. Adequate
means of skin protection (barrier creams etc.)
and washing facilities must be provided.
• Wear eye protection (e.g. goggles or face
shield) if there is a risk of eye contamination.
Eye wash facilities should be provided in the
close vicinity of the work area.
Avoid excessive skin contact with used engine
oils and always adhere to the following health
protection recommendations:
Environmental Protection Precautions
Health Protection Precautions
• Avoid prolonged and repeated contact with
oils, particularly used engine oils.
• Wear protective clothing, including
impervious gloves where practicable.
• Do not put oily rags in pockets.
• Avoid contaminating clothes (particularly
underpants) with oil.
• Overalls must be cleaned regularly. Discard
heavily soiled clothing and oil impregnated
footwear.
• First aid treatment should be obtained
immediately for open cuts and wounds.
• Where practicable, degrease components
prior to handling.
It is illegal to pour used oil on to the ground, down
sewers or drains, or into water courses.
Burning of used engine oil in small space heaters or
boilers should only be considered for units of
approved design and in compliance with the
equipment manufacturer’s recommendations. The
heating system must meet the regulatory standards
of HMIP for small burners of less than 0.4 MW. If in
doubt check with the appropriate local authority
and/or manufacturer of the approved appliance.
Dispose of used oil and filters through authorised
waste disposal contractors and licensed waste
disposal sites, or through the waste oil reclamation
trade. If in doubt, contact the Local Authority for
advice on disposal facilities.
• Use barrier creams: apply before each work
period to help removal of engine oil from the
skin.
• Wash with soap and water to ensure all oil is
removed (propriety skin cleansers and nail
brushes will help).
• Use moisturisers after cleaning; preparations
containing lanolin help replace the skin’s
natural oils which have been removed.
2
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS
GENERAL INFORMATION
Precautions against damage
SAFETY INSTRUCTIONS
CAUTION: Always fit wing and seat covers
before commencing work. Avoid spilling
brake fluid or battery acid on paintwork;
immediately wash off with water if this occurs.
Whenever possible, use a lift or pit when working
beneath vehicle, in preference to jacking. Chock
wheels as well as applying parking brake.
Jacking
CAUTION: Disconnect the battery earth
lead before starting work, see
ELECTRICAL PRECAUTIONS.
CAUTION: Always use the recommended
service tool or a satisfactory equivalent
where specified.
The recommended jacking points are shown in the
LIFTING AND TOWING sub-section of the
INFORMATION section.
Always ensure that any lifting apparatus has
sufficient load capacity for the weight to be lifted.
Ensure the vehicle is standing on level ground prior
to lifting or jacking.
Apply the handbrake and chock the wheels.
CAUTION: Protect exposed bearing
surfaces, sealing surfaces and screw
threads from damage.
WARNING: Never rely on a jack as the sole
means of support when working beneath
the vehicle. Use additional safety supports
beneath the vehicle.
Do not leave tools, lifting equipment, spilt oil,
etc., around or on the work bench area. Always
keep a clean and tidy work area.
Brake shoes and pads
WARNING: Always fit the correct grade
and specification of brake linings.
When renewing brake pads and brake
shoes always replace as complete axle sets
only.
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS
3
GENERAL INFORMATION
Brake hydraulics
WARNING: It is imperative that the correct
brake fittings are used and that threads of
components are compatible.
• Always use two spanners when loosening or
tightening brake pipe or hose connections.
• Ensure that hoses run in a natural curve and are
not kinked or twisted.
• Fit brake pipes securely in their retaining clips
and ensure that the pipe run cannot contact a
potential chafing point.
• Containers used for hydraulic fluid must be kept
absolutely clean.
• Do not store hydraulic fluid in an unsealed
container, it will absorb water and in this
condition would be dangerous to use due to a
lowering of its boiling point.
• Do not allow hydraulic fluid to be contaminated
with mineral oil, or use a container which has
previously contained mineral oil.
GENERAL FITTING INSTRUCTIONS
Component removal
Whenever possible, clean components and
surrounding area before removal.
• Blank off openings exposed by component
removal.
• Immediately seal fuel, oil or hydraulic lines when
apertures are exposed; use plastic caps or plugs
to prevent loss of fluid and ingress of dirt.
• Close open ends of oilways exposed by
component removal with tapered hardwood plugs
or conspicuous plastic plugs.
• Immediately a component is removed, place it in
a suitable container; use a separate container for
each component and its associated parts.
• Clean bench and provide marking materials,
labels, containers and locking wire before
dismantling a component.
• Do not re-use fluid from the system.
• Always use clean brake fluid or a recommended
alternative to clean hydraulic components.
• Fit a blanking cap to an hydraulic union and a
plug to its socket after removal to prevent the
ingress of dirt.
CAUTION: Absolute cleanliness must be
observed with hydraulic components.
Engine coolant caps and plugs
WARNING: Extreme care is necessary
when removing engine coolant caps and
plugs when the engine is hot and
especially if it is overheated. To avoid the
possibility of scalding allow the engine to cool
before attempting coolant cap or plug removal.
4
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS
GENERAL INFORMATION
Dismantling
Cleaning components
Observe scrupulous cleanliness when dismantling
components, particularly when brake, fuel or
hydraulic system parts are being worked on.
Always use the recommended cleaning agent or
equivalent.
CAUTION: A particle of dirt or a cloth
fragment could cause a serious
malfunction if trapped in these systems.
• Blow out all tapped holes, crevices, oilways and
fluid passages with an air line. Ensure that any
O-rings used for sealing are correctly replaced or
renewed, if disturbed during the process.
• Use marking ink to identify mating parts and
ensure correct reassembly. Do not use a centre
punch or scriber to mark parts, they could initiate
cracks or distortion in marked components.
• Wire together mating parts where necessary to
prevent accidental interchange (e.g. roller
bearing components).
• Wire labels on to all parts which are to be
renewed, and to parts requiring further inspection
before being passed for reassembly; place these
parts in separate containers from those
containing parts for rebuild.
• Do not discard a part due for renewal until after
comparing it with a new part, to ensure that its
correct replacement has been obtained.
WARNING: Ensure that adequate
ventilation is provided when volatile
degreasing agents are being used.
CAUTION: Do not use degreasing
equipment for components containing
items which could be damaged by the use
of this process.
General Inspection
• Never inspect a component for wear or
dimensional check unless it is absolutely clean; a
slight smear of grease can conceal an incipient
failure.
• When a component is to be checked
dimensionally against recommended values, use
the appropriate measuring equipment (surface
plates, micrometers, dial guages etc.). Ensure
the measuring equipment is calibrated and in
good serviceable condition.
• Reject a component if its dimensions are outside
the specified tolerances, or if it appears to be
damaged. A part may be refitted if its critcal
dimension is exactly to its tolerance limit and it
appers to be in satisfactory condition.
• Use ’Plastigauge’ 12 Type PG-1 for checking
bearing surface clearances.
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS
5
GENERAL INFORMATION
BALL AND ROLLER BEARINGS
CAUTION: Never refit a ball or roller
bearing without first ensuring that it is in a
fully serviceable condition.
CAUTION: When hub bearings are
removed or displaced, NEW bearings must
be fitted; do not attempt to refit the old
hub bearings.
• Remove all traces of lubricant from bearing
under inspection by cleaning with a suitable
degreaser; maintain absolute cleanliness
throughout operations.
• Conduct a visual inspection for markings on
rolling elements, raceways, outer surface of outer
rings or inner surface of inner rings. Reject any
bearings found to be marked, since marking in
these areas indicates onset of wear.
• Hold inner race of bearing between finger and
thumb of one hand and spin outer race to check
that it revolves absolutely smoothly. Repeat,
holding outer race and spinning inner race.
• Rotate outer ring gently with a reciprocating
motion, while holding inner ring; feel for any
check or obstruction to rotation. Reject bearing if
action is not perfectly smooth.
• When fitting a bearing to a shaft, only apply force
to the inner ring of the bearing. When fitting a
bearing into a housing, only apply force to the
outer ring of the bearing.
• In the case of grease lubricated bearings (e.g.
hub bearings) fill the space between bearing and
outer seal with the recommended grade of
grease before fitting seal.
• Always mark components of separable bearings
(e.g. taper roller bearings) when dismantling, to
ensure correct reassembly. Never fit new rollers
in a used outer ring; always fit a complete new
bearing assembly.
• Lubricate bearing with generous amounts of
lubricant appropriate to installation.
• Inspect shaft and bearing housing for
discoloration or other markings which indicate
movement between bearing and seatings.
• Ensure that shaft and housing are clean and free
from burrs before fitting bearing.
• If one bearing of a pair shows an imperfection, it
is advisable to replace both with new bearings;
an exception could be if the faulty bearing had
covered a low mileage, and it can be established
that damage is confined to only one bearing.
6
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS
GENERAL INFORMATION
OIL SEALS
Always renew oil seals which have been removed
from their working location (whether as an individual
component or as part of an assembly).
• Carefully examine seal before fitting to ensure
that it is clean and undamaged.
• Grease outside diameter of seal, place square to
housing recess and press into position using
great care, and if possible a ’bell piece’ to ensure
that seal is not tilted. Never let weight of
unsupported shaft rest in seal.
NOTE: In some cases it may be preferable
to fit seal to housing before fitting to shaft.
• Ensure the surface on which the new seal is to
run is free of burrs or scratches. Renew the
component if the original sealing surface cannot
be completely restored.
• Protect the seal from any surface which it has to
pass when being fitted. Use a protective sleeve
or tape to cover the relevant surface.
• Lubricate the sealing lips with a recommended
lubricant before use to prevent damage during
initial use. On dual lipped seals, smear the area
between the lips with grease.
• If a seal spring is provided, ensure that it is fitted
correctly.
• Place lip of seal towards fluid to be sealed and
slide into position on shaft. Use fitting sleeve
where possible to protect sealing lip from
damage by sharp corners, threads or splines. If a
fitting sleeve is not available, use plastic tube or
tape to prevent damage to the sealing lip.
• Use the recommended service tool to fit an oil
seal. If the correct service tool is not available,
use a suitable tube approximately 0.4 mm (0.015
in.) smaller than the outside diameter of the seal.
Use an hammer VERY GENTLY on drift if a
suitable press is not available.
• Press or drift the seal in to the depth of its
housing with the sealing lip facing the lubricant to
be retained if the housing is shouldered, or flush
with the face of the housing where no shoulder is
provided. Ensure that the seal does not enter the
housing in a tilted position.
NOTE: Most cases of failure or leakage of
oil seals are due to poor fitting, which can
result in damage to both seals and sealing
surfaces. NEVER use a seal which has been
improperly stored or handled, such as hung on a
hook or nail.
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS
7
GENERAL INFORMATION
JOINTS AND JOINT FACES
LOCKING DEVICES
Fit joints dry unless specified otherwise.
Tab Washers
• Always use the correct gaskets as specified.
• When jointing compound is used, apply in a thin
uniform film to metal surfaces; take care to
prevent jointing compound from entering oilways,
pipes or blind tapped holes.
• If gaskets and/or jointing compound is
recommended for use; remove all traces of old
jointing material prior to reassembly. Do not use
a tool which will damage the joint faces and
smooth out any scratches or burrs using an oil
stone. Do not allow dirt or jointing material to
enter any tapped holes or enclosed parts.
• Prior to reassembly, blow through any pipes,
channels or crevices with compressed air.
CAUTION: Always release locking tabs
and fit new locking washers, do not re-use
locking tabs. Ensure the new tab washer
is the same design as that replaced.
Locking Nuts
Always use a backing spanner when slackening or
tightening brake and fuel pipe unions.
Roll Pins
Always fit new roll pins of an interference fit in the
hole.
Circlips
Always fit new circlips of the correct size for the
groove.
Locking wire
Always fit locking wire of the correct type. Arrange
wire so that its tension tends to tighten the bolt
heads or nuts to which it is fitted.
Keys and Keyways
• Remove burrs from edges of keyways with a fine
file and clean thoroughly before attempting to
refit key.
• Clean and inspect key closely; keys are suitable
for refitting only if indistinguishable from new, as
any indentation may indicate the onset of wear.
Fitting a split pin
CAUTION: Always fit new split-pins of the
correct size for the hole in the bolt or stud.
Do not slacken nut to enter split-pin.
8
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS
GENERAL INFORMATION
SCREW THREADS
BOLT IDENTIFICATION
Metric threads to ISO standards are used.
Damaged nuts, bolts and screws must always be
discarded.
NOTE: Cleaning damaged threads with a
die or tap impairs the strength and
closeness of fit of the threads and is not
recommended.
CAUTION: Always ensure that
replacement bolts are at least equal in
strength to those replaced.
Castellated nuts must not be slackened to accept a
split-pin, except in recommended cases when this
forms part of an adjustment.
Do not allow oil or grease to enter blind threaded
holes. The hydraulic action on screwing in the bolt or
stud could split the housing.
Always tighten a nut or bolt to the recommended
torque figure. Damaged or corroded threads can
affect the torque reading.
An ISO metric bolt or screw made of steel and larger
than 6 mm in diameter can be identified by either of
the symbols ISO M or M embossed or indented on
top of the bolt head.
In addition to marks identifying the manufacturer, the
top of the bolt head is also marked with symbols
indicating the strength grade, e.g. 8.8; 10.9; 12.9;
14.9. As an alternative, some bolts and screws have
the M and strength grade symbol stamped on the
flats of the hexagon.
Encapsulated bolts and screws
To check or re-tighten a bolt or screw to a specified
torque figure, first slacken a quarter of a turn, then
retighten to the correct torque figure.
Oil thread lightly before tightening to ensure a free
running thread, except in the case of threads treated
with sealant / lubricant, and self-locking nuts.
Encapsulated bolts and screws have a
micro-encapsulated locking agent pre-applied to the
thread. They are identified by a coloured section
which extends 360° around the thread. The locking
agent is released and activated by the assembly
process and is then chemically cured to provide the
locking action.
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS
9
GENERAL INFORMATION
Unless a specific repair procedure states otherwise,
encapsulated bolts may be re-used providing the
threads are undamaged and the following procedure
is adopted:
NUT IDENTIFICATION
• Remove loose adhesive from the bolt and
housing threads.
• Ensure threads are clean and free of oil and
grease.
• Apply an approved locking agent.
NOTE: Always fit a new encapsulated bolt
when replacing; or if not available, a bolt
of equivalent specification treated with an
approved locking agent.
Self-locking bolts and screws
A nut with an ISO metric thread is marked on one
face or on one of the flats of the hexagon with the
strength grade symbol 8, 12, or 14. Some nuts with
a strength grade 4, 5 or 6 are also marked and some
have the metric symbol M on the flat opposite the
strength grade marking.
Self-locking bolts and screws, i.e. nylon patched or
trilobular thread can be re-used providing resistance
can be felt when the locking portion enters the
female thread.
Nylon patched bolts and screws have a locking
agent pre-applied to the threads. They are identified
by the presence of a coloured section of thread
which extends for up to 180° around the thread.
A clock face system is sometimes used as an
alternative method of indicating the strength grade.
The external chamfers or a face of the nut is marked
in a position relative to the appropriate hour mark on
a clock face to indicate the strength grade.
A dot is used to locate the 12 o’clock position and a
dash to indicate the strength grade. If the grade is
above 12, two dots identify the 12 o’clock position.
Trilobular bolts (i.e. Powerlok) have a special thread
form which creates a slight interference in the
tapped hole or threads of the nut into which it is
screwed.
CAUTION: DO NOT re-use self-locking
fasteners in critical locations (e.g. engine
bearings, flywheel). Always use the
correct replacement self-locking nut, bolt or
screw.
CAUTION: DO NOT fit non self-locking
fasteners in applications where a
self-locking nut, bolt or screw is specified.
10
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS
GENERAL INFORMATION
Self-locking nuts
FLEXIBLE HYDRAULIC PIPES AND HOSES
WARNING: Do not disconnect any pipes in
an air conditioning refrigeration system
unless trained and instructed to do so. A
refrigerant is used which can cause blindness if
allowed to contact eyes.
• Before removing any brake or power steering
hose, clean end fittings and area surrounding
them as thoroughly as possible.
Self-locking nuts, i.e. nylon insert or deferred thread
nuts can be re-used providing resistance can be felt
when the locking portion of the nut passes over the
thread of the bolt or stud.
CAUTION: Do not apply heat in an attempt
to free deferred thread nuts or fittings; as
well as causing damage to protective
coatings, there is a risk of damage to electronic
equipment and brake linings from stray heat.
When tightening a slotted or castellated nut, never
loosen it to insert a split pin or locking wire except
where recommended as part of an adjustment. If
difficulty is experienced, alternative washers or nuts
should be selected, or the washer thickness
reduced.
Where self-locking nuts have been removed, it is
advisable to replace them with new ones of the
same type.
• Obtain appropriate plugs or caps before
detaching hose end fittings, so that the ports can
be immediately covered to prevent the ingress of
dirt.
• Clean hose externally and blow through with
airline. Examine carefully for cracks, separation
of plies, security of end fittings and external
damage. Reject any faulty hoses.
• When refitting a hose, ensure that no
unnecessary bends are introduced, and that
hose is not twisted before or during tightening of
union nuts.
• Fit a cap to seal a hydraulic union and a plug to
its socket after removal to prevent ingress of dirt.
• Absolute cleanliness must be observed with
hydraulic components at all times.
• After any work on hydraulic systems, carefully
inspect for leaks underneath the vehicle while a
second operator applies maximum brake
pressure to the brakes (engine running) and
operates the steering.
NOTE: Where bearing pre-load is involved
nuts should be tightened in accordance
with special instructions.
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS
11
GENERAL INFORMATION
Fuel System Hoses
CAUTION: All fuel hoses are made up of
two laminations, an armoured rubber
outer sleeve and an inner viton core. If any
of the fuel system hoses have been
disconnected, it is imperative that the internal
bore is inspected to ensure that the viton lining
has not become separated from the armoured
outer sleeve. A new hose must be fitted if
separation is evident.
DYNAMOMETER TESTING - NON ANTI-LOCK
BRAKE VEHICLES
The front and rear wheels cannot be driven
independently due to the viscous coupling. This
eliminates the need for differential lock by
progressively applying more torque to the rear
wheels if the front wheels start to slip.
WARNING: DO NOT attempt to drive
individual wheels with vehicle supported
on floor jacks or stands.
Four wheel dynamometers
Provided that front and rear dynamometer rollers are
rotating at identical speeds and that normal
workshop safety standards are applied, there is no
speed restriction during testing, except any that may
apply to the tyres.
Two wheel dynamometers
IMPORTANT: Use a four wheel dynamometer for
brake testing if possible.
If brake testing on a single rig is necessary, the
following procedures should be ensured:
• propeller shaft to the rear axle is removed
SERVICE TOOLS AND GARAGE EQUIPMENT
Special service tools have been developed to
facilitate removal, dismantling and assembly of
mechanical components in a cost effective and time
efficient manner. The use of such special tools also
helps prevent the potential for damage to
components.
Some operations described in this Manual cannot be
carried out properly without the aid of the relevant
service tools.
• neutral selected in gearbox
• hill descent control not selected.
When checking brakes, run engine at idle speed to
maintain servo vacuum.
Where specific garage equipment is required for
diagnosis and repair, reference should be made to
the Service Tools and Equipment Programme where
details of the equipment recommended by Land
Rover Service may be found.
12
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS
GENERAL INFORMATION
DYNAMOMETER TESTING - VEHICLES WITH
ANTI-LOCK BRAKES (ABS)
WARNING: Do not attempt to test ABS
function on a dynamometer
Four wheel dynamometers
NOTE: Before testing a vehicle on a four
wheel dynamometer disconnect the ABS
valve relay. The ABS function will not
work, the ABS warning light will illuminate.
Normal braking will be available.
Provided that front and rear rollers are rotating at
identical speeds and that normal workshop safety
standards are applied, there is no speed restriction
during testing except any that may apply to the
tyres.
Two wheel dynamometers
IMPORTANT: Use a four wheel dynamometer for
brake testing if possible.
NOTE: ABS will not function on a two
wheel dynamometer. The ABS light will
illuminate during testing. Normal braking
will be available.
If brake testing on a single rig is necessary, the
following procedures should be ensured:
• propeller shaft to the rear axle is removed
• neutral selected in gearbox
• hill descent control not selected
If checking engine performance, ensure hill descent
control is not selected and drive shaft to rear
differential is disconnected.
GENERAL PRECAUTIONS AND FITTING INSTRUCTIONS
13
GENERAL INFORMATION
FUEL HANDLING PRECAUTIONS
Fuel tank drainage
General
WARNING: Petrol/gasoline must not be
extracted or drained from any vehicle
whilst it is standing over a pit.
Draining or extraction of petrol/gasoline from a
vehicle fuel tank must be carried out in a well
ventilated area.
The receptacle used to contain the
petrol/gasoline must be more than adequate for
the full amount of fuel to be extracted or drained.
The receptacle should be clearly marked with its
contents, and placed in a safe storage area
which meets the requirements of local authority
regulations.
The following information provides basic precautions
which must be observed if petrol (gasoline) is to be
handled safely. It also outlines other areas of risk
which must not be ignored. This information is
issued for basic guidance only, if in doubt consult
your local Fire Officer.
Petrol - Gasoline
Petrol/gasoline vapour is highly flammable and in
confined spaces is also explosive and toxic.
When petrol/gasoline evaporates it produces 150
times its own volume in vapour, which when diluted
with air becomes a readily ignitable mixture. The
vapour is heavier than air and will always fall to the
lowest level. The vapour can be easily distributed
throughout a workshop by air currents;
consequently, even a small spillage of
petrol/gasoline is potentially very dangerous.
WARNING: Do not use a pit when
removing fuel system components.
Always have a fire extinguisher containing FOAM,
CO2, GAS or POWDER close at hand when
handling or draining fuel or when dismantling fuel
systems. Fire extinguishers should also be located
in areas where fuel containers are stored.
Always disconnect the vehicle battery before
carrying out dismantling or draining work on a fuel
system.
WARNING: When petrol/gasoline has been
extracted or drained from a fuel tank the
precautions governing naked lights and
ignition sources should be maintained.
Fuel tank removal
When the fuel line is secured to the fuel tank outlet
by a spring steel clip, the clip must be released
before the fuel line is disconnected or the fuel tank is
removed. This procedure will avoid the possibility of
residual petrol fumes in the fuel tank being ignited
when the clip is released.
As an added precaution fuel tanks should have a
’PETROL (GASOLINE) VAPOUR’ warning label
attached to them as soon as they are removed from
the vehicle.
Whenever petrol/gasoline is being handled, drained
or stored, or when fuel systems are being
dismantled, all forms of ignition must be
extinguished or removed; any leadlamps must be
flameproof and kept clear of spillage.
WARNING: No one should be permitted to
repair components associated with
petrol/gasoline without first having
specialist training.
FUEL HANDLING PRECAUTIONS
1
GENERAL INFORMATION
Fuel tank repairs
Under no circumstances should a repair to any fuel
tank be carried out without first rendering the tank
SAFE, by using one of the following methods:
a. STEAMING: With the filler cap and tank unit
removed, empty the tank. Steam the tank for at least
two hours with low pressure steam. Position the tank
so that condensation can drain away freely, ensuring
that any sediment and sludge not volatized by the
steam is washed out during the steaming process.
b. BOILING: With the filler cap and tank unit
removed, empty the tank. Immerse the tank
completely in boiling water containing an effective
alkaline degreasing agent or a detergent, with the
water filling and also surrounding, the tank for at
least two hours.
After steaming or boiling, a signed and dated label to
this effect should be attached to the tank.
Body repairs
WARNING: When body repairs involve the
use of heat, all fuel pipes which run in the
vicinity of the repair area must be
removed, and the tank outlet plugged, BEFORE
HEAT IS APPLIED. If the repair is in the vicinity
of the fuel tank, the tank must be removed.
Plastic fuel pipes are particularly susceptible to heat,
even at relatively low temperature, and can be
melted by heat conducted from some distance away.
Fuel lines or tanks must not be removed whilst the
vehicle is over an inspection pit.
2
FUEL HANDLING PRECAUTIONS
GENERAL INFORMATION
ELECTRICAL PRECAUTIONS
Ensure that any protection (covers, insulation etc.) is
replaced if disturbed.
General
The following guidelines are intended to ensure the
safety of the operator whilst preventing damage to
the electrical and electronic components fitted to the
vehicle. Where necessary, specific precautions are
detailed in the relevant sections of this Manual which
should be referred to prior to commencing repair
operations.
Equipment
Prior to commencing any test procedure on the
vehicle ensure that the relevant test equipment is
working correctly and any harness or connectors are
in good condition. It is particularly important to
ensure the propriety of the lead and plugs of mains
operated equipment.
Having confirmed a component to be faulty:
• switch off the ignition and disconnect the battery.
• remove the component and support the
disconnected harness.
• when replacing the component keep oily hands
away from electrical connection areas and push
connectors home until any locking tabs fully
engage.
Battery disconnection
Before disconnecting the battery, disable the alarm
system and switch off all electrical equipment. If the
radio is to be serviced, ensure the security code has
been deactivated.
Polarity
Never reverse connect the vehicle battery and
always ensure the correct polarity when connecting
test equipment.
High Voltage Circuits
Whenever disconnecting live ht-circuits always use
insulated pliers and never allow the open end of the
ht-lead to contact other components - particularly
ECU’s.
CAUTION: To prevent damage to electrical
components ALWAYS disconnect the
battery when working on the vehicle
electrical system. The earth lead must be
disconnected first and reconnected last.
Always ensure that battery leads are routed
correctly and are not close to any potential
chafing points.
Battery charging
CAUTION: Exercise caution when
measuring the voltage on the coil
terminals while the engine is running, high
voltage spikes can occur on these terminals.
Connectors and Harnesses
Only recharge the battery with it removed from the
vehicle.
Always ensure any battery charging area is well
ventilated and that every precaution is taken to avoid
naked flames and sparks.
The engine compartment of a vehicle is a
particularly hostile environment for electrical
components and connectors. Always ensure
electrically related items are dry and oil free before
disconnecting and connecting test equipment.
CAUTION: Ensure disconnected
multiplugs and sensors are protected from
being contaminated with oil, coolant or
other solutions. Contamination could impair
performance or result in catastrophic failure.
Never force connectors apart using tools to prise
apart or by pulling on the wiring harness.
Always ensure locking tabs are disengaged before
disconnection, and match orientation to enable
correct reconnection.
ELECTRICAL PRECAUTIONS
1
GENERAL INFORMATION
Ignition system safety precautions
Grease for electrical connectors
WARNING: Before commencing work on
an ignition system, all high tension
terminals, adapters and diagnostic
equipment should be inspected.
Some under bonnet and under body connectors may
be protected against corrosion by the application of
a special grease during vehicle production. Should
connectors be disturbed in service, or repaired or
replaced, additional grease should be re-applied:
Part No. BAU 5811, available in 150 gm tubs.
Ensure all cables, connectors and components
are adequately insulated and shielded.
Accidental contact with a poorly insulated
ignition system component could result in a
severe electrical shock.
Wearers of surgically implanted pacemaker
devices should not be in close proximity to
ignition circuits or diagnostic equipment.
Disciplines
Switch off the ignition prior to making any connection
or disconnection in the system to prevent electrical
surges caused by disconnecting ’live’ connections
damaging electronic components.
Ensure hands and work surfaces are clean and free
of grease, swarf, etc. Grease collects dirt which can
cause electrical tracking (short-circuits) or
high-resistance contacts.
When handling printed circuit boards, treat with care
and hold by the edges only; note that some
electronic components are susceptible to body
static.
Connectors should never be subjected to forced
removal or refit, especially inter-board connectors.
Damaged contacts can cause short-circuit and
open-circuit fault conditions.
Prior to commencing test, and periodically during a
test, touch a good vehicle body earth to discharge
static charge. Some electronic components are
vulnerable to the static electricity that may be
generated by the operator.
2
ELECTRICAL PRECAUTIONS
NOTE: The use of greases other than BAU
5811 must be avoided as they can migrate
into relays, switches etc. contaminating
the contacts and leading to intermittent
operation or failure.
GENERAL INFORMATION
SUPPLEMENTARY RESTRAINT SYSTEM
PRECAUTIONS
General
The Supplementary Restraint System (SRS)
provides active protection for vehicle occupants in
the event of a serious collision. The system
components include airbags and pre-tensioner
seatbelts which are automatically deployed when a
severe frontal crash condition is detected.
WARNING: Do not use rear facing child
seats in the front passenger seat if the
vehicle is fitted with a passenger airbag.
In order to assure system integrity, it is essential that
the SRS system is regularly checked and
maintained so that it is ready for operation in the
event of an accident.
It should be noted that these precautions are not
restricted to operations performed when servicing
the SRS system, the same care should be exercised
when working on ancilliary systems and components
located in the vicinity of SRS components; these
include but are not limited to steering system
(steering wheel airbag), body and trim components
(passenger airbag and seat belt pre-tensioners) and
electrical system components (SRS harnesses etc.).
WARNING: Always follow the Safety
Guidelines and correct procedures for
working on SRS components.
NOTE: Airbag modules should be replaced
every ten years.
The SRS system contains components which could
be potentially hazardous to the service engineer if
not serviced and handled correctly. The following
guidelines are intended to alert the service engineer
to potential sources of danger and emphasise the
importance of ensuring integrity of the SRS
components fitted to the vehicle.
Where necessary, additional specific precautions
are detailed in the relevant sections of this Manual
which should be referred to prior to commencing
repair operations.
SRS PRECAUTIONS
1
GENERAL INFORMATION
Preliminary Procedures
WARNING: Always remove the ignition
key from the starter switch, disconnect the
vehicle battery and wait 10 minutes before
and commencing work on the SRS system.
The SRS system uses energy reserve capacitors
that keep the system active in the event of electrical
supply failure under crash conditions. It is necessary
to allow the capacitor sufficient time to discharge (10
minutes) in order to avoid the risk of accidental
deployment.
CAUTION: Always disconnect both battery
leads before beginning work on the SRS
system. Disconnect the negative battery
cable first. Never reverse connect the vehicle
battery and always ensure the correct polarity
when connecting test equipment.
CAUTION: Always disconnect the vehicle
battery before carrying out any electric
welding on a vehicle fitted with an SRS
system.
CAUTION: Do not expose an airbag
module or seat belt pre-tensioner to heat
exceeding 85°C (185°F).
WARNING: Carefully inspect any SRS
component before installation. Do not
install any SRS component that shows
signs of damage such as dents, cracks or
deformity.
CAUTION: Ensure SRS components are
not contaminated with oil, grease,
detergent or water.
CAUTION: Prior to commencing any test
procedure on the vehicle, ensure that only
test equipment approved for the purpose
is being utilised and that it is in good working
order. Ensure any harness or connectors are in
good condition and any warning lamps are
functional.
2
SRS PRECAUTIONS
WARNING: Never use multimeters or other
general purpose test equipment on SRS
system components or connectors.
System faults should be diagnosed through the
use of recommended test equipment only.
GENERAL INFORMATION
Component handling
Storage
WARNING: Always store airbag modules
with the cover face up. If the airbag
module is stored face down, accidental
deployment could propel the unit with enough
force to cause serious injury.
WARNING: The SRS components are
sensitive and potentially hazardous if not
handled correctly; always comply with the
following handling precautions:
• Never drop an SRS component. The airbag
diagnostic control unit is a particularly shock
sensitive device and must be handled with
extreme care. Airbag modules and seat belt
pre-tensioner units could deploy if subjected
to a strong shock.
• Never wrap your arms around an airbag
module. If an airbag module has to be carried,
hold it by the cover, with the cover uppermost
and the base away from your body.
• Never transport airbag modules or seat belt
pre-tensioners in the cabin of a vehicle.
Always use the luggage compartment of the
vehicle for carrying airbag modules and seat
belt pre-tensioner units.
WARNING: Airbag modules and seat belt
pre-tensioners are classed as explosive
devices. For overnight and longer term
storage, they must be stored in a secure steel
cabinet which has been approved as suitable for
the purpose and has been registered by the local
authority.
CAUTION: For the temporary storage of an
airbag module or seat belt pre-tensioner
during service, place in a designated
storage area. If there is no designated storage
area available, store in the luggage compartment
of the vehicle and inform the workshop
supervisor.
CAUTION: Always observe the following
precautions when temporarily storing an
airbag module:
• Ensure the cover is facing upwards and the
luggage compartment is secured.
• Always keep components cool, dry and free
from contamination.
• Do not allow anything to rest on the airbag
module.
• Store any removed airbag assembly on a
secure flat surface away from electrical
equipment and heat sources (exceeding 85°C
(185°F).
SRS PRECAUTIONS
3
GENERAL INFORMATION
Installation and Testing Precautions
WARNING: The integrity of SRS system
components are critical for safety
reasons. Ensure the following precautions
are always adhered to:
• Never install used SRS components from
another vehicle or attempt to repair an SRS
component.
• When repairing an SRS system only use
genuine new parts.
• Never apply electrical power to an SRS
component unless instructed to do so as part
of an approved test procedure.
• Special Torx bolts are necessary for installing
the airbag assembly - do not use other bolts.
Ensure bolts are tightened to the specified
torque (refer to SRS section).
• Ensure that SRS component fixings are
correctly positioned and torqued during
service and repair.
• Always use new fixings when replacing an
SRS component.
• Ensure the SRS Electronic Control Unit (ECU)
is always installed correctly. There must not
be any gap between the ECU and the bracket
to which it is mounted. An incorrectly
mounted unit could cause the system to
malfunction.
4
SRS PRECAUTIONS
• The SRS Electronic Control Unit is a
non-serviceable component and no attempt
should be made to repair or modify the unit.
• Do not try to disassemble the airbag
assembly. It has no serviceable parts. Once
an airbag has been deployed, it cannot be
repaired or reused.
• If you suspect an airbag assembly could be
defective, install a new unit and dispose of
the old unit. Manually deploy the old unit
before disposal. See RESTRAINT SYSTEMS,
Precautions.
WARNING: When removing, testing or
installing an airbag module do not lean
directly over it.
GENERAL INFORMATION
SRS Harnesses and Connectors
CAUTION: Always observe the following
precautions with regards to SRS systems:
• ever attempt to modify, splice or repair
N
SRS wiring.
CAUTION: Ensure all airbag harness
connectors are mated correctly and
securely fastened. Do not leave the
connectors hanging loose.
• Do not allow SRS components to hang from
their harnesses.
• Never install electronic equipment (such as a
mobile telephone, two way radio or in-car
entertainment system) in such a way that it
could generate electrical interference in the
airbag harness. Seek specialist advice when
installing such equipment.
NOTE: SRS wiring can be identified by a
special yellow outer protective covering
(black with yellow stripe protective
coverings are sometimes used).
CAUTION: Always ensure SRS harnesses
are routed correctly. Be careful to avoid
trapping or pinching the SRS harness.
Route the harness to avoid possible points of
chafing.
• Always use specified earth fixings tightened
to the correct torque. Poor earthing can
cause intermittent problems that are difficult
to diagnose.
SRS PRECAUTIONS
5
GENERAL INFORMATION
Rotary Coupler
Warning Labels
CAUTION: Always follow the procedure for
fitting and checking the rotary coupler as
instructed in the SRS section of this
manual. Comply with all safety and installation
procedures to ensure the system functions
correctly. Observe the following precautions:
Warning symbols are displayed at various positions
in the vehicle (either in a suitable prominent position
such as driver and passenger side glass, or
attached to the component itself) to indicateSRS
items which must be treated with particular care.
These include:
• Do not install a rotary coupler if it is
suspected to be defective.
A - The need for caution when working in close
proximity to SRS components.
• Do not attempt to service, modify or repair a
rotary coupler.
B - Refer to the publication where the procedures,
instructions and advice can be found (usually
Workshop Manual or Owner’s Handbook) for
working on the SRS system.
• Do not cut, splice or modify the wires
attached to yellow SRS connector and lead.
• Always ensure the rotary coupler connectors
are mated correctly and securely fastened.
C - Do not use rear facing child seats in the front
passenger seat if the vehicle is fitted with a
passenger airbag.
• Always ensure the battery is disconnected
before working on the rotary coupler.
• Always ensure the rotary coupler is removed
and installed in its centered position and with
the front road wheels in the straight ahead
position - refer to the SRS section of this
manual for the full correct removal and
installation procedure.
• If a new rotary coupler is being installed,
ensure the locking tab holding the coupler’s
rotational position is not broken; units with a
broken locking tab should not be used.
Driver and Passenger side windows
6
SRS PRECAUTIONS
GENERAL INFORMATION
NOTE: It is imperative that the appropriate
publication is read thoroughly prior to any
work being undertaken on the SRS
system.
End of Fascia
NOTE: Exact positions of SRS warning
labels may vary dependent on legislation
and market trends.
Refer to the Owner’s Handbook for additional
information regarding the SRS system.
Rotary coupler
Label warning the owner not to use rear facing child
seats in the front passenger seat in vehicles fitted
with a passenger side airbag.
A - Refer to the Workshop Manual for detailed
instructions.
B - Ensure wheels are in the straight ahead position
before removal and refitting.
C - LAND ROVER Part Number/Bar code - The
code must be recorded and quoted for ordering
purposes.
SRS PRECAUTIONS
7
GENERAL INFORMATION
Airbag and Pre-tensioner Deployment
WARNING: Only personnel who have
undergone the appropriate training should
undertake deployment of airbag and
pre-tensioner modules.
WARNING: A deployed airbag is very hot,
DO NOT return to a deployed airbag
module until at least 30 minutes have
elapsed since deployment.
WARNING: Deployment procedures and
precautions as detailed in this service
manual should be strictly adhered to. The
following precautions must be complied with:
• Only use deployment equipment approved for
the intended purpose.
• Before beginning deployment procedure,
ensure deployment tool functions properly by
performing the self test procedure detailed in
SRS section of this manual.
• Deployment of airbag / pre-tensioner modules
should be performed in a well ventilated area
which has been designated for the purpose.
• Ensure airbag / pre-tensioner modules are
not damaged or ruptured before attempting to
deploy.
• Notify the relevant authorities of intention to
deploy airbag and pre-tensioner units.
• When deploying airbag pre-tensioner units,
ensure that all personnel are at least 15
metres away from the deployment zone.
• Ensure deployment tool is connected
correctly, in compliance with the instructions
detailed in the SRS section of this manual. In
particular, ensure deployment tool is NOT
connected to battery supply before
connecting to airbag module connector.
• When deploying seat belt pre-tensioners,
ensure pre-tensioner unit is secured correctly
to seat.
• When removing deployed airbag modules
and pre-tensioner units, wear protective
clothing. Use gloves and seal deployed units
in a plastic bag.
• Following deployment of any component of
the SRS system within the vehicle, all SRS
components must be replaced. DO NOT
re-use or salvage any parts of the SRS
system.
• Do not lean over airbag module when
connecting deployment equipment.
8
SRS PRECAUTIONS
WARNING: If a vehicle is to be scrapped,
undeployed airbag modules and
pre-tensioner units must be manually
deployed. In this case airbags can be deployed
in the vehicle; before deployment, ensure the
airbag module is secure within its correct
mounting position.
CAUTION: Deployment of the driver side
airbag in the vehicle may damage the
steering wheel; if the vehicle is not being
scrapped, deploy the module outside of the
vehicle.
GENERAL INFORMATION
COMPONENT REPLACEMENT POLICY
IMPACTS WHICH DO NOT DEPLOY AIRBAGS
CAUTION: Check for structural damage in
the area of the impact, paying particular
attention to bumper armatures,
longitudinals, crash cans and bracketry.
IMPACTS WHICH DEPLOY AIRBAGS
CAUTION: Renew the following
components:
•
•
•
•
•
Airbag ECU.
Airbag module(s).
Facia harness.
Pretensioners.
Rotary coupler and link harness.
SRS PRECAUTIONS
9
GENERAL INFORMATION
AIR CONDITIONING SYSTEM PRECAUTIONS
General
The air conditioning system contains fluids and
components which could be potentially hazardous to
the service engineer or the environment if not
serviced and handled correctly. The following
guidelines are intended to alert the service engineer
to potential sources of danger and emphasise the
importance of ensuring the integrity of the Air
Conditioning operating conditions and components
fitted to the vehicle.
Where necessary, additional specific precautions
are detailed in the relevant sections of this Manual
which should be referred to prior to commencing
repair operations.
The refrigerant used in the air conditioning system is
HFC-134a (Hydrofluorocarbon) R134a.
WARNING: The air conditioning system is
charged with a high pressure, potentially
toxic refrigerant. Repairs or servicing
must only be carried out by a trained operator
familiar with both the vehicle system and the
charging and testing equipment.
WARNING: All operations pertaining to the
air conditioning system must be carried
out in a well ventilated area. Always
observe the following precautions:
• R134a is odourless and colourless. Do not
handle or discharge in an enclosed area, or
any area where the vapour and liquid can
come into contact with a naked flame or hot
metal. R134a is not flammable, but it can
cause a highly toxic gas.
WARNING: HFC-134a (R134a) is a
hazardous liquid which if handled
incorrectly can cause serious injury. The
following precautions should be adhered to at all
times when working on an air conditioning
system:
• Suitable protective clothing must be worn
when carrying out service operations on the
air conditioning system.
• Air conditioning connections should be
opened carefully to allow any liquid or
pressure to bleed off slowly.
• Do not allow a refrigerant container to be
heated by direct flame or to be placed near
any heating appliance. A refrigerant container
must not be heated above 50°C.
• Do not leave a refrigerant container without
its cap fitted.
• Do not transport a refrigerant container that
is unrestrained (especially in the luggage
compartment of a car).
• Do not allow fluids, other than R134a or
compressor lubricant, to enter the air
conditioning system; spontaneous
combustion could occur.
• R134a splashed onto exposed skin will cause
immediate freezing of that area.
• Refrigerant cylinders and replenishment
trolleys can become cooled when
discharging, this could cause skin to become
frozen to them if contact is made.
• The refrigerant used in an air conditioning
system must be reclaimed in accordance with
the recommendations stipulated by a
Refrigerant Recovery, Recycling &
Recharging Station.
• Do not smoke or weld in areas where R134a
is in use.
• Inhalation of concentrations of vapour can
cause dizziness, disorientation,
incoordination, narcosis, nausea or vomiting.
• Refrigerant R134a from domestic and
commercial sources must not be used in
motor vehicle air conditioning systems.
AIR CONDITIONING PRECAUTIONS
1
GENERAL INFORMATION
Protective Clothing
NOTE: Suitable protective clothing
comprises:
• Wrap round safety glasses or helmet
• Heat proof gloves
• Rubber apron, or waterproof overalls
• Rubber boots.
REMEDIAL ACTIONS
If an accident involving R134a should occur, conduct
the following remedial actions:
• If liquid R134a enters the eye, do not rub it.
Gently run large quantities of eye wash over
affected eye to raise the temperature. If an eye
wash is not available, cool, clean water may be
used to flush the eye. After rinsing, cover the eye
with a clean pad and seek immediate medical
attention.
• If liquid R134a is splashed onto the skin, run
large quantities of water over the affected area to
raise the temperature. Implement the same
action if the skin comes in contact with
discharging cylinders. Wrap the contaminated
body parts in blankets (or similar materials) and
seek immediate medical attention.
• If the debilitating effects of inhalation of R134a
vapour is suspected, seek fresh air. If the
affected person is unconscious, move them away
from the contaminated area to fresh air and apply
artificial respiration and/or oxygen and seek
immediate medical attention.
WARNING: Due to its low evaporating
temperature of -30°C, R134a should be
handled with extreme care.
2
AIR CONDITIONING PRECAUTIONS
GENERAL INFORMATION
SERVICE PRECAUTIONS
CAUTION: Observe the following
precautions when handling components
used in the air conditioning system:
• Air conditioning units must not be lifted by
their hoses, pipes or capillary lines.
• Hoses and lines must not be subjected to any
twist or stress - the efficiency of the system
will be impaired by kinks or restrictions.
Ensure that hoses are correctly positioned
before tightening couplings, and ensure that
all clips and supports are utilised.
• Flexible hoses should not be postioned close
to the exhaust manifold (less than 100mm)
unless protected by heat shielding.
• The receiver/drier should be the last
component connected to the system to
ensure optimum dehydration and maximum
moisture protection of the system.
• Whenever the refrigerant system is opened,
the receiver/dryer must be renewed
immediately before evacuating and
recharging the system.
• Use alcohol and a clean lint-free cloth to
clean dirty connections.
• Ensure that all new parts fitted are marked for
use with R134a.
• When a major repair has been completed, a
leak test should be conducted; refer to the air
conditioning section of this manual for the
correct procedure.
• Completed assemblies must be checked for
refrigeration lines touching metal panels. Any
direct contact of components and panels may
transmit noise and so must be eliminated.
• The appropriate torque wrench must be used
when tightening refrigerant connections to
the stipulated value. An additional spanner
must be used to hold the union to prevent
twisting of the pipe when tightening
connections.
• Before connecting any hose or pipe, ensure
that refrigerant oil is applied to the seat of the
new ’O’ ring seals, BUT NOT to the threads of
the connection.
• All protective plugs must remain in place to
seal the component until immediately prior to
connection.
• Ensure components are at room temperature
before uncapping, to prevent condensation of
moisture from the air that enters it.
• Components must not remain uncapped for
longer than 15 minutes. In the event of a
delay, the caps must be fitted.
• When disconnecting, immediately cap all air
conditioning pipes to prevent ingress of dirt
and moisture into the system.
• The receiver/dryer contains desiccant which
absorbs moisture. It must be positively
sealed at all times. A receiver/drier that has
been left uncapped must not be used, fit a
new unit.
AIR CONDITIONING PRECAUTIONS
3
GENERAL INFORMATION
Refrigerant oil
Rapid refrigerant discharge
Use an approved refrigerant lubricating oil:
CAUTION: If the air conditioning system is
involved in accident damage and the
system is punctured, the refrigerant will
discharge rapidly. The rapid discharge of
refrigerant will also result in the loss of most of
the oil from the system. The compressor must be
removed and all the remaining oil in the
compressor drained and refilled as instructed in
the air conditioning section of this manual.
ND Oil 8
CAUTION: Do not use any other type of
refrigerant oil.
CAUTION: Refrigerant oil easily absorbs
water and must not be stored for long
periods. Do not pour unused oil back into
the container.
When renewing system components, add the
quantities of refrigerant oil recommended in the Air
Conditioning section of this manual.
Compressor
A new compressor is sealed and pressurised with
Nitrogen gas. When fitting a new compressor, slowly
release the sealing cap; gas pressure should be
heard to vent as the seal is broken.
CAUTION: A new compressor should
always have its sealing cap in place and
must not be removed until immediately
prior to fitting the compressor air conditioning
pipes.
4
AIR CONDITIONING PRECAUTIONS
GENERAL INFORMATION
PRECAUTIONS FOR REFRIGERANT RECOVERY,
RECYCLING AND RECHARGING
WARNING: Refrigerant must always be
recycled before reuse to ensure that the
purity of the refrigerant is high enough for
safe use in the air conditioning system.
WARNING: Recycling should always be
carried out with equipment which is
design certified by Underwriter Laboratory
Inc. for compliance with SAE-J1991. Other
equipment may not recycle refrigerant to the
required level of purity.
A R134a Refrigerant, Recovery, Recycling and
Recharging Station must not be used with any
other type of refrigerant.
CAUTION: When using an air conditioning
portable Refrigerant, Recovery, Recycling
and Recharging Station the operator must
adhere to the equipment manufacturer’s
instructions.
CAUTION: The system must be evacuated
immediately before recharging
commences. Delay between evacuation
and recharging must not be permitted.
CAUTION: Overcharging the air
conditioning system will cause excessive
head pressure.
AIR CONDITIONING PRECAUTIONS
5
GENERAL INFORMATION
VEHICLE IDENTIFICATION NUMBER
Vehicle identification number
Example: SALLNABB7VA600172
Location
The Vehicle Identification Number (VIN) plate is
attached to the LH ’B’ post.
The VIN is also stamped in the following locations:
• At the centre top of the engine bulkhead.
S = Geographic area (S = Europe)
A = Country (A = UK)
L = Manufacturer (L = Land Rover)
LN = Marque/Model (LN = Freelander)
A = Trim Level (A = Trim Level 1)
B = Body
A = 3 door models
B = 5 door models
• On a plate behind the LH lower corner of the
windscreen.
B = Engine
A = K16 Petrol engine models
B = TCIE Diesel engine models
7 = Transmission and Steering
7 = RHD manual steering
8 = LHD manual steering
V = Model change (V = 1997 Model year)
A = Assembly plant (A = Solihull)
6 figures = Serial number
Paint and Trim colour codes:
A - Vehicle Identification Number (VIN)
B - Gross vehicle weight
C - Gross train weight
D - Maximum front axle load
E - Maximum rear axle load
F - Paint Code
G - Trim Code
Paint Code (F) - 3-digit code identifying the original
Paint colour is stamped on the VIN plate:
Example: 601
601 = Rioja Red
507 = Caledonian Blue
603 = Chawton White
624 = Cobar Blue
618 = White Gold
622 = Venetian Mauve
587 = Altai Silver
610 = Charleston Green
961 = Epson Green
416 = Beluga Black
Refer to Parts Catalogue for full list of colour
codes.
Trim (G) - a code identifying the original trim type
and colour is stamped on the VIN plate, refer to the
relevant Parts Catalogue for coding details:
VEHICLE IDENTIFICATION NUMBER
1
GENERAL INFORMATION
IDENTIFICATION NUMBER LOCATIONS
Engine number
1.8 ’K’ Series Engine: Stamped on the front face of
the cylinder block adjacent to the gearbox.
1. Vehicle identification number
2. Engine number
3. Gearbox number
Vehicle Identification Number
The VIN is displayed at the centre top of the engine
bulkhead and on a plate behind the LH lower corner
of the windscreen.
2.0 ’L’ Series Engine: Stamped on the front face of
the cylinder block at top centre.
Gearbox number (3)
Manual Gearbox - PG1: Stamped on a label
attached to the front face of the clutch housing.
2
VEHICLE IDENTIFICATION NUMBER
INFORMATION
CONTENTS
Page
LIFTING AND TOWING
JACKING ..................................................................................................................
TOWING ...................................................................................................................
TRANSPORTING THE VEHICLE BY TRAILER .......................................................
EMERGENCY STARTING ........................................................................................
1
4
5
5
GENERAL DATA
STEERING ............................................................................................................... 1
DIMENSIONS ........................................................................................................... 1
WEIGHTS ................................................................................................................. 2
COMPONENT LOCATIONS
ELECTRONIC CONTROL UNITS ............................................................................ 1
BODY REPAIRS
BODY REPAIRS ....................................................................................................... 1
BODY DIMENSIONS
DIMENSIONAL INFORMATION ............................................................................... 1
GAPS AND PROFILES ........................................................................................... 12
SEALING AND CORROSION PROTECTION
APPROVED MATERIALS .........................................................................................
MATERIALS APPLICATIONS ..................................................................................
APPLICATION EQUIPMENT ....................................................................................
WATER LEAKS ........................................................................................................
1
4
5
8
INFORMATION
JACKING
The following instructions must be carried out before
raising the vehicle off the ground:
• Use a solid level surface.
• Apply parking brake.
• Select 1st. gear in main gearbox and ensure
HDC is not selected.
CAUTION: To avoid damage to under body
components of the vehicle, adhere to the
following jacking procedures:
DO NOT POSITION JACKS OR AXLE STANDS
UNDER THE FOLLOWING COMPONENTS:
•
•
•
•
•
•
•
•
Bumpers
Brake or Fuel lines
Exhaust pipe
Suspension components
Steering rack and linkages
Fuel tank
Engine sump
Gearbox
Jack or support vehicle only on approved
jacking points as detailed in the illustration
below:
LIFTING AND TOWING
1
INFORMATION
2
LIFTING AND TOWING
INFORMATION
Vehicle jack
Raising the rear of a vehicle
The jack provided with the vehicle is only intended to
be used in an emergency, for changing a tyre. Do
NOT use the jack for any other purpose. Refer to the
Owner’s Handbook for vehicle jack location points
and procedure. Never work under a vehicle only
supported by the vehicle jack.
Position cup of hydraulic arm under the centre of the
rear subframe crossmember at the position identified
by the embossed arrows.
Hydraulic jack
Use jack to raise rear road wheels to enable safety
stands to be installed under the rear ends of the
body longitidinal members as shown.
Carefully lower jack until vehicle sits securely on
both safety stands. Remove trolley jack.
A hydraulic jack with a minimum 1500 kg (3,300 lbs)
load capacity must be used.
Before working on the underside of a vehicle,
re-check the stability of the vehicle on the stands.
WARNING: Do not work on the underside
of a vehicle until suitable stands have
been positioned.
Use the reverse procedure when removing a vehicle
from stands.
Wheel-free lift
Raising the front of a vehicle
Position the cup of the hydraulic arm under the
centre of the front body crossmember assembly.
Use jack to raise front road wheels to enable safety
stands to be installed under the front end of each
longitudinal member as shown.
Carefully lower jack until vehicle sits securely on
both safety stands. Remove trolley jack.
Locate the lifting pads under the ends of the body
longitudinal members shown. Raise the ramp to
support the weight of the vehicle, ensure the vehicle
is secure on the lifting pads, then raise the ramp to
the required height.
Before working on the underside of a vehicle
re-check the stability of the vehicle on the stands.
Use the reverse procedure when removing a vehicle
from stands.
NOTE: For some repair operations it may
be necessary to use a jack to support the
engine under the sump. In this case, a
block of wood should be used on the jack to
protect the sump.
LIFTING AND TOWING
3
INFORMATION
TOWING
CAUTION: The vehicle has permanent
four-wheel drive. The following towing
instructions must be adhered to:
Towing the vehicle on all four wheels with driver
operating steering and brakes.
Suspended tow by breakdown vehicle
CAUTION: To prevent vehicle damage,
rear propeller shaft MUST BE removed.
Mark propeller shaft drive flanges and mating
flanges with identification lines to enable the
propeller shaft to be refitted in its original position.
Remove the propeller shaft fixings then remove the
shaft from the vehicle.
If the front of the vehicle is to be trailed, turn ignition
key to position ’I’ to release steering lock.
CAUTION: If it is considered unsafe to turn
the starter switch to position ’I’ due to
accident damage or an electrical fault;
disconnect the battery before turning the ignition
switch.
WARNING: Do not turn the starter switch
to position ’0’ or remove the ignition key
while the vehicle is being towed.
• Turn ignition key turn to position ’1’ to release
steering lock and then to position ’II’ to enable
the brake lights, wipers and direction indicators
to be operated, if necessary.
• Select neutral in gearbox and ensure HDC (hill
descent control) is deselected.
• Secure tow rope, chain or cable to towing eye.
• Release the parking brake.
CAUTION: The brake servo and power
assisted steering system will not be
functional without the engine running.
Greater pedal pressure will be required to apply
the brakes and the steering system will require
greater effort to turn the front road wheels.
The vehicle tow connection should only be used
under normal road conditions, ’snatch’ recovery
should be avoided.
4
LIFTING AND TOWING
CAUTION: The steering wheel and/or
linkage must be secured in a straight
ahead position. DO NOT use the steering
lock mechanism for this purpose.
CAUTION: Under no circumstances
should the vehicle be towed or recovered
by means of lashing to the rear subframe.
Serious damage to the subframe and body could
result.
CAUTION: Only use the rear towing eye
for towing another vehicle.
INFORMATION
TRANSPORTING THE VEHICLE BY TRAILER
EMERGENCY STARTING
Lashing rings are provided at the front and rear of
the body to facilitate the securing of the vehicle to a
trailer or other means of transportation.
WARNING: Hydrogen and oxygen gases
are produced during normal battery
operation. This gas mixture can explode if
sources of combustion (e.g. flames, sparks or
lighted tobacco etc.) are brought near the
battery. When charging or using a battery in an
enclosed space, always ensure ventilation and
wear eye protection (goggles etc.).
CAUTION: Underbody components must
not be used as lashing points. The lashing
rings must not be used for towing.
WARNING: Keep dangerous substances
out of the reach of children.
Batteries contain sulphuric acid; avoid
contact with skin, eyes, or clothing.
If handling batteries, wear a protective industrial
apron and gloves and wear safety goggles to
protect against possible splashing of acid
solution.
In case of acid contacting with skin, eyes, or
clothing; flush immediately with water for a
minimum of fifteen minutes.
If acid is swallowed, drink large quantities of
milk or water, followed by milk of magnesia, a
beaten egg, or vegetable oil.
SEEK MEDICAL AID IMMEDIATELY.
Install the vehicle on trailer and apply the parking
brake. Select neutral.
To Jump Start - Negative Ground Battery
WARNING: To avoid any possibility of
injury use particular care when connecting
a booster battery to a discharged battery.
Position vehicles so that jump leads will reach,
ensuring that vehicles DO NOT TOUCH,
alternatively a fully charged slave battery may be
positioned on the floor adjacent to the vehicle.
Ensure that:
• the ignition and all electrical accessories are
switched off
• the parking brake is applied and neutral is
selected on gearbox
LIFTING AND TOWING
5
INFORMATION
Connect the jump leads as follows:
WARNING: Making final cable connection
could cause an electrical arc which if
made near battery could cause an
explosion.
CAUTION: If vehicle fails to start within a
maximum time of 12 seconds, switch
ignition off and investigate cause. Failure
to follow this instruction could result in
irreparable damage to catalyst.
To disconnect:
A. Connect one end of first jumper cable to
positive (+) terminal of booster battery.
• Remove negative (-) jumper cable from the
engine and then terminal of booster battery.
B. Connect other end of first jumper cable to
positive (+) terminal of discharged battery.
• Remove positive (+) jumper cable from positive
terminals of booster battery and discharged
battery.
C. Connect one end of second jumper cable to
negative terminal of booster battery.
D. Connect other end of second jumper cable to a
good earth point on the engine, NOT TO
NEGATIVE TERMINAL OF DISCHARGED
BATTERY.
CAUTION: Keep jumper leads away from
moving parts, pulleys, drive belts and fan
blade assembly.
If the booster battery is installed in another vehicle,
start engine and allow to idle.
Start engine of vehicle with discharged battery,
following starting procedure in Owners’ Handbook.
6
LIFTING AND TOWING
INFORMATION
STEERING
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power assisted rack and pinion
Steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Height adjustable by 3.5° or 30 mm vertical movement of
steering wheel
Turns - lock to lock: . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
Turning circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6 m (38.1 ft) kerb to kerb
Wheel alignment (unladen)
Front:
Camber angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Castor angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
King pin inclination . . . . . . . . . . . . . . . . . . . . . . . . . . .
Toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- 0° 15’ ± 45’
3° 30’ ± 1°
12° 18’
- 0° 10’ ± 5’
Rear:
Camber angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 0° 30’ ± 45’
Thrust angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0° 0’ ± 5’
Toe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . + 0° 20’ ± 15’
Power Assistance System
Maximum Operating Pressure . . . . . . . . . . . . . . . . . . 9203 -300 kPa (1334 -43.5 lbf.in2), limited by pressure
relief valve in pump
Maximum flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 -0.5 litres/min. (1.45 -0.13 US gal/min), limited by flow
control valve in pump
Displacement
1.8 ’K’ Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2 cm3/rev (0.50 in3/rev)
2.0 ’L’ Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 cm3/rev (0.58 in3/rev)
DIMENSIONS
Overall length (inc. spare) . . . . . . . . . . . . . . . . . . . . .
Overall width:
Including mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . .
Excluding mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overall height (including roof rails)* . . . . . . . . . . . . . .
Ground clearance *:
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overhang:
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear (inc. spare wheel) . . . . . . . . . . . . . . . . . . . . . .
Track:
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.382 m
2.074 m
1.805 m
1.757 m
186 mm
220 mm
214 mm
2.555 m
836 mm
989 mm
1534 mm
1545 mm
* At unladen weight
GENERAL DATA
1
INFORMATION
WEIGHTS
Unladen weight (no options):
Petrol models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1380 - 1425 kg
Diesel models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1480 -1525 kg
3045 - 3140 lb
3265 - 3365 lb
Unladen weight (all options):
Petrol models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1449 - 1484 kg
Diesel models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1545 -1580 kg
3195 - 3270 lb
3405 - 3485 lb
Maximum gross vehicle weight:
Petrol models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1960 kg
Diesel models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2050 kg
4322 lb
4520 lb
Maximum front axle weight . . . . . . . . . . . . . . . . . . . . 1050 kg
Maximum rear axle load (must NOT be
exceeded) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1120 kg
2315 lb
Maximum braked trailer weight . . . . . . . . . . . . . . . . . 1800 kg
Maximum Gross Towing Weight
Petrol models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3760 kg
Diesel models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3850 kg
3970 lb
Towing hitch downward load (nose weight) . . . . . . . . 140 kg
309 lb
Maximum roof rack load (includes weight of rack) . . . 75 kg
165 lb
2
GENERAL DATA
2470 lb
8291 lb
8489 lb
INFORMATION
ELECTRONIC CONTROL UNITS
Equipment
The electronic control units (ECU) fitted to vehicles
make it advisable to follow suitable precautions prior
to carrying out welding repair operations. Harsh
conditions of heat and vibration may be generated
during these operations which could cause damage
to the units. See GENERAL INFORMATION,
Electrical precautions.
Prior to commencing any test procedure on the
vehicle, ensure that the relevant test equipment is
working correctly and any harness or connectors are
in good condition. This particularly applies to
electronic control units.
In particular, it is essential to follow the appropriate
precautions when disconnecting or removing the
airbag ECU. See GENERAL INFORMATION, SRS
Precautions.
ECU locations (3 door model shown, 5 door model similar)
1. Central control unit (on forward side of
passenger compartment fuse box, behind
driver’s glove box)
2. Airbag ECU (on transmission tunnel below
heater)
3. ABS ECU (below RH front seat)
4. Engine control module (rear of battery on LH
side of engine compartment)
COMPONENT LOCATIONS
1
INFORMATION
BODY REPAIRS
General
Body shells are of monocoque construction. Front
and rear sections of the shell are designed as
’energy absorbing’ zones. This means they are
designed to deform progressively when subjected to
impact in order to minimise the likelihood of injury to
vehicle occupants.
It is essential that design dimensions and strength
are restored in accident rectification. It is important
that neither structural weakness nor excessive local
stiffness are introduced into the vehicle during body
repair.
Repairs usually involve a combination of operations
ranging from straightening procedures to renewal of
individual panels or panel assemblies. The repairer
will determine the repair method and this decision
will take into account a balance of economics
between labour and material costs and the
availability of repair facilities in both equipment and
skills. It may also involve considerations of the
vehicles’ downtime, replacement vehicle availability
and repair turn-around time.
It is expected that a repairer will select the best and
most economic repair method possible, making use
of the facilities available. The instructions given are
intended to assist a skilled body repairer by
expanding approved procedures for panel
replacement. The objective is to restore the vehicle
to a safe running condition by carrying out a repair
which is as close as is feasible to original standard.
The results should not advertise to the experienced
eye that the vehicle has been damaged, although
the repair might not be identical in all respects to the
original factory build. Commercial bodyshop repair
facilities cannot always duplicate methods of
construction used during production.
Body repairs often involve the removal of
mechanical and electrical units and associated
wiring. Where necessary, refer to the relevant
section of the Workshop Manual for removal and
refitting instructions. Component removal and
refitting instructions for the BODY and SRS sections
are also included in this Manual.
Body components
Taking into consideration the differences in body
styles, suspension systems and engine and
transmission layouts, the location of the following
components as applicable to a particular vehicle is
critical:
• Front suspension upper damper mountings.
• Front suspension or sub frame mountings.
• Rear suspension upper damper mountings.
• Rear suspension mountings or lower pivots.
Additional points which can be used to check
alignment and assembly are:
• Inner holes in crossmember - side - main floor.
• Holes in front longitudinals.
• Holes in side member.
• Holes in rear longitudinals.
• Holes in rear lower panels or extension rear floor.
Apertures for windscreen, backlight, bonnet and
doors can be measured and checked using the
dimensional information provided and also by
offering up an undamaged component as a gauge.
Operations covered in this Manual do not include
reference to testing the vehicle after repair. It is
essential that work is inspected and suspension
geometry checked after completion. Where
necessary a road test of the vehicle should be
carried out, particularly where safety-related items
are concerned.
Where major units have been disconnected or
removed it is necessary to ensure that fluid levels
are checked and topped up where necessary. It is
also necessary to ensure that the repaired vehicle is
in a roadworthy condition in respect of tyre
pressures, lights, washer fluid etc.
BODY REPAIRS
1
INFORMATION
Straightening
Whenever possible, structural members should be
cold straightened under tension. Do not attempt to
straighten with a single pull but rework the damaged
area using a series of pulls, releasing tension
between each stage and using the opportunity to
check alignment.
Body jig
Unless damage is limited to cosmetic panels, all
repair work to body members must be carried out on
a body jig, to ensure that impact damage has not
spread into more remote parts of the structure.
Mounting on a jig will also ensure that the
straightening and panel replacement procedures do
not cause further distortion.
If original dimensions cannot be satisfactorily
restored by these methods, damaged structural
members should be replaced. Damaged areas
should be cut away using a high speed saw, NOT an
oxy-acetylene torch.
As a rule, body dimensions are symmetrical about
the centre line. A good initial check for distortion is
therefore to measure diagonally and to investigate
apparent differences in dimensions.
Inspection
Every accident produces individual variations in
damage. Each repair is influenced by the extent of
the damage and the facilities and equipment
available for its rectification.
Most accident damage can be visually inspected
and the approximate extent of damage assessed.
Sometimes deformation will extend beyond the
directly damaged area, and the severity of this must
be accurately established so that steps can be taken
to restore critical body components to their original
dimensions. An initial check can be carried out by
means of drop checks or, preferably, trammels.
Gauges are available which will accurately check for
body twist.
2
BODY REPAIRS
INFORMATION
DIMENSIONAL INFORMATION
The following dimensional information is shown so
as to assist the technician in the diagnosis and
repair of body panels. The information is shown in
two different ways. There are X,Y,Z dimensions and
actual point to point dimensions.
The X,Y,Z dimensions are the measuring planes
used within Rover Group for the measurement of
body panels. The whole bodyshell is within a parallel
grid system.
The X plane is an imaginary vertical line starting at
the front of the vehicle. It is parallel to the body and
measures the length of the vehicle.
The Y plane is an imaginary line through the center
of the vehicle. All Y dimensions start from this line.
As a rule, body dimensions are symmetrical about
the centre line.
The Z plane is set at a fixed distance parallel and
perpendicular to the underside of the vehicle. All Z
dimensions start from this plane.
The point to point measurements are actual
distances between two points. These points can be
holes or intersection points. Where holes are taken,
the point of measurement is always from the hole
centre.
All measurements shown are in millimetres.
BODY DIMENSIONS
1
INFORMATION
Underbody dimensional information (see following Figure)
No.
Description
X
Y
Z
1
Front sidemember, jig location hole
420
481
314
2
Front crossmember, jig location hole
340.5
350
170
3
Front damper, inboard fixing hole
975.5
515
693.5
4
Front subframe, front fixing
1036
386
98
5
Front subframe, rear outboard fixing
1326
429.5
127
6
Reinforcement outrigger, datum hole
1326
330
127
7
Front production location hole
1395
535
125
8
Trailing link fixing, centre hole
2765
463
160
9
Rear longitudinal, front jig location hole 2900
432
131.5
10
Rear subframe, front fixing
3302
465
274.5
11
Rear damper, rear fixing
3636
610
728.5
12
Rear subframe, rear fixing
3671.5
515
305
13
Rear longitudinal, rear jig location hole
4000
527
305
14
Rear production location hole
4122.5
410
301
2
BODY DIMENSIONS
INFORMATION
BODY DIMENSIONS
3
INFORMATION
4
BODY DIMENSIONS
INFORMATION
BODY DIMENSIONS
5
INFORMATION
6
BODY DIMENSIONS
INFORMATION
Front end dimensional information (see above Figure)
No.
Description
X
Y
Z
1
Front damper large hole
997
578.5
718.5
2
Front damper, inboard fixing hole
975.4
514.9
693.7
3
Front wing fixing
605
669
806
4
Rear wing fixing, dash side
1220
690
848.2
5
Outboard headlamp fixing hole
465
615
788.3
6
Inboard headlamp fixing hole
377
485
772
7
Bonnet locking platform, jig location
hole
390
445
765
8
Sidemember jig location hole
500
446
388
9
Headlamp mounting panel, jig location
hole
304
536
335
10
Front valance jig location hole
540
671.7
525
BODY DIMENSIONS
7
INFORMATION
8
BODY DIMENSIONS
INFORMATION
The measurements shown on the front windscreen aperture are the same for 5 door models.
BODY DIMENSIONS
9
INFORMATION
10
BODY DIMENSIONS
INFORMATION
BODY DIMENSIONS
11
INFORMATION
GAPS AND PROFILES
The following information is to be used as a guide to
assist the technician in refitting exterior body panels
and trim items so as to achieve a correctly aligned
vehicle.
Gap A - Bonnet to Bumper overrider. Even gaps
side to side, tolerance +/- 1.0mm.
Gap B - Bonnet to headlamp. Even gaps side to
side, tolerance +/- 1.0mm.
12
BODY DIMENSIONS
Gap C - Headlamp to Bumper overrider. Visually
even gaps within 2.0mm.
INFORMATION
Section D-D, headlamp to wing, gap (3.0mm
minimum). If the wing has been exposed to oven
curing set gap to 4.4 mm to enable subsequent
expansion.
Section H-H and J-J, front door frame to body, gap.
Profile of front door frame to body is -2.5mm
nominal, tolerance +0.0/-1.0mm.
Section E-E and F-F, wing to bonnet, gaps.
Section K-K and L-L, front door to rear door, gaps.
Profile of front door to rear door is 0.0mm nominal,
tolerance +0.0/-1.0mm.
Section G-G, wing to front door, gap. Profile of wing
to front door is 0.0mm nominal, tolerance
+1.0/-0.0mm.
Section M-M, bottom of door to sill, gap.
Section N-N and P-P, rear door to body, gaps.
Profile of rear door to body is 0.0mm nominal,
tolerance +1.0/-0.0mm.
BODY DIMENSIONS
13
INFORMATION
Section P-P, taildoor to rear lamp, gap.
14
BODY DIMENSIONS
Section Q-Q, taildoor to rear bumper, gap.
INFORMATION
APPROVED MATERIALS
Description - Usage
Supplier
Part Number
Inner Cavity Wax (Amber)
3M
08901/11/21
Inner Cavity Wax (Transparent)
3M
08909/19/29
Cavity Wax
Croda
PW57
Astrolan Engine Bay Wax and Cosmetic Wax
Astors
DA3243/1
Engine Bay and Cosmetic Wax/Lacquer
Croda
PW197
Engine Bay Cosmetic Wax/Lacquer
Dinol
4010
Aerosol Auto Adhesive (Trim) - impact adhesive for trim parts
3M
08080
Flexible Parts Repair Material - rubber modified polypropylene parts
3M
05900
Waterproof Cloth Tape - sealing panel apertures
3M
Y387/Y3998
Sound Dampening Foam
Gurit-Essex
Water Shedder Repair (Aerosol)
Teroson
Cavity waxes
Engine bay waxes/lacquers
Miscellaneous materials
Betacore 7999
-
Seam sealers
Body Caulking - type (b) gaps between panels
3M
08568
Bolted Panel Sealer - between bolted panels
3M
08572
Drip Chek Clear - bolted, spot welded and bonded panel edges; type
(a) and (b) gaps between panels; type (c) clinch joints
3M
08401
Drip Chek Heavy - type (b) gaps between panels; type (c) clinch joints
3M
08531
Continued.....
SEALING AND CORROSION PROTECTION
1
INFORMATION
Description - Usage
Supplier
Part Number
Polyurethane Seam Sealer - bolted, spot welded and bonded panel
edges; type (a) and (b) gaps between panels; type (b) clinch joints
3M
08684/89/94
Polyurethane Sealer (Sachet) - bolted panel edges; type (b) clinch
joints
3M
08703/83/88
Sprayable Sealer - lap joints
3M
08800/23
Super Seam Sealer - lap joints; type (b) clinch joints
3M
08537
Weld Thru’ Sealer - between spot welded panels
3M
08626
Betafill Clinch and Brushable Sealer - type (b) clinch joints
Gurit-Essex
10211/15/20
Clinch, Joint and Underbody Coating - lap joints
Gurit-Essex
10101/10707
Leak Chek Clear - between bolted panels; spot welded and bonded
panel edges; type (c) clinch joints; type (a) gaps between panels
Kent Industries
10075
Putty - type (b) gaps between panels
Kent Industries
-
Polyurethane Seam Sealer - bolted, spot welded and bonded panel
edges; between bonded panels; type (a) and (b) gaps between panels
PPG
Polyurethane Seam Sealer - bolted, spot welded and bonded panel
edges; between bonded panels; type (b) gaps between panels
Teroson
Seam sealers (continued)
6500
92
Terolan Light Seam Sealer - bolted, spot welded and bonded panel
Teroson
edges; type (a) and (b) gaps between panels; between bonded panels;
type (c) clinch joints
-
Terolan Special Brushable Seam Sealer - lap joints
Teroson
-
Terostat Sprayable Seam Sealer - bolted, spot welded and bonded
panel edges; between bonded panels; type (b) gaps between panels
Teroson
9320
Terostat 1K PU Seam Sealer (SE 20) - type (a) and (b) gaps between
panels; spot welded and bonded panel edges
Teroson
-
Sealing Compound - bolted, spot welded and bonded panel edges;
between bonded panels; type (b) gaps between panels
Wurths
8901001/-/6
Continued.....
2
SEALING AND CORROSION PROTECTION
INFORMATION
Description - Usage
Supplier
Part Number
Structural adhesives
Automotive Structural Adhesive - between bonded panels; type (a)
clinch joints
3M
Two Part Structural Epoxy - between bonded and spot welded panels;
type (a) clinch joints
Ciba-Geigy
08122
XB5106/7
Underbody sealers
Body Schutz
3M
08861
Spray Schutz
3M
08877
Crodapol Brushable Underbody Sealer
Croda
PV75
Terotex Underseal (CP 02)
Teroson
9320
Underbody waxes
Bodyguard (Aerosol)
3M
08158/9
Underbody Wax
Croda
PW61
Underbody Wax
Dinol
Tectacote 205
Weld-through primers
Weld Thru’ Coating
3M
05913
Zinc Spray
3M
09113
Zinc Rich Primer
ICI
P-565 634
SEALING AND CORROSION PROTECTION
3
INFORMATION
MATERIALS APPLICATIONS
1.
2.
3.
4.
5.
6.
4
Between panels - bolted
Panel edges - bolted
Between panels - spot welded
Panel edges - spot welded
Between panels - bonded
Panel edges - bonded
SEALING AND CORROSION PROTECTION
7.
8.
9.
10.
11.
12.
Clinch joints - type (a)
Clinch joints - type (b)
Clinch joints - type (c)
Gaps between panels - type (a)
Gaps between panels - type (b)
Lap joint
INFORMATION
APPLICATION EQUIPMENT
Suitable application equipment is available from the
following manufacturers and suppliers:
3M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automotive Trades Group
3M UK Plc
3M House
PO Box 1
Market Place
Bracknell
Berks. RG12 1JU
Tel. (01344) 858611
Cooper Pegler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Burgess Hill
Sussex RH15 9LA
Tel. (014 446) 42526
SATA Spray Equipment . . . . . . . . . . . . . . . . . . . . . Minden Industrial Ltd.
16 Greyfriars Road
Moreton Hall
Bury St. Edmunds
Suffolk IP32 7DX
Tel. (01284) 760791
3M Body Schutz Pistol Spraygun 08004
3M Applicator Gun 08190.
A pistol type spraygun constructed from case and
machined light alloy and designed for use with 3M
screw fit Body Schutz containers.
For the application of 3M Structural Adhesive 08120.
NOTE: Always clean gun after use with
appropriate solvent to maintain efficiency.
3M Caulking Gun 8002
3M Inner Cavity Wax Applicator Gun
This equipment accepts 1-litre canisters and has a
750mm flexible tube.
The approved system is available from all 3M
refinishing factors.
A lightweight, robust metal skeleton gun designed to
accept 325mm (13") cartridge for dispensing
sealants etc. This gun provides rapid cartridge
insertion and loading, with a quick-release lever for
accurate control of material ejection and shut-off.
3M Pneumatic Cartridge Gun 08012
Air line-fed gun for applying 3M cartridge products.
Excellent for ease of application to obtain a smooth
bead. Regulator valve for additional control.
3M Pneumatic Applicator Guns
Air line-fed gun for application of 3M sachet sealers
(Part Number 08006 for 200ml and 310ml sachet
applications, and Part Number 08007 for all size
sachets including 600ml).
Also available: Heavy Duty Manual Gun 08013.
SEALING AND CORROSION PROTECTION
5
INFORMATION
Cooper Pegler Falcon Junior Pneumatic Gun
(Airless)
Cavity wax application equipment and
techniques
Intended primarily for applying transit wax, this
pneumatic sprayer has a 5-litre container with
integral hand pump and provides an effective means
of wax spraying without the need for compressed air
or additional services.
A selection of nozzles, lances, hose lengths and a
trigger valve assembly with integral filter allows
flexibility in use. Additional applications include
general maintenance, wax injection and paint
application. Heavy-bodied materials may also be
applied. All parts are fully replaceable and a wide
range of nozzle configurations is available.
SATA Schutz Gun Model UBE
The SATA Schutz Gun is approved for the
retreatment of vehicle underbody areas with
protective coatings as supplied in 1 litre,
purpose-designed ’one-way’ containers. The screw
thread fitting (female on the gun) is standard to most
Schutz-type packs.
Full operating details are supplied with the
equipment.
NOTE: Always clean gun after use with
appropriate solvent to maintain efficiency.
SATA HKD1 Wax Injection Injection Equipment
This equipment is approved for carrying out cavity
wax re-treatment. The SATA HKD1 set comprises a
high quality forged gun with 1-litre pressure feed
container, a flexible nylon lance, a straight 1100mm
steel lance and hooked- wand lance. A
quick-change coupling is provided as a standard
fitting to allow lances to be easily interchanged.
Each lance has an integral, machined nozzle with
specialised spray characteristics to suit the type of
box section to be treated.
Specifications of Model UBE:
Air consumption: 7 ft3/min (200 litres/min) @ 45
lbf.in2
Weight: 23.3oz (220 grams)
6
SEALING AND CORROSION PROTECTION
1. Air inlet
2. Flow control (spray pattern adjustment)
3. Pressure cup (1 litre capacity). Maximum
pressure 140PSI (9.7 bar, 9.84kg/cm3)
4. Gun connector
5. Lance nipple connection
6. Flexible lance
7. Rigid directional hook wand (forward cone
spray pattern)
8. Flexible nylon lance (1100mm) with 360° spray
pattern
9. Rigid lance (1100mm) with 360° spray pattern
INFORMATION
When re-treating wax-injected areas which have
been disturbed during repairs, it is necessary to use
a compressed air spray gun with integral pressure
cup and a selection of interchangeable lances.
The following points must be observed during use,
according to the attachments fitted:
• Use the rigid or flexible lance attachments with
360° spray dispersal when treating enclosed
areas, to ensure maximum coverage.
• Where openings are restricted, use the hook
nozzle to provide a more directional spray (e.g.
inside narrow or short box sections).
• Spray exposed underbody surfaces directly from
the gun less lance attachment and without
disconnecting the fluid coupling.
1100mm rigid lance
The nozzle on the rigid lance produces a 360°
circular spray pattern combined with a
forward-directed spray. Although wax is distributed
to all box section surfaces in a single stroke,
effective and complete coverage is obtained in long
straight structures and box section cavities by
spraying on both inward and outward strokes of the
lance.
Hook nozzle on flexible lance
The rigid hook produces a highly atomised,
forward-directed, fully conical spray pattern having
long range and good dispersion characteristics. This
combination has good directional capabilities for
treating short, narrow sections, and may also be
used for direct spraying of inner wheel arches etc.
In use, position the flat area at the end of the lance
at 180° to the nozzle spray direction. This will help to
guide the spray more accurately when it is
concealed in a box section or access hole.
For general spraying, move the nozzle in an arc
from side to side as required, to ensure full
coverage.
NOTE: Ensure that all wax
injection/application equipment is kept
clean. Use white spirit for this purpose
immediately after wax injection operations.
The rigid lance also provides the positional accuracy
required in shaped sections, by allowing visual
assessment.
CAUTION: Do not force the lance into
access holes when using this attachment.
1100mm flexible nylon lance
This lance is similar in pattern to the rigid version,
but provides the additional penetration required for
curved sections or in places where access is
difficult. Its main limitation is a lack of positional
accuracy inside box sections.
Carry out all spraying on the outward stroke of the
lance. Withdraw the lance slowly to ensure sufficient
coverage. Do not withdraw the lance too quickly.
Ensure that the nylon tube of the lance is kept away
from the edges of the access hole to eliminate
abrasion and extend the life of the tube. Take care
to ensure that spraying ceases just before the
nozzle emerges from the access hole. To assist in
this process paint the final 30mm of the nozzle with
RED paint.
SEALING AND CORROSION PROTECTION
7
INFORMATION
WATER LEAKS
Where water leakage is involved, always adopt a
logical approach to the problem using a combination
of skill, experience and intuition. Do not reach a
conclusion based only on visual evidence, such as
assuming that a wet footwell is caused by a leak
emanating from the windscreen. It will often be found
that the source of the leak is elsewhere. Use of the
correct procedure will increase the chance of
locating a leak, however obscure it may seem.
Tools and equipment
The following tools and equipment are
recommended for the purpose of detection and
rectification of water leaks:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Garden sprayer (hand-operated).
Wet/dry vacuum cleaner.
Dry, absorbent cloths.
Battery torch.
Small mirror.
Weatherstrip locating tool.
Trim panel remover.
Small wooden or plastic wedges.
Dry compressed air supply.
Hot air blower.
Sealer applicators.
Ultrasonic leak detector.
During leak detection, the vehicle should be
considered in three basic sections:
• The front interior space.
• The rear passenger space.
• The loadspace or boot.
Testing
From the information supplied by the customer it
should be possible for the bodyshop operator to
locate the starting point from which the leak may be
detected. After the area of the leak has been
identified, find the actual point of entry into the
vehicle.
A simple and effective means in the first instance is
an ordinary garden spray with provision for pressure
and jet adjustment, which will allow water to be
directed in a jet or turned into a fine spray. Use a
mirror and a battery-powered torch (NOT a mains
voltage inspection lamp) to see into dark corners.
8
SEALING AND CORROSION PROTECTION
The sequence of testing is particularly important.
Start at the lowest point and work slowly upwards, to
avoid testing in one area while masking the leak in
another. For example, if testing started at the level of
the windscreen, any water cascading into the
plenum chamber could leak through a bulkhead
grommet and into the footwells. Even at this point it
could still be wrongly assumed that the windscreen
seal was at fault.
Another important part of identifying a water leak is
by visual examination of door aperture seals,
grommets and weatherstrips for damage,
deterioration or misalignment, together with the fit of
the door itself against the seals.
Sealing
When the point of the leak has been detected, it will
then be necessary to rectify it using the following
procedure:
1. Renew all door aperture seals and
weatherstrips which have suffered damage,
misalignment or deterioration.
2. Check all body seals to ensure that they are
correctly located on their mounting
flanges/faces using a lipping tool if necessary.
3. Dry out body seams to be treated using
compressed air and/or a hot air blower as
necessary.
4. Apply sealant on the outside of the joint
wherever possible to ensure the exclusion of
water.
5. When rectifying leaks between a screen glass
and its weatherstrip (or in the case of direct
glazing, between the glass and bodywork),
avoid removing the glass if possible. Apply the
approved material at the appropriate location
(i.e. glass to weatherstrip or glass to body).
RESTRAINT SYSTEMS
CONTENTS
Page
DESCRIPTION AND OPERATION
SEAT BELTS & SUPPLEMENTARY RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . 1
SEAT BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SUPPLEMENTARY RESTRAINT SYSTEM (SRS) . . . . . . . . . . . . . . . . . . . . . . . . . 4
REPAIRS
SEAT BELT - FRONT - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SEAT BELT - FRONT - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SEAT BELT - CENTRE - REAR - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SEAT BELT - SIDE - REAR - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ADJUSTABLE MOUNTING - SEAT BELT - ’B/C’ POST . . . . . . . . . . . . . . . . . . . . . 5
SEAT BELT BUCKLE - REAR - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SEAT BELT BUCKLE - REAR - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
PRETENSIONER - SEAT BELT - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SEAT BELT BUCKLE - CENTRE - REAR - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . 8
AIRBAG - STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
AIRBAG - PASSENGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ROTARY COUPLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSTIC CONTROL UNIT (DCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
RESTRAINT SYSTEMS
SEAT BELTS & SUPPLEMENTARY RESTRAINT
SYSTEM
Seat belts are provided as the primary restraint for
all occupants. The supplementary restraint system
provides additional protection for front seat
occupants.
SEAT BELTS
An inertia reel, three point seat belt is installed at
each seat position. The inertia reels are of the
Emergency Locking Retractor (ELR) type which
incorporate a liftshaft locking system with webbing
sensor and car sensor activating mechanisms. The
webbing sensor activates the locking system if the
webbing is subjected to a sharp pull. The car sensor
activates the locking system if the vehicle is
subjected to sudden deceleration or a severe tilt
angle.
Front seat belts
The inertia reel of each front seat belt is attached to
the related B/C post, behind the finishers. The
webbing runs from the inertia reel, through a height
adjuster, to an anchor point either at the base of the
B/C post (five door models), or on a bar attached to
the inner sill (three door models).
The buckle assembly for each belt, consisting of a
buckle attached to a flexible stalk and an integrated
pretensioner, is secured to the inboard side of the
related front seat frame.
Front seat belt components
Three door models
Five door models
DESCRIPTION AND OPERATION
1
RESTRAINT SYSTEMS
Rear seat belts
Three door models
The inertia reel of each rear seat belt is attached to a
bracket on top of the related rear suspension turret,
behind the loadspace rear quarter trim. The webbing
runs from the inertia reel, through a loop on the D
post, to an anchor point in the rear wheel arch.
The buckle for each belt is directly attached to the
inboard side of the related rear seat frame.
Rear seat belt components - three door models
2
DESCRIPTION AND OPERATION
RESTRAINT SYSTEMS
Five door models
The inertia reel of each outboard rear seat belt is
attached to the related D post, behind the D/E post
finisher. The webbing runs from the inertia reel,
through a loop on the D post, to an anchor point in
the rear wheel arch.
The buckle assembly for each belt, consisting of a
buckle attached to a length of webbing, is fixed to
the lower frames of the rear seats. The buckle
assembly for the right seat belt shares an anchor
point with the webbing of the centre seat belt.
The inertia reel for the centre rear seat belt is
installed in a recess in the back of the rear seat. The
webbing runs from the inertia reel, over the top of
the seat, to an anchor point in the lower frame of the
right rear seat.
Rear seat belt components - five door models
DESCRIPTION AND OPERATION
3
RESTRAINT SYSTEMS
SUPPLEMENTARY RESTRAINT SYSTEM (SRS)
Precautions
When carrying an airbag module, hold it by the
cover, with the cover uppermost and the base away
from your body. Do not wrap your arms around the
module.
Making the system safe
Before working on, or in the area of, the SRS, make
the system safe as follows:
1. Remove the key from ignition switch.
2. Disconnect both battery leads, earth lead first.
3. Wait 10 minutes to allow the SRS back-up power
to fully discharge.
Do not try to disassemble an airbag module or seat
belt pretensioner. They have no serviceable parts
and, once deployed, cannot be repaired or reused.
Do not expose an airbag module or seat belt
pretensioner to heat exceeding 85°C/185°F) or allow
it to be contaminated with oil, grease, detergent or
water.
General
Carefully inspect SRS parts before installation. Do
not install a part that shows signs of being dropped
or improperly handled, such as dents, cracks or
deformation.
The airbag ECU is a shock sensitive device and
must be handled with extreme care. Because the
crash sensor is incorporated inside the airbag ECU,
it is imperative that the bolts securing the airbag
ECU and its bracket are tightened to their correct
torque.
Do not install used SRS parts from another vehicle.
When repairing a SRS, use only new parts.
Always use new fixings when replacing SRS parts.
Do not use a multimeter or other general test
equipment to check SRS parts or connectors.
After completing work, check that the electrical
connectors are installed correctly.
Handling and storage
WARNING: If the airbag is improperly
stored face down, accidental deployment
could propel the unit with enough force to
cause serious injury.
CAUTION: Improper handling or storage
can internally damage the airbag module,
making it inoperative. If you suspect the
airbag module has been damaged, install a new
unit and refer to the Workshop Manual for
Deployment/Disposal Procedures.
Do not allow anything to rest on an airbag module.
4
DESCRIPTION AND OPERATION
For temporary storage of an airbag module or seat
belt pretensioner during service, place in a
designated storage area or, if no designated storage
area is available, in the loadspace of the vehicle;
always lock the vehicle and inform the workshop
supervisor.
Airbag modules and seat belt pretensioners are
classed as explosive articles. For overnight and
longer term storage, they must be stored in an
approved, secure steel cabinet which has been
registered by the local authority.
RESTRAINT SYSTEMS
SRS wiring
Never attempt to modify, splice or repair SRS wiring.
Never install electronic equipment such as a mobile
telephone, two way radio or in car entertainment
system in such a way that it interferes electrically
with the SRS wiring.
Always ensure SRS wiring is routed correctly. Be
careful to avoid trapping or pinching the SRS wiring.
Ensure the are no possible chafing points.
Always use specified earth fixings tightened to the
correct torque. Poor earthing can cause intermittent
problems that are difficult to diagnose.
Ensure all SRS wiring connectors are mated
correctly and securely fastened. Do not leave the
connectors hanging loose.
Warning labels
Warning labels are displayed on SRS parts and
prominent places on the vehicle to indicate:
• The need for caution when working in close
proximity to SRS parts.
• That, if a passenger airbag module is installed,
rearward facing child seats are prohibited on
front passenger seats.
• The publication where suitable reference and
advice can be found (usually the Workshop
Manual or Owner’s Handbook).
DESCRIPTION AND OPERATION
5
RESTRAINT SYSTEMS
System description
Impact zone for SRS activation (approximate)
The supplementary restraint system (SRS) provides
additional protection for front seat occupants during
a frontal collision above a preset severity.
SRS component location
1. SRS warning lamp
2. Passenger’s airbag module (optional)
3. Rotary coupler
6
DESCRIPTION AND OPERATION
4. Driver’s airbag module
5. Airbag ECU
6. Seat belt pretensioners
RESTRAINT SYSTEMS
The SRS is an electronically controlled, single point
sensing system. The system comprises an airbag
Electronic Control Unit (ECU), a driver’s airbag
module, a passenger’s airbag module (optional), two
seat belt pretensioners and a warning lamp.
Interconnecting wiring for the system is contained in
yellow sleeving and integrated into the vehicle
harnesses. A rotary coupler connects the vehicle
harness to the driver’ airbag module. On vehicles
with a passenger’s airbag module, a link lead
connects the module to the vehicle harness. An ISO
9141 K line (bi-directional) serial communication link
connects the airbag ECU to the vehicle’s diagnostic
socket.
The system is operational only while the ignition is
on. With the ignition on, any frontal collision is
detected by the airbag ECU. If the impact is above
the preset severity, the ECU sends out simultaneous
fire signals to the airbag modules and the seat belt
pretensioners. The airbag modules then deploy
protective airbags in front of the driver and front seat
passenger, and the seat belt pretensioners retract to
tighten the front seat belts. Collision detection to full
deployment of the airbags and pretensioners takes
approximately 45 milliseconds.
WARNING: All the SRS parts, including the
wiring harness, link lead (where fitted) and
rotary coupler, must be renewed after the
airbags and pretensioners have deployed.
SRS schematic
1.
2.
3.
4.
5.
Ignition power supply
Instrument pack
Warning lamp
Airbag ECU
Rotary coupler
6.
7.
8.
9.
Driver’s airbag module
Passenger’s airbag module
Seat belt pretensioners
Diagnostic socket
DESCRIPTION AND OPERATION
7
RESTRAINT SYSTEMS
Airbag ECU
Power back-up
The airbag ECU controls the operation of the system
and also contains the collision detection sensors.
The airbag ECU is attached to a bracket on the
transmission tunnel, directly below the heater. A
vehicle earth output connects to one of the fixings. A
30 pin connector provides the airbag ECU
connection with the vehicle harness.
The airbag ECU incorporates capacitors to ensure
the system will function if the external power supply
is disconnected during a collision:
• A hardware capacitor provides power for 200
milliseconds to enable system operation and
collision recording.
• Individual capacitors for each fire signal output
provide power for 150 milliseconds.
Incorporated into the airbag ECU is a mechanical
safing sensor, an electronic single point sensor and
integrated circuits for control and diagnostics. The
mechanical safing sensor is a normally open switch
that closes at the preset deceleration limit. The
single point sensor is an accelerometer that
produces an output proportional to the vehicle’s
deceleration .
The capacitors are kept charged while the ignition is
on by a dc-dc voltage converter incorporated into the
airbag ECU. It can take up to 10 minutes from the
ignition being switched off for the energy stored in
the capacitors to fully dissipate and make the
system inert.
Airbag ECU
Airbag ECU pin connections
Pin Description
1.
2.
3.
4.
5.
6.
7.
8.
8
RH pretensioner (+ve)
RH pretensioner (-ve)
LH pretensioner (+ve)
LH pretensioner (-ve)
Vehicle supply
Vehicle earth
SRS warning lamp
Not used
DESCRIPTION AND OPERATION
Pin Description
9.
10.
11.
12.
13.
14.
15.
ISO 9141 K line
Driver airbag module (+ve)
Driver’s airbag module (-ve)
Not used
Passenger’s airbag (+ve) - where fitted
Passenger’s airbag (-ve) - where fitted
to 30. Not used
RESTRAINT SYSTEMS
Operation
Diagnostics
When the ignition is switched on, the airbag ECU
performs a bulb check of the SRS warning lamp as
part of the power up procedure. The lamp should be
extinguished after approximately 5 seconds,
indicating that the system is fully operational. If the
lamp remains illuminated, a fault has been detected
and repair action is required.
While the ignition is on the diagnostic function of the
airbag ECU monitors the SRS for faults. If a fault is
detected, the airbag ECU stores a related fault code
in memory and switches the earth output to
illuminate the SRS warning lamp. With a supply
voltage range fault, the warning lamp is illuminated
only for the duration of the fault. With all other faults,
including intermittent faults, the warning lamp is
illuminated for the remainder of the drive cycle. At
the next ignition on, if the fault is still present the
warning lamp remains illuminated after the lamp
check; if the fault does not recur, the warning lamp
extinguishes but the fault code remains stored in
memory. An intermittent fault will be cleared from
memory if 40 drive cycles are completed without its
recurrence.
While the ignition is on, data from the single point
sensor is continuously monitored by the airbag ECU.
If the data from the single point sensor indicates
vehicle deceleration is at or above the preset limit,
and the mechanical safing sensor is closed, the
ECU interprets this as a collision that requires
deployment of the airbags and retraction of the seat
belt pretensioners. It then activates transistors to
send fire signals to the airbag modules and the seat
belt pretensioners. Simultaneously, the airbag ECU
records in memory the following information:
• The error code of the last permanent fault (if any)
detected before the collision.
• Internal program information about the collision
as seen by the airbag ECU.
• The diagnostic status of the airbag and seat belt
pretensioner circuits before deployment.
• The voltage of each power backup capacitor
before deployment.
• Information on the airbag ECU internal program
status.
If external power is lost during the collision,
recording of the last three above items only occurs if
there is sufficient power in the backup capacitors
after outputting the fire signals.
After detecting a fault, the system may retain some
operational capability:
• If a fault is detected in an airbag or pretensioner
circuit, only that circuit is disabled; the other
airbag and pretensioner circuits remain
operational and their related components will still
be deployed in a collision.
• If an internal or power supply fault is detected,
the complete system will be disabled.
• If a fault exists in the SRS warning lamp circuit,
the lamp will not illuminate during the lamp check
at ignition on, but, provided there are no other
faults, the system will otherwise be fully
operational.
When deployment and collision event recording has
been completed, the airbag ECU enters crash
locked mode and illuminates the SRS warning lamp.
In crash locked mode the airbag ECU is
permanently disabled and must be replaced during
subsequent repair action. Crash locked mode
cannot be cleared using Testbook.
DESCRIPTION AND OPERATION
9
RESTRAINT SYSTEMS
Fault code retrieval and fault diagnosis of the SRS
can only be done using Testbook. Additional SRS
information that can be read using Testbook is the:
• Airbag ECU bar code.
• Evolution number of the hardware, software and
diagnostic protocol.
• Status of the crash locked mode.
• Vehicle identification number (VIN) data.
Diagnostic checks performed by the airbag ECU
include:
• Monitoring of the airbag and pretensioner circuits
for open/short circuits.
• Internal errors.
• Supply voltage (limits are 8.6 to 19.0 V at power
up, 6.0 to 19.0 V during drive cycle).
Airbag modules
During a frontal collision each airbag module
deploys a gas filled bag to form a protective cushion
between the front seat occupant and the steering
wheel or fascia/windshield. The driver’s airbag
module is attached to the centre of the steering
wheel. Where fitted, the passenger’s airbag module
is installed in the fascia, above the glovebox.
Each airbag module has a gas generator attached to
a folded airbag installed in a housing. The driver’s
airbag has an inflated volume of 45 litres; the
passenger’s airbag has an inflated volume of 120
litres. The gas generator of the driver’s airbag
module is filled with a nitrocellulose based material;
the gas generator of the passenger’s airbag module
is filled with a sodium azide based material.
The outlet of the gas generators incorporates a filter
screen to prevent solid combustion by-products
entering the airbag during deployment. An igniter
(squib) in each generator provides an ignition source
when triggered by a fire signal from the airbag ECU.
A 2 pin connector provides the interface between the
igniter and the vehicle wiring.
On the driver’s airbag module, the housing is closed
by a cover that forms the steering wheel centre pad;
split lines are formed in the inner surface of the
cover to direct the airbag through the required exit
point during deployment. On the passenger’s airbag
module, the housing is closed by a trim panel
profiled to match the fascia; a tethered deployment
door forms an integral part of the trim panel.
10
DESCRIPTION AND OPERATION
RESTRAINT SYSTEMS
Both airbag modules operate in the same way. On
receipt of a fire signal from the airbag ECU, the
igniter ignites the material in the gas generator. The
burning material rapidly produces a large amount of
nitrogen gas which passes through the filter screen
into the airbag, forcing the airbag to unfold. On the
driver airbag module, the unfolding airbag ruptures
the cover along the split lines; on the passenger
airbag module, the unfolding airbag breaks the
deployment door fixings to the module housing and
trim panel, and the deployment door lifts off the
fascia (but remains tethered to the module housing).
Once free of the housing the airbag inflates to its full
extent. Vents in the airbag prevent excess pressure
bursting the bag and, as soon as the material in the
gas generator is exhausted, allows the airbag to
instantly deflate.
DESCRIPTION AND OPERATION
11
RESTRAINT SYSTEMS
Driver’s airbag module components
1.
2.
3.
4.
5.
12
Cover
Split lines
Electrical connector
Housing
Fixing
DESCRIPTION AND OPERATION
Passenger’s airbag module components
1.
2.
3.
4.
5.
6.
Trim panel
Deployment door section
Housing
Fixing bracket
Tethers
Electrical connector
RESTRAINT SYSTEMS
Seat belt pretensioners
Seat belt pretensioner components
During a frontal collision the seat belt pretensioners
tighten the front seat belts to ensure the occupants
are securely held in their seats. A pretensioner is
integrated into the buckle assembly of each front
seat belt.
The two pretensioners are handed, but otherwise
identical. Each pretensioner has a tube containing
propellant and a piston. The piston is attached to a
steel cable, the opposite end of which is attached to
the seat belt buckle. An igniter (squib) in the base of
tube provides an ignition source when triggered by a
fire signal from the airbag ECU. A fly lead with a 2
pin connector links the igniter to the vehicle wiring.
On receipt of a fire signal from the airbag ECU, the
igniter ignites the propellant. The burning propellant
rapidly produces nitrogen gas that drives the piston
along the tube, pulling on the cable and drawing the
buckle towards the buckle assembly fixing point on
the seat.
SRS warning lamp
The SRS warning lamp provides system status
information for the driver. The lamp consists of a
bulb behind a red SRS graphic at the base of the
tachometer in the instrument pack. The bulb is a
serviceable item that can be renewed from the rear
of the instrument pack.
1.
2.
3.
4.
5.
6.
7.
8.
Seat belt buckle
Gaiter
Steel cable
Fixing
Igniter
Fly lead
Vent
Tube
DESCRIPTION AND OPERATION
13
RESTRAINT SYSTEMS
Rotary coupler
Rotary coupler components
The rotary coupler is installed on the steering
column to provide the interface between the fixed
wiring harness and the moveable driver airbag
module and horn buttons on the steering wheel.
A rotating link harness is encapsulated into a plastic
cassette comprising outer and inner housings with
integral connectors. Screws attach the outer housing
to the steering column switch assembly and the
inner housing is keyed to the steering wheel by its
connector. The inner housing can turn a maximum
of six revolutions in relation to the outer housing. For
maintenance purposes the outer housing
incorporates a position indicator wheel; a white tab
is visible on the wheel when the rotary coupler is
centralised. To prevent breaking the rotating link
harness, both the steering and the rotary coupler
must be centralised when removing and installing
the steering wheel.
1.
2.
3.
4.
14
DESCRIPTION AND OPERATION
Fly lead (to airbag module)
Outer housing
Position indicator wheel
Inner housing
RESTRAINT SYSTEMS
SEAT BELT - FRONT - 3 DOOR
Service repair no - 76.73.13
Remove
1. Remove seat base finisher. See BODY, Seats
and seat belts.
2. Remove body side rear trim casing. See
BODY, Interior trim components.
Refit
1. Position reel and tighten bolt to 31 Nm.
2. Extend belt, position top mounting and tighten
Torx bolt to 31 Nm.
3. Fit top mounting cover.
4. Secure belt retaining strap.
5. Fit lower mounting to seat belt, position
mounting, fit and tighten Torx bolts to 40 Nm.
6. Fit trim casing. See BODY, Interior trim
components.
7. Fit seat base finisher. See BODY, Seats and
seat belts.
3. Remove 2 Torx bolts securing seat belt lower
mounting and remove mounting from seat belt.
4. Release seat belt retaining strap.
5. Remove cover from upper mounting.
6. Remove Torx bolt from upper mounting.
7. Remove bolt from seat belt reel and remove
reel.
REPAIRS
1
RESTRAINT SYSTEMS
SEAT BELT - FRONT - 5 DOOR
Service repair no - 76.73.13
Remove
1. Remove seat base finisher. See BODY, Seats
and seat belts.
2. Remove ’B/C’ post upper finisher. See BODY,
Interior trim components.
3. Release seat belt retaining strap.
4. Remove nut from seat belt upper mounting.
5. Remove bolt from seat belt reel and remove
reel.
2
REPAIRS
Refit
1. Position reel and tighten bolt to 31 Nm.
2. Extend belt, position top mounting and tighten
nut to 31 Nm.
3. Secure belt retaining strap.
4. Fit ’B/C’ post upper finisher. See BODY,
Interior trim components.
5. Fit seat base finisher. See BODY, Seats and
seat belts.
RESTRAINT SYSTEMS
SEAT BELT - CENTRE - REAR - 5 DOOR
Service repair no - 76.73.20
Remove
1. Remove RH rear seat. See BODY, Seats and
seat belts.
4. Remove 5 screws and remove both end covers
from seat hinges.
5. Remove 3 Torx bolts and remove squab from
cushion.
2. Remove 2 screws and remove seat belt reel
cover.
6. Release rear of cushion cover from seat frame.
7. Release sides and front of cushion cover from
seat frame.
3. Remove nut and release seat belt reel.
REPAIRS
3
RESTRAINT SYSTEMS
SEAT BELT - SIDE - REAR - 5 DOOR
Service repair no - 76.73.23
Remove
1. Remove rear quarter upper trim casing. See
BODY, Interior trim components.
8. Release cover and pad from seat frame.
9. Remove Torx bolt from centre seat belt
anchor/right seat belt buckle.
10. Remove seat belt and right seat belt buckle.
Refit
1. Position centre seat belt anchor and right seat
belt buckle to seat and tighten Torx bolt to 40
Nm.
2. Fit cover and pad to seat frame.
3. Fit front and sides of cushion cover to seat
frame.
4. Fit rear of cushion cover to seat frame.
5. Fit cushion to squab and tighten Torx bolts.
6. Fit end covers and tighten screws.
7. Position seat belt reel and tighten nut to 32
Nm.
8. Fit seat belt reel cover and tighten screws.
9. Fit rear seat. See BODY, Seats and seat
belts.
2. Remove Torx bolt from seat belt upper
mounting.
3. Remove Torx bolt from seat belt reel and
remove reel.
Refit
1. Position reel and tighten Torx bolt to 50 Nm.
2. Extend belt, position top mounting and tighten
Torx bolt to 32 Nm.
3. Fit rear quarter upper trim casing. See BODY,
Interior trim components.
4
REPAIRS
RESTRAINT SYSTEMS
ADJUSTABLE MOUNTING - SEAT BELT - ’B/C’
POST
Service repair no - 76.73.26
Remove
2. Remove nut from seat belt upper mounting and
remove belt bracket.
3. Remove 2 Torx screws from mounting and
remove mounting.
Refit
1. Position mounting and tighten Torx screws to
26 Nm.
2. Fit upper belt bracket and tighten nut to 31 Nm.
3. Position ’B/C’ post upper finisher and secure
with clips.
1. Release ’B/C’ post upper finisher from 6 clips
and position aside.
REPAIRS
5
RESTRAINT SYSTEMS
SEAT BELT BUCKLE - REAR - 3 DOOR
Service repair no - 76.73.32
Remove
1. Remove rear seat. See BODY, Seats and
seat belts.
5. Remove Torx bolt and remove seat belt buckle.
2. Remove 2 screws from hinge cover and
remove cover from seat hinge.
3. Remove 4 screws and remove rear seat centre
console.
4. Release rear seat cushion cover retainers and
position cushion aside.
6
REPAIRS
Refit
1. Fit buckle to seat frame and tighten Torx bolt to
40 Nm.
2. Position seat cushion and secure cover
retainers.
3. Fit centre console and tighten screws.
4. Fit hinge cover and tighten screws.
5. Fit rear seat. See BODY, Seats and seat
belts.
RESTRAINT SYSTEMS
SEAT BELT BUCKLE - REAR - 5 DOOR
PRETENSIONER - SEAT BELT - FRONT
Service repair no - 76.73.32
Service repair no - 76.73.75
Remove
Remove
1. Position rear seat forward.
WARNING: See GENERAL INFORMATION,
SRS Precautions.
1. Make the SRS system safe. See GENERAL
INFORMATION, SRS Precautions.
2. Remove rear console. See BODY, Interior
trim components.
2. Remove 3 screws from end cover and remove
covers from seat hinges.
3. Remove 4 Torx bolts from seat lock down
catch and remove catch assembly.
4. Remove Torx bolt from seat belt buckle and
remove buckle.
Refit
1. Fit buckle to catch assembly and tighten Torx
bolt to 40 Nm.
2. Fit catch assembly to seat and tighten Torx
bolts.
3. Fit end cover and tighten screws.
4. Reposition seat.
3. Disconnect and secure pretensioner multiplug.
4. Remove Torx bolt from pretensioner, release
pretensioner from seat location and remove
pretensioner assembly.
WARNING: Store the pretensioner in
accordance with the storage procedures.
See GENERAL INFORMATION, SRS
Precautions.
REPAIRS
7
RESTRAINT SYSTEMS
Refit
SEAT BELT BUCKLE - CENTRE - REAR - 5
DOOR
NOTE: If the pretensioner is to be
replaced, the bar code of the new
pretensioner must be recorded.
Service repair no - 76.73.98
Remove
1. Position pretensioner in seat location and
tighten Torx bolt to 32 Nm.
2. Connect and secure pretensioner multiplug.
3. Fit rear console. See BODY, Interior trim
components.
4. Connect battery leads, earth lead last.
5. Carry out system check by turning the ignition
on and checking that the SRS warning lamp
illuminates, then extinguishes after
approximately 5 seconds.
1. Remove RH rear seat. See BODY, Seats and
seat belts.
2. Remove 2 screws and remove seat belt reel
cover.
8
REPAIRS
RESTRAINT SYSTEMS
6. Release rear of cushion cover from frame.
7. Release sides and front of cushion cover from
frame.
3. Remove nut and release seat belt reel.
8. Release cover and pad from frame.
9. Remove Torx bolt from seat belt buckle and
remove buckle.
4. Remove 5 screws and remove both end covers
from seat hinges.
5. Remove 3 Torx bolts and remove squab from
cushion.
REPAIRS
9
RESTRAINT SYSTEMS
Refit
AIRBAG - STEERING WHEEL
1. Position seat belt buckle and tighten Torx bolt
to 40 Nm.
2. Fit cover and pad to frame.
3. Fit front and sides of cushion cover to frame.
4. Fit rear of cushion cover to frame.
5. Fit cushion to squab and tighten Torx bolts.
6. Fit end covers and tighten screws.
7. Position seat belt reel and tighten nut to 32
Nm.
8. Fit seat belt reel cover and tighten screws.
9. Fit rear seat. See BODY, Seats and seat
belts.
Service repair no - 76.74.01
Remove
WARNING: See GENERAL INFORMATION,
SRS Precautions.
1. Make the SRS system safe. See GENERAL
INFORMATION, SRS Precautions.
2. Remove 2 Torx bolts securing the airbag
module to steering wheel.
3. Release airbag module from steering wheel.
CAUTION: Do not allow the airbag module
to hang by the harness.
4. Disconnect harness connector from the airbag
module.
5. Remove airbag module.
WARNING: Store the airbag module in
accordance with the storage procedures.
See GENERAL INFORMATION, SRS
Precautions.
10
REPAIRS
RESTRAINT SYSTEMS
Refit
AIRBAG - PASSENGER
NOTE: If the airbag module is to be
replaced, the bar code of the new module
must be recorded.
1. Position airbag module and make connection
with harness upwards as shown in illustration.
2. Fit airbag to steering wheel and hand start the
2 Torx screws. Tighten screws to 9 Nm.
3. Connect battery leads, earth lead last.
Service repair no - 76.74.02
Remove
WARNING: See GENERAL INFORMATION,
SRS Precautions.
1. Make the SRS system safe. See GENERAL
INFORMATION, SRS Precautions.
2. Remove 2 screws securing fascia trim.
3. Remove cover.
4. Remove 4 Torx screws securing airbag to
fascia.
5. Release airbag from fascia.
CAUTION: Do not allow the airbag module
to hang by the harness.
6. Disconnect multiplug holder and multiplug from
airbag.
7. Remove airbag.
WARNING: Store the airbag module in
accordance with the storage procedures.
See GENERAL INFORMATION, SRS
Precautions.
REPAIRS
11
RESTRAINT SYSTEMS
Refit
ROTARY COUPLER
NOTE: If the airbag module is to be
replaced, the bar code of the new module
must be recorded.
1. Position airbag to fascia, connect multiplug and
multiplug holder.
2. Align airbag to fascia and tighten torx screws to
9 Nm.
3. Position fascia trim and tighten screws.
4. Connect battery leads, earth lead last.
Service repair no - 76.74.20
Remove
WARNING: See GENERAL INFORMATION,
SRS Precautions.
1. Make the SRS system safe. See GENERAL
INFORMATION, SRS Precautions.
CAUTION: Ensure front road wheels are in
the straight ahead position.
2. Remove steering wheel. See STEERING,
Repairs.
3. Remove 2 screws securing lower half of
steering column nacelle.
4. Remove lower and upper halves of nacelle.
12
REPAIRS
RESTRAINT SYSTEMS
DIAGNOSTIC CONTROL UNIT (DCU)
Service repair no - 76.74.68
Service repair no - 76.74.68/20
Remove
WARNING: See GENERAL INFORMATION,
SRS Precautions.
1. Make the SRS system safe. See GENERAL
INFORMATION, SRS Precautions.
2. Remove heater assembly. See HEATING &
VENTILATION, Repairs.
5. If the rotary coupler is being re-used place
adhesive tape around moulding to prevent
rotation.
6. Disconnect 2 multiplugs from rotary coupler.
7. Remove 4 screws and remove rotary coupler.
Models with air conditioning fitted
CAUTION: Do not dismantle the rotary
coupler, it has no serviceable parts and
must be replaced as a complete assembly.
Refit
CAUTION: Ensure front road wheels are in
the straight ahead position.
1. Ensure the rotary coupler is installed in its
centred position, as indicated by the white
segment on the indicator wheel.
2. Fit rotary coupler and secure with screws.
3. Connect multiplugs to rotary coupler.
4. Fit upper and lower halves of nacelle to
steering column and tighten screws.
5. If fitting existing rotary coupler, remove
retaining tape from rotary coupler. If fitting new
rotary coupler, remove blue locking tab from
rotary coupler.
6. Fit steering wheel. See STEERING, Repairs.
3. Disconnect 2 multiplugs from air conditioning
switches.
4. Remove 2 nuts securing evaporator.
5. Release evaporator from drain hose and air
intake.
6. Remove evaporator.
7. Collect air duct and pipe seal.
REPAIRS
13
RESTRAINT SYSTEMS
All models
Refit
1. Fit DCU.
2. Fit earth lead and tighten bolts to 9 Nm.
WARNING: The vehicle crash sensor is
incorporated inside the DCU, it is
imperative that bolts securing the DCU are
tightened to their correct torque.
3.
4.
5.
6.
Connect multiplug to DCU.
Fit carpet and secure to bulkhead.
Fit carpet retainer, fit and tighten Torx screws.
Fit scrivet to front of carpet retainer.
Models with air conditioning fitted
8. Remove scrivet from front of passenger side
carpet retainer.
9. Remove 5 Torx screws from carpet retainer.
10. Remove carpet retainer.
7. Fit air duct and pipe seal.
8. Fit evaporator assembly to drain hose and air
intake.
9. Fit evaporator to studs and secure with nuts.
10. Connect multiplugs to air conditioning
switches.
11. Fit NEW receiver drier. See AIR
CONDITIONING, Repairs.
All models
12. Fit heater assembly. See HEATING &
VENTILATION, Repairs.
13. Connect battery leads, earth lead last.
11. Remove 3 retainers securing carpet to
bulkhead.
12. Pull carpet back for access to DCU.
13.
14.
15.
16.
14
Disconnect multiplug from DCU.
Remove 3 bolts securing DCU.
Release earth lead.
Remove DCU.
REPAIRS
BODY
CONTENTS
Page
DESCRIPTION AND OPERATION
FRONT WINDOW REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WINDOW REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TAIL DOOR WINDOW REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DOOR CENTRAL LOCKING COMPONENTS . . . . . . . . . . . . . . . . . . . . . .
REAR DOOR CENTRAL LOCKING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . .
TAIL DOOR LOCKING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CENTRAL DOOR LOCKING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
3
4
5
6
7
ADJUSTMENTS
DOOR STRIKER - CHECK AND ADJUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DOOR - ALIGN ON HINGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DOORS
DOOR ASSEMBLY - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DOOR ASSEMBLY - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DOOR ASSEMBLY - TAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GLASS - FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
GLASS - REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SEAL - GLASS CHANNEL - REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SCREEN - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
QUARTER LIGHT - REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REGULATOR - REAR DOOR GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REGULATOR - REAR SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
WAIST SEAL - TAIL DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CASING - FRONT DOOR - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CASING - FRONT DOOR - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
CASING - REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
CASING - TAIL DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
WATER SHEDDER - LOWER - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
POCKET - FRONT DOOR - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
WATER SHEDDER - UPPER - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
WATER SHEDDER - TAIL DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
WATER SHEDDER - FRONT DOOR - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . 20
WATER SHEDDER - REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
LATCH - FRONT DOOR - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
LATCH - FRONT DOOR - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
LATCH - REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
LATCH - TAIL DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DOOR RELEASE - INTERIOR - FRONT DOOR - 3 DOOR . . . . . . . . . . . . . . . . . . 26
DOOR RELEASE - INTERIOR - FRONT DOOR - 5 DOOR . . . . . . . . . . . . . . . . . . 26
DOOR RELEASE - INTERIOR - REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CABLE - INTERIOR DOOR RELEASE - FRONT DOOR . . . . . . . . . . . . . . . . . . . . 27
CABLE - INTERIOR DOOR RELEASE - REAR DOOR . . . . . . . . . . . . . . . . . . . . . 28
FINISHER - UPPER - TAIL DOOR GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
FINISHER - SIDE - TAIL DOOR GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
HANDLE - EXTERIOR - REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
HANDLE - EXTERIOR - TAIL DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
HANDLE - EXTERIOR - FRONT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
DOOR PULL - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
BODY
CONTENTS
Page
EXTERIOR FITTINGS
WING - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
WHEEL ARCH LINER - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PANEL - UNDERBELLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MIRROR - EXTERIOR - ELECTRIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MUD FLAP - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MUD FLAP - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MOUNTING BRACKET - SPARE WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SIDE RAIL - ROOF RACK - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
BONNET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CABLE - BONNET RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
BUMPER VALANCE - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
BUMPER VALANCE - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FINISHER - SILL - LOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FINISHER - ROOF PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
WHEEL ARCH EXTENSION - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
GRILLE - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
VENT - REAR QUARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INTERIOR TRIM COMPONENTS
SUN VISOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FINISHER - ’A’ POST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CASING - REAR QUARTER LOWER - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CASING - REAR QUARTER LOWER - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CASING - REAR QUARTER UPPER - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CASING - REAR QUARTER UPPER - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FINISHER - ’B/C’ POST UPPER - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FINISHER -’B/C’ POST LOWER - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CASING - BODY SIDE - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CONSOLE - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
CONSOLE - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FASCIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
STOWAGE BOX - FASCIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CARPET - LOADSPACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
HEADLINING - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
HEADLINING - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SCREENS
WINDSCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
GLASS - BODY SIDE - REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
BODY
CONTENTS
Page
SEATS AND SEAT BELTS
SEAT - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SEAT - RH REAR - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CUSHION AND SQUAB - REAR SEAT - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . 3
CUSHION COVER - FRONT SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CUSHION COVER - RH REAR SEAT - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CUSHION COVER - REAR SEAT - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
CUSHION COVER - LH REAR SEAT - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . 10
FINISHER - SEAT BASE - FRONT SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FINISHER - CUSHION SIDE - FRONT SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LUMBAR SUPPORT - FRONT SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LATCH ASSEMBLY - REAR SQUAB - RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
LATCH ASSEMBLY - REAR SQUAB - LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SQUAB COVER - FRONT SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SQUAB COVER - REAR SEAT - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SQUAB COVER - LH REAR SEAT - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SQUAB COVER - RH REAR SEAT - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
SUNROOF
SUN ROOF ASSEMBLY - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
WIND DEFLECTOR - GLASS SUN ROOF - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . 3
SEAL - SUN ROOF TRAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SUN ROOF ASSEMBLY - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PANEL GLASS - SUN ROOF - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SEAL - PANEL GLASS - SUN ROOF - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MOTOR - SUN ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
DRIVE CABLES & SLIDE ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DRAIN TUBE - SUN ROOF - FRONT - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DRAIN TUBE - SUN ROOF - REAR - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FINISHER - SUN ROOF FLANGE TO HEADLINING . . . . . . . . . . . . . . . . . . . . . . . 9
WIND DEFLECTOR - SUN ROOF - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
BLIND - SUN ROOF - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SWITCH - SUN ROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SEAL - SUN ROOF TRAY - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
BODY
DOOR ASSEMBLY - FRONT
Service repair no - 76.28.01/99
Remove
Refit
1. With assistance position door to hinges.
2. Fit ’C’ clips to hinge pins.
3. Position check strap to ’A’ post and secure with
NEW roll pin.
4. Feed door harness through ’A’ post and secure
harness sheath.
5. Connect and secure multiplugs at base of ’A’
post.
6. Check door alignment. See Adjustments.
1. Release and disconnect 2 multiplugs from
lower ’A’ post.
2. Release harness sheath from ’A’ post and pull
door harness through ’A’ post.
3. Remove roll pin from door check strap, and
release check strap from ’A’ post.
4. Discard roll pin.
5. Remove 2 ’C’ clips from door hinges.
6. With assistance raise and remove door.
DOORS
1
BODY
DOOR ASSEMBLY - REAR
Service repair no - 76.28.02/99
Remove
1. Release ’B/C’ post upper finisher and position
aside. See Interior trim components.
2. Release and disconnect multiplug from lower
’B/C’ post.
3. Release harness sheath from ’B/C’ post and
pull door harness through ’B/C’ post.
4. Remove roll pin from door check strap, and
release check strap from ’B/C’ post.
5. Discard roll pin.
6. Remove 2 ’C’ clips from door hinges.
7. With assistance raise and remove door.
2
DOORS
Refit
1. With assistance position door to hinges.
2. Fit ’C’ clips to hinge pins.
3. Position check strap to ’B/C’ post and secure
with NEW roll pin.
4. Feed door harness through ’B/C’ post and
secure harness sheath.
5. Connect and secure multiplug at base of ’B/C’
post.
6. Fit ’B/C’ post upper finisher. See Interior trim
components.
7. Check door alignment. See Adjustments.
BODY
DOOR ASSEMBLY - TAIL
Service repair no - 76.28.29/99
Remove
1. Remove spare wheel from tail door.
2. Remove RH rear quarter lower trim casing.
See Interior trim components.
3. Release and disconnect 3 multiplugs and rear
washer tube from lower ’E’ post.
5. Release door harness sheath from ’E’ post and
pull harness through ’E’ post.
6. Mark the outline of hinges to body.
7. Support the weight of the tail door.
8. Remove 6 bolts securing tail door to body.
9. With assistance remove door.
Refit
1. With assistance position door, fit but do not
tighten securing bolts.
2. Position check strap, fit and tighten bolts.
3. Align hinges and tighten bolts to 30 Nm.
4. Feed door harness through ’E’ post and secure
harness sheath.
5. Connect and secure multiplugs and rear
washer tube at ’E’ post.
6. Fit rear quarter lower casing.See Interior trim
components.
7. Fit spare wheel to tail door.
4. Remove 2 screws from tail door check strap,
release strap and position aside.
DOORS
3
BODY
GLASS - FRONT DOOR
Service repair no - 76.31.01
Remove
1. Remove front door water shedder. See this
section.
2. Remove 4 screws securing door speaker.
3. Disconnect multiplug from door speaker.
4. Remove door speaker.
7. Release glass from clamps, raise and rotate
glass to remove from door frame.
Refit
1. Locate glass in door frame and rotate into
position to engage seal and clamps.
2. Tighten bolts securing glass to 8 Nm.
3. Raise/lower glass to check operation.
4. Position door speaker, connect multiplug, fit
and tighten screws.
5. Fit water shedder. See this section.
5. Lower glass to access clamp bolts.
6. Loosen 2 bolts securing glass to clamps.
4
DOORS
BODY
GLASS - REAR DOOR
Service repair no - 76.31.02
Remove
1. Remove rear door water shedder. See this
section.
2.
3.
4.
5.
6.
Lower glass to access nuts on clamps.
Loosen 2 nuts securing clamps to glass.
Remove seal from door.
Release glass from quarter light seal.
Raise glass and remove from door.
Refit
1. Fit glass to door and locate in quarter light
seal.
2. Fit seal to door.
3. Position glass in clamps and tighten nuts to 8
Nm.
4. Raise/lower glass to check seal fit.
5. Fit water shedder. See this section.
DOORS
5
BODY
SEAL - GLASS CHANNEL - REAR DOOR
Service repair no - 76.31.14
Remove
1. Remove rear door glass. See this section.
2. Release seal from flange. Remove lower
section first, then the front vertical section,
followed by the top section.
CAUTION: If seal is to be re-used, do not
use excessive force or seal will be
damaged.
3. Release top corner of quarter light from frame.
Rotate quarter light and seal, release rest of
seal from flange and remove quarter light and
seal from door.
4. Remove quarter light from seal.
Refit
1. Fit quarter light to seal.
2. Lubricate seal around quarter light with soft
soap.
3. Position quarter light and seal to flange at
bottom rear corner of window aperture and
rotate into top rear corner. Using dividing bar,
pull quarter light rearwards to locate seal
around quarter light on flange.
6
DOORS
4. Starting at top of divider bar, push seal onto
top flange and locate in top front corner.
Ensure radius of seal matches door profile.
5. Ease seal away from front flange and locate
seal in bottom front corner. Ensure radius of
seal at bottom front corner matches profile of
door and that seal is still correctly located in
top front corner, then push seal onto front
flange.
6. Push seal onto bottom flange.
7. Fit rear door glass. See this section.
BODY
SCREEN - REAR
Service repair no - 76.31.20
Remove
1. Remove tail door water shedder. See this
section.
3. Lower screen to access clamp bolts.
CAUTION: Remove screen carefully to
avoid damaging element connections.
4. Loosen both clamp bolts, release and remove
rear screen.
2. Disconnect 2 Lucars from heater element.
DOORS
7
BODY
Refit
10. Ensure there is full screen to seal contact.
11. Lower glass and tighten lock nuts to 14 Nm.
CAUTION: Fit screen carefully to avoid
damaging heater element connections.
CAUTION: Always tighten lock nuts with
the screen lowered.
12. Recheck pre-load.
13. Raise and lower screen to confirm correct
alignment.
14. Fit water shedder. See this section.
1. Position screen to door and align in clamps
using timing marks on screen.
2. Ensure glass is fully pushed down in clamp
closest to door hinge, then tighten clamp bolt.
Position screen horizontally by lifting clamp
closest to door latch so that screen heater
element is aligned with waist seal.
3. Tighten clamp bolts to 8 Nm.
4. Raise screen and connect Lucars to screen
heater element.
5. Ensure a 5mm equal gap exists between
screen and both ’E’ post finishers. If required,
adjust screen again using timing marks.
6. Loosen lower adjuster lock nuts.
7. Loosen pre-load screws so screen clears seal.
8. Adjust pre-load screws until screen is just in
contact with seal.
9. Adjust pre-load screws until screen applies a
1mm pre-load on seal.
8
DOORS
BODY
QUARTER LIGHT - REAR DOOR
REGULATOR - REAR DOOR GLASS
Service repair no - 76.31.31
Service repair no - 76.31.46
The procedure for renewing the quarter light is
identical to renewing the rear door glass channel
seal. See this section.
Remove
1. Remove water shedder from rear door. See
this section.
2. Lower glass to access clamp nuts.
3. Loosen 2 nuts securing glass to clamps.
4. Release glass from clamps, raise glass and
secure in position with a suitable wedge.
5. Remove 4 bolts securing regulator to door.
6. Manoeuvre regulator into bottom of door and
remove through aperture.
Refit
1. Position regulator in door and align to bolt
holes, fit and tighten bolts.
2. Remove wedge and lower glass.
3. Locate glass to clamps and tighten clamp nuts
to 8 Nm .
4. Raise and lower glass to ensure correct
operation.
5. Fit water shedder. See this section.
DOORS
9
BODY
REGULATOR - REAR SCREEN
Service repair no - 76.31.65
Remove
1. Remove rear screen. See this section.
2. Disconnect multiplug from regulator motor.
3.
4.
5.
6.
7.
10
Remove 3 nuts securing regulator motor.
Remove 4 nuts securing top of cable guides.
Remove 2 nuts securing pre-load adjusters.
Release regulator from door.
Remove regulator from door.
DOORS
Refit
1. Position regulator to door and unclip motor
transit package from rail.
2. Connect harness clip and align regulator to
door.
3. Fit pre-load adjusters to cable guides and
tighten nuts.
4. Fit and tighten nuts to top of cable guides.
5. Fit and tighten nuts to regulator motor.
6. Connect multiplug to regulator motor.
7. Fit rear screen. See this section.
BODY
WAIST SEAL - TAIL DOOR
Service repair no - 76.31.67
Remove
1. Lower rear screen.
2.
3.
4.
5.
Raise wiper blade away from seal.
Remove 2 screws from ends of seal.
Release seal from door flanges.
Remove waist seal.
Refit
1.
2.
3.
4.
Position seal to door flanges.
Fit and tighten screws.
Lower wiper blade onto seal.
Raise rear screen.
DOORS
11
BODY
CASING - FRONT DOOR - 3 DOOR
Service repair no - 76.34.01
6. Remove 6 Torx screws securing door casing,
release casing from 3 studs and sill button,
remove casing.
Remove
7. Release 7 clips securing speaker grill and
remove grill.
8. Remove 4 casing studs.
9. Remove sill button support.
Refit
1. Release cheater panel.
2. Disconnect Lucars and remove cheater panel.
1.
2.
3.
4.
5.
6.
7.
8.
9.
3. Remove door pull centre trim.
4. Remove 2 screws securing door pull and
remove door pull.
5. Remove screw securing door handle
escutcheon and remove escutcheon.
12
DOORS
Position speaker grill and secure clips.
Fit sill button support.
Ensure casing studs are in position.
Position casing to door, locate sill button and
secure in studs.
Fit and tighten Torx screws.
Position door escutcheon, fit and tighten screw.
Position door pull, fit and tighten screws.
Fit door pull centre trim.
Connect Lucars to cheater panel and locate
panel in position.
BODY
CASING - FRONT DOOR - 5 DOOR
Service repair no - 76.34.01
Remove
7.
8.
9.
10.
11.
Remove 2 screws from door pull.
Remove cup retainer.
Remove 5 screws securing door pocket.
Release 7 trim studs.
Remove casing.
1. Release cheater panel from door.
2. Disconnect Lucars from tweeter speaker.
3. Remove cheater panel.
4. Remove screw securing door release
escutcheon.
5. Push escutcheon in and to the rear of door to
release securing catch.
6. Remove escutcheon.
DOORS
13
BODY
Do not carry out further dismantling if
component is removed for access only.
Refit
1.
2.
3.
4.
5.
Position casing to door and engage trim studs.
Fit screws securing door pocket.
Fit cup holder.
Fit door pull.
Position door release escutcheon and secure
with screw.
6. Connect Lucars to tweeter speaker.
7. Fit cheater panel.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
14
Remove 7 trim studs from casing.
Remove 4 Torx screws securing door pocket.
Remove door pocket.
Remove 4 Torx screws from door pull.
Remove door pull.
Remove 4 Torx screws from door speaker
grille.
Remove speaker grille.
Release retainer and remove sill button guide.
Fit sill button guide to replacement casing and
secure with retainer.
Fit speaker grille to replacement casing and
secure with Torx screws.
Fit door pull to replacement casing and secure
with Torx screws.
Fit door pocket to replacement casing and
secure with Torx screws.
Fit trim studs to replacement casing.
DOORS
BODY
Do not carry out further dismantling if
component is removed for access only.
CASING - REAR DOOR
Service repair no - 76.34.04
Remove
1. Remove clip from window winder handle,
remove handle and escutcheon.
2. Remove screw securing door release
escutcheon.
3. Push escutcheon in and to the rear of door to
release from securing catch, remove
escutcheon.
4. Remove 2 screws from door pull.
5. Release 10 trim studs.
6. Remove casing.
7. Remove 4 Torx screws from door pull, and
remove door pull.
8. Remove 4 Torx screws from speaker grille and
remove grille.
9. Release retainer and remove sill button guide.
10. Remove 10 trim studs.
11. Fit trim studs to replacement trim casing.
12. Fit sill button guide to replacement casing and
secure with retainer.
13. Fit speaker grille to replacement casing and
secure with Torx screws.
14. Fit door pull to replacement casing and secure
with Torx screws.
Refit
1. Position casing to door and engage trim studs.
2. Fit door pull screws.
3. Position door release escutcheon and secure
with screw.
4. Fit window winder escutcheon and window
winder and secure with clip.
DOORS
15
BODY
CASING - TAIL DOOR
Service repair no - 76.34.10
Remove
1. Remove 4 screws securing bottom of casing.
2. Release 7 clips securing sides and bottom of
casing.
3. Release 5 clips securing top of casing.
4. Remove casing.
5. Remove 7 trim studs.
16
DOORS
Refit
1.
2.
3.
4.
Ensure trim studs are in position.
Position casing and secure in top clips.
Secure clips on side and bottom of casing.
Fit screws to bottom of casing.
BODY
WATER SHEDDER - LOWER - 3 DOOR
POCKET - FRONT DOOR - 3 DOOR
Service repair no - 76.34.18
Service repair no - 76.34.19
NOTE: Always replace a damaged water
shedder.
Remove
1. Remove front door pocket. See this section.
Remove
1. Remove 8 Torx screws securing pocket to door
and remove pocket.
Refit
1. Position pocket, fit and tighten Torx screws.
2. Release and discard water shedder.
Refit
1. Clean door contact area with white spirit.
2. Position NEW water shedder to door and seal
in position, by applying hand pressure to centre
bottom of shedder first then move out from this
point in both directions applying an even
pressure to the seal, smooth out any creases.
CAUTION: It is crucial that no creases are
present along the base of the water
shedder.
NOTE: To obtain an effective seal when
fitting a new water shedder, ensure that
the water shedder and door contact
surface are at room temperature: 18 °C to 30 °C.
3. Fit front door pocket. See this section.
DOORS
17
BODY
WATER SHEDDER - UPPER - 3 DOOR
Service repair no - 76.34.24
NOTE: Always replace a damaged water
shedder.
Remove
1. Remove front door casing. See this section.
Refit
1. Clean door contact area with white spirit.
2. Position NEW water shedder to door and seal
in position, by applying hand pressure to centre
bottom of shedder first then move out from this
point in both directions applying an even
pressure to the seal, smooth out any creases.
CAUTION: It is crucial that no creases are
present along the base of the water
shedder.
NOTE: To obtain an effective seal when
fitting a new water shedder, ensure that
the water shedder and door contact
surface are at room temperature: 18 °C to 30 °C.
3. Fit front door casing. See this section.
2. Release and discard water shedder.
18
DOORS
BODY
WATER SHEDDER - TAIL DOOR
Service repair no - 76.34.25
NOTE: Always replace a damaged water
shedder.
Remove
1. Remove tail door casing. See this section.
Refit
1. Clean door contact area with white spirit.
2. Position NEW water shedder to door and seal
in position, by applying hand pressure to centre
bottom of shedder first then move out from this
point in both directions applying an even
pressure to the seal, smooth out any creases.
CAUTION: It is crucial that no creases are
present along the base of the water
shedder.
NOTE: To obtain an effective seal when
fitting a new water shedder, ensure that
the water shedder and door contact
surface are at room temperature: 18 °C to 30 °C.
3. Fit tail door casing. See this section.
2. Release and discard water shedder.
DOORS
19
BODY
WATER SHEDDER - FRONT DOOR - 5 DOOR
Service repair no - 76.34.26
NOTE: Always replace a damaged water
shedder.
Remove
1. Remove front door speaker. See
ELECTRICAL, Repairs.
Refit
1. Clean door contact area with white spirit.
2. Position NEW water shedder to door and seal
in position, by applying hand pressure to centre
bottom of shedder first then move out from this
point in both directions applying an even
pressure to the seal, smooth out any creases.
CAUTION: It is crucial that no creases are
present along the base of the water
shedder.
NOTE: To obtain an effective seal when
fitting a new water shedder, ensure that
the water shedder and door contact
surface are at room temperature: 18 °C to 30 °C.
3. Fit door casing retainers.
4. Fit front door speaker. See ELECTRICAL,
Repairs.
2. Noting their fitted position, remove door casing
retainers.
3. Release and discard water shedder.
20
DOORS
BODY
WATER SHEDDER - REAR DOOR
Service repair no - 76.34.28
NOTE: Always replace a damaged water
shedder.
Remove
1. Remove rear door speaker. See
ELECTRICAL, Repairs.
Refit
1. Clean door contact area with white spirit.
2. Position NEW water shedder to door and seal
in position, by applying hand pressure to centre
bottom of shedder first then move out from this
point in both directions applying and even
pressure to the seal, smooth out any creases.
CAUTION: It is crucial that no creases are
present along the base of the water
shedder.
NOTE: To obtain an effective seal when
fitting a new water shedder, ensure that
the water shedder and door contact
surface are at room temperature: between 18 °C
to 30 °.
3. Fit 10 trim stud retainers and 2 door pull
securing screw retainers.
4. Fit rear door speaker. See ELECTRICAL,
Repairs.
2. Noting their fitted position, remove 10 trim stud
retainers and 2 door pull securing screw
retainers.
3. Release and discard water shedder.
DOORS
21
BODY
LATCH - FRONT DOOR - 3 DOOR
Service repair no - 76.37.12
Remove
1. Remove upper water shedder. See this
section.
8. Open latch security flap.
9. Release interior release cable clamp from
latch.
10. Disengage interior release cable from latch.
Refit
2.
3.
4.
5.
6.
Remove sill button lock rod from latch.
Release control rod from exterior handle.
Disconnect multiplug from latch.
Remove 3 Torx screws from latch
On driver’s door, release door lock barrel
paddle from latch.
7. Remove latch from aperture.
22
DOORS
1. Secure interior release cable to latch and close
latch security flap.
2. Fit interior release cable clamp to latch.
3. Position latch to door. On driver’s door, align
lock barrel paddle to latch.
4. Fit and tighten Torx screws securing latch.
5. Connect multiplug to latch.
6. Connect exterior handle control rod to latch.
7. Fit sill button lock rod to latch.
8. Check operation of latch.
9. Fit front door water shedder. See this section.
BODY
LATCH - FRONT DOOR - 5 DOOR
Service repair no - 76.37.12
Remove
1. Remove water shedder from front door. See
this section.
9. Open latch security flap.
10. Release interior release cable clamp from
latch.
11. Disengage interior release cable from latch.
Refit
2.
3.
4.
5.
Remove sill button lock rod from latch.
Release control rod from exterior handle.
Disconnect multiplug from latch.
Remove 2 screws securing RH glass cable
guide and position guide aside.
6. Remove 3 Torx screws from latch
7. On driver’s door, release door lock barrel
paddle from latch.
8. Remove latch from aperture.
1. Secure interior release cable to latch and close
latch security flap.
2. Fit interior release cable clamp to latch.
3. Position latch to door. On driver’s door, align
lock barrel paddle to latch.
4. Fit and tighten Torx screws securing latch.
5. Position RH glass cable guide and tighten
screws.
6. Connect multiplug to door latch.
7. Connect exterior handle control rod to latch.
8. Fit sill button lock rod to latch.
9. Check operation of door latch.
10. Fit front door water shedder. See this section.
DOORS
23
BODY
LATCH - REAR DOOR
Service repair no - 76.37.13
Remove
1. Remove rear door water shedder See this
section.
7. Open latch security flap.
8. Release interior release cable clamp from
latch.
9. Disengage interior release cable from latch.
Refit
2. Release exterior handle control rod from latch.
3. Release sill button lock rod and remove lock
rod.
4. Disconnect multiplug from latch.
5. Remove 3 Torx screws securing latch.
6. Remove latch through aperture.
24
DOORS
1. Secure interior release cable to latch and close
latch security flap.
2. Position latch to door, fit and tighten torx
screws.
3. Connect multiplug to latch.
4. Connect exterior handle control rod to latch.
5. Fit and secure sill button lock rod.
6. Check operation of latch.
7. Fit water shedder. See this section.
BODY
LATCH - TAIL DOOR
Service repair no - 76.37.16
Remove
1. Remove tail door water shedder. See this
section.
7. Remove screw from solenoid motor and
remove motor from latch.
Refit
1. Position solenoid motor to latch, fit and tighten
screw.
2. Position door latch, connect multiplugs and
harness clips.
3. Locate door latch in position, fit and tighten
screws.
4. Fit water shedder. See this section.
2. Remove 4 screws securing door latch.
3. Release door latch to access harness clips and
multiplugs.
4. Disconnect 2 multiplugs from door latch.
5. Release door harness clip from latch.
6. Remove door latch.
DOORS
25
BODY
DOOR RELEASE - INTERIOR - FRONT DOOR - 3
DOOR
DOOR RELEASE - INTERIOR - FRONT DOOR - 5
DOOR
Service repair no - 76.37.31
Service repair no - 76.37.31
Remove
Remove
1. Remove upper water shedder. See this
section.
1. Remove front door water shedder. See this
section.
2. Drill out 2 rivets from door release.
3. Remove door release.
4. Release cable from door release.
2. Drill out 2 rivets from door release.
3. Remove door release.
4. Release cable from door release.
Refit
Refit
1. Connect cable to door release.
2. Position door release and secure with rivets.
3. Fit water shedder. See this section.
26
DOORS
1. Connect cable to door release.
2. Position door release and secure with rivets.
3. Fit water shedder. See this section.
BODY
DOOR RELEASE - INTERIOR - REAR DOOR
CABLE - INTERIOR DOOR RELEASE - FRONT
DOOR
Service repair no - 76.37.32
Service repair no - 76.37.60
Remove
Remove
1. Remove rear door water shedder. See this
section.
2. Release cable from door release.
3. Drill out 2 rivets from door release.
4. Remove door release.
1. Remove front door latch. See this section.
2. Release cable from interior door release and
remove cable.
Refit
Refit
1. Connect cable to door release.
2. Position door release and secure with rivets.
3. Fit water shedder. See this section.
1. Connect cable to interior door release.
2. Fit door latch. See this section.
DOORS
27
BODY
CABLE - INTERIOR DOOR RELEASE - REAR
DOOR
FINISHER - UPPER - TAIL DOOR GLASS
Service repair no - 76.43.74
Service repair no - 76.37.61
Remove
Remove
1. Remove rear door latch. See this section.
2. Release cable from door release and remove
cable.
1. Remove tail door glass side finishers. See this
section.
2. Release 5 clips securing finisher to bracket.
3. Remove tail door glass upper finisher.
4. Remove and discard clips from finisher and/or
bracket.
Refit
Refit
1. Connect and secure cable to door release.
2. Fit door latch. See this section.
28
DOORS
1. Fit NEW clips to finisher.
2. Fit finisher and secure clips to bracket.
3. Fit tail door glass side finishers. See this
section.
BODY
FINISHER - SIDE - TAIL DOOR GLASS
Service repair no - 76.43.81
Remove
Refit
1. Fit NEW fixings to finisher.
2. Fit door glass seal to flange.
3. Fit finisher and secure fixings.
1. Open tail door.
2. Release tail door glass seal from aperture for
access to side finisher fixings.
3. Using a suitable trim stud removal tool, release
3 side finisher fixings from studs on body.
4. Remove side finisher from upper fixing.
5. Remove and discard fixings from finisher.
DOORS
29
BODY
HANDLE - EXTERIOR - REAR DOOR
Service repair no - 76.58.02
Remove
1. Remove rear door water shedder. See this
section.
2. Release door latch control rod.
3. Remove grommet to access screw.
4. Remove 3 Torx screws securing door latch
release and lower latch to access screw.
5. Remove 2 screws securing door handle.
6. Remove door handle.
7. Remove door latch control rod.
30
DOORS
Refit
1. Fit door latch control rod to handle.
2. Position handle to door and tighten securing
screws.
3. Position door latch, fit and tighten Torx screws.
4. Fit grommet.
5. Connect door latch control rod.
6. Fit water shedder. See this section.
BODY
HANDLE - EXTERIOR - TAIL DOOR
Service repair no - 76.58.05
Remove
1. Remove tail door water shedder. See this
section.
2. Raise glass by clicking latch.
7. Collect gasket.
Do not carry out further dismantling if
component is removed for access only.
8. Remove nut from lock barrel.
9. Remove lock barrel from handle.
10. Fit lock barrel to replacement handle. Fit and
tighten nut.
Refit
3. Remove 3 nuts securing handle to tail door.
4. Release handle from tail door.
1. Position gasket on handle.
2. Connect multiplug to handle locking
mechanism.
3. Connect Lucars to number plate lamp.
4. Position housing on door, fit and tighten nuts to
5 Nm.
5. Fit water shedder. See this section.
6. Reset latch to lower glass.
7. Close door.
5. Disconnect 2 Lucars from number plate lamp.
6. Disconnect multiplug from locking mechanism
and remove handle.
DOORS
31
BODY
HANDLE - EXTERIOR - FRONT DOOR
Service repair no - 76.58.07
Remove
3 door models
1. Remove upper water shedder. See this
section.
5 door models
2. Remove front door water shedder. See this
section.
7. Remove door handle.
8. Remove latch control rod from handle.
Refit
1. Fit door latch control rod to handle.
2. Position handle to door, fit and tighten screws.
3. Fit grommet.
5 door models
4. Position latch, locate door lock paddle, fit and
tighten Torx screws.
All models
5. Connect control rod to door latch.
6. Fit water shedder. See this section.
All models
3. Release clip securing latch control rod to door
latch, and release rod.
5 door models
4. Remove Torx screws securing door latch,
lower latch and release door lock paddle.
All models
5. Remove grommet to access screw.
6. Remove 2 screws securing door handle.
32
DOORS
BODY
DOOR PULL - FRONT
Service repair no - 76.58.25
Remove
1. Remove front door casing. See this section.
2. Remove 4 Torx screws securing door pull to
door casing.
3. Remove door pull.
Refit
1. Position door pull to door casing, fit and tighten
Torx screws.
2. Fit front door casing. See this section.
DOORS
33
BODY
WING - FRONT
Service repair no - 76.10.24
Remove
1. Remove front mud flap. See this section.
2. Remove lower sill finisher. See this section.
6. Remove 4 bolts securing top of wing.
7. Remove 2 bolts securing front of wing.
8. Remove screw securing wheelarch liner to
under side of wing.
9. Release wing from body, disconnect multiplug
from repeater lamp.
10. Remove front wing from body.
3. Remove 3 Torx screws and 1 bolt securing
rear of front wing.
4. Release wheel arch liner from rear of front
wing.
5. Remove 2 bolts securing wing bracket to ’A’
post.
EXTERIOR FITTINGS
1
BODY
Refit
1.
2.
3.
4.
WHEEL ARCH LINER - FRONT
Position front wing to body.
Connect repeater lamp multiplug.
Align front wing to body.
Fit, but do not tighten, the following:
Torx screws and bolt securing rear of wing to
•
’A’ post.
Bolts securing wing bracket to ’A’ post.
•
Bolts securing top of wing.
•
Bolts securing front of wing.
•
Service repair no - 76.10.48
Remove
1. Raise front of vehicle, one side.
WARNING: Support on safety stands.
2. Remove road wheel(s).
3. Remove front mud flap. See this section.
5. Align wing and tighten bolts and Torx screws,
in sequence shown above, to 5 Nm.
6. Align wheel arch liner to rear of wing.
7. Fit screw securing wheelarch liner to under
side of wing.
8. Fit lower sill finisher. See this section.
9. Fit front mud flap. See this section.
4. Remove 5 screws securing wheel arch to front
wing.
5. Remove 8 scrivets securing wheel arch to
inner wing.
6. Remove wheel arch liner from inner wing.
Refit
1. Position wheel arch liner to inner wing, locate
behind wheel arch cladding.
2. Fit scrivets securing wheel arch liner to inner
wing.
3. Fit screws securing wheel arch liner to front
wing.
4. Fit mud flap. See this section.
5. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque wrench
settings.
6. Remove stand(s) and lower vehicle.
2
EXTERIOR FITTINGS
BODY
PANEL - UNDERBELLY
MIRROR - EXTERIOR - ELECTRIC
Service repair no - 76.10.50
Service repair no - 76.10.57
Remove
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove 2 screws securing bumper valance to
underbelly panel brackets.
3. Remove 2 bolts securing rear of underbelly
panel.
4. Remove 8 bolts securing underbelly panel
frame.
5. Remove underbelly panel.
Refit
1. Position underbelly panel to vehicle.
2. Fit bolts securing frame and tighten to 45 Nm.
3. Fit bolts securing rear of panel and tighten to 8
Nm.
4. Fit screws securing bumper valance to
brackets.
5. Remove stand(s) and lower vehicle.
1. Remove cheater panel.
2. Disconnect 2 Lucars from tweeter and place
cheater panel aside.
3. Disconnect multiplug from mirror.
4. Hold mirror and remove 2 Torx screws.
5. Remove mirror.
6. Collect clamping plate.
Refit
1. Position mirror, locate clamping plate, fit and
tighten Torx screws to 6 Nm.
2. Connect multiplug to mirror.
3. Connect Lucars to tweeter in cheater panel.
4. Fit cheater panel.
EXTERIOR FITTINGS
3
BODY
MUD FLAP - FRONT
MUD FLAP - REAR
Service repair no - 76.10.83
Service repair no - 76.10.85
Remove
Remove
1. Raise rear of vehicle.
WARNING: Support on safety stands.
2. Remove road wheel(s).
1. Turn steering wheel to full lock.
2. Remove 3 screws securing mud flap.
3. Remove mud flap.
Refit
1. Position mud flap to body and secure with
screws.
2. Straighten steering.
3. Remove 3 screws securing mud flap.
4. Remove mud flap.
Refit
1. Position mud flap to body and secure with
screws.
4
EXTERIOR FITTINGS
BODY
MOUNTING BRACKET - SPARE WHEEL
Service repair no - 76.11.18
Remove
5. Remove 6 bolts and 2 nuts securing spare
wheel mounting bracket to tail door.
6. Remove mounting bracket.
Refit
1. Lower tail door glass and remove 3 screws
securing high mounted stop lamp.
2. Disconnect multiplug and remove lamp.
1. Position spare wheel mounting bracket to tail
door and tighten bolts to Nm.
2. Tighten mounting bracket nuts to Nm.
3. Position stop lamp and connect multiplug.
4. Fit and tighten screws securing stop lamp.
5. Fit spare wheel and tighten nuts to 45 Nm.
6. Raise tail door glass.
3. Remove 3 nuts securing spare wheel to
mounting bracket.
4. Remove spare wheel from mounting bracket.
EXTERIOR FITTINGS
5
BODY
SIDE RAIL - ROOF RACK - 5 DOOR
BONNET
Service repair no - 76.11.30
Service repair no - 76.16.01/99
Remove
Remove
1. Support bonnet in open position.
2. Fit protection covers to wings and mark hinge
outline on bonnet if bonnet is to be refitted.
1. Remove finishers from feet of side rail.
2. Unscrew 4 Torx bolts securing side rail to roof
panel.
3. Remove side rail and 2 gaskets.
Do not carry out further dismantling if
component is removed for access only.
4. Remove seal from each Torx bolt.
5. Remove Torx bolts from side rail.
6. Fit Torx bolts and seals to replacement side
rail.
Refit
1. Fit gaskets to side rail.
2. Position side rail and tighten Torx bolts to 22
Nm.
3. Fit finishers to feet of side rail.
6
EXTERIOR FITTINGS
3. Disconnect windscreen washer tube at elbow
joint.
4. With assistance, remove bolts securing bonnet
and remove bonnet.
Refit
1. With assistance, position bonnet and align
hinges to marks on bonnet.
2. Lightly tighten bolts.
3. Connect windscreen washer tube.
4. Close bonnet to safety catch position, check
that bonnet is aligned to both front wings and
that gaps are equal.
5. Finally tighten hinge bolts to 9 Nm.
BODY
CABLE - BONNET RELEASE
Service repair no - 76.16.29
Remove
1. Remove front grille. See this section.
Models with air conditioning:
2. Remove condenser. See AIR
CONDITIONING, Repairs.
All models:
9. Remove bolt securing bonnet release lever to
’A’ post lower panel.
10. Remove bonnet release cable from lever.
11. Remove release lever.
3. Remove radiator threaded retainers from
bonnet locking platform.
4. Drill out 5 rivets and remove bonnet bonnet
latch shield.
5. Disconnect bonnet release cable from lock.
6. Tie a draw string to end of bonnet release
cable and pull cable from bonnet locking
platform.
7. Untie draw string.
8. Remove 3 cable ties securing bonnet release
cable to main harness.
EXTERIOR FITTINGS
7
BODY
Refit
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
12. Pull sound insulation away from bulkhead for
access to bonnet release cable grommet.
13. Remove grommet from bulkhead.
14. Remove bonnet release cable.
11.
12.
Fit bonnet release cable through bulkhead.
Position bonnet release lever.
Connect bonnet release cable to lever.
Fit release lever to ’A’ post and tighten bolt to 9
Nm.
Fit bonnet release cable grommet to bulkhead.
Fit cable ties and secure bonnet release to
main harness.
Fit sound insulation material to bulkhead.
Tie draw string to end of bonnet release cable.
Pull on draw string to feed bonnet release
cable through bonnet locking platform.
Untie draw string and connect bonnet release
cable to bonnet lock lever.
Fit bonnet latch shield and secure with 5 rivets.
Fit and tighten radiator threaded retainers in
bonnet locking platform.
Models with air conditioning:
13. Fit condenser. See AIR CONDITIONING,
Repairs.
All models:
14. Fit front grille. See this section.
15. Close bonnet and check for correct locking
operation.
8
EXTERIOR FITTINGS
BODY
BUMPER VALANCE - FRONT
Service repair no - 76.22.72
Remove
1. Remove front grille. See this section.
2. Remove 12 screws securing bumper valance
to body.
4. Remove wheelarch liner access panel and
loosen bolts under front of each wing.
5. With assistance, remove bumper valance.
Do not carry out further dismantling if
component is removed for access only.
6. Remove number plate.
3. Remove 3 scrivets from bumper valance.
EXTERIOR FITTINGS
9
BODY
7.
8.
9.
10.
11.
Remove 2 screws from bumper grille.
Remove bumper grille.
Remove 2 spire nuts.
Fit spire nuts to replacement bumper valance.
Position bumper grille on replacement bumper
valance and secure with screws.
12. Fit number plate on replacement bumper
valance.
Refit
1. With assistance position bumper valance to
body.
2. Tighten bolts under each front wing to 5 Nm.
3. Fit wheelarch liner access panel.
4. Fit scrivets.
5. Fit screws securing bumper valance to body.
6. Fit front grille. See this section.
10
EXTERIOR FITTINGS
BODY
BUMPER VALANCE - REAR
Service repair no - 76.22.74
Remove
1. Remove rear mud flaps. See this section.
2. Remove both tail lamps. See ELECTRICAL,
Repairs.
3. Remove rear wheel arch extensions. See this
section.
4.
5.
6.
7.
Remove 10 screws securing bumper valance.
Remove 5 scrivets securing bumper valance.
Remove 2 mud flap brackets.
With assistance, remove bumper valance.
EXTERIOR FITTINGS
11
BODY
Refit
FINISHER - SILL - LOWER
1. With assistance, fit bumper valance. Secure
bumper valance with scrivets and screws.
2. Fit mud flap brackets and secure with screws.
3. Fit rear wheel arch extensions. See this
section.
4. Fit both tail lamps. See ELECTRICAL,
Repairs.
5. Fit mud flaps. See this section.
Service repair no - 76.43.28
Remove
1. Raise front of vehicle.
WARNING: Support on safety stands.
2. Remove both jacking point covers.
3. Remove 7 scrivits securing finisher.
4. Release and remove finisher from sill.
Refit
1. Clean mating faces of finisher.
2. Position finisher to sill, locate over jacking
points and secure with scrivits.
3. Fit jacking point covers.
4. Remove stand(s) and lower vehicle.
12
EXTERIOR FITTINGS
BODY
FINISHER - ROOF PANEL
Service repair no - 76.43.68
Remove
1. Remove tail door glass side finisher. See
Doors.
2. Remove roof finisher caps or, if roof rack fitted,
remove side rail. See this section.
3. Using a suitable hooked tool in the front foot
hole of the roof finisher, slide the finisher’s 2
forward clips rearward from the roof channel.
4. Slide the clip rear of the foot hole forward from
the roof channel.
5. Slide the remaining 7 clips from the roof
channel.
6. Remove nut securing rear end of roof finisher.
7. Remove finisher.
EXTERIOR FITTINGS
13
BODY
Refit
1. Fit clips to finisher.
2. Fit finisher to roof channel with forward two
clips.
3. Slide finisher to align with screen. Feed
forward clip below screen seal.
4. Fit remaining clips to roof channel.
5. Fit nut to secure rear end of finisher.
6. Ensure full length of finisher is correctly seated
in roof channel.
7. Fit roof finisher caps or roof rack side rail. See
this section.
8. Fit tail door glass side finisher. See Doors.
14
EXTERIOR FITTINGS
BODY
WHEEL ARCH EXTENSION - REAR
3 door models
Service repair no - 76.43.94
Remove
1. Raise rear of vehicle.
2. Remove road wheel(s).
5 door models
6. Remove 6 scrivets securing extension to edge
of wheel arch and sill panel.
7. Remove wheel arch extension from 8 fixing
studs.
8. Remove fasteners from arch extension
3. Remove 2 scrivets securing extension to edge
of wheel arch.
4. Remove wheel arch extension from 2 fixing
studs.
5. Remove fasteners from arch extension.
EXTERIOR FITTINGS
15
BODY
Refit
GRILLE - FRONT
1.
2.
3.
4.
Fit fasteners to arch extension.
Fit wheel arch extension to studs.
Fit scrivets securing extension to wheel arch.
Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque wrench
settings.
5. Remove stand(s) and lower vehicle.
Service repair no - 76.55.03
Remove
1. Remove 4 screws from grille.
2. Release 2 catches securing bottom of grille.
3. Remove grille.
Refit
1. Position grille to body, locate with securing
catches.
2. Fit and tighten screws.
16
EXTERIOR FITTINGS
BODY
VENT - REAR QUARTER
Service repair no - 76.81.24
Remove
8. Remove screw securing catch to vent.
9. Remove catch from vent.
10. Remove nut from vent and discard sealing
washers.
Refit
1. Fit nut and NEW sealing washer to vent.
2. Fit catch and tighten screw.
3. With assistance fit vent and tighten catch
screw.
4. Using NEW sealing washers fit nuts and
hinges to vent. Fit and tighten hinge screws to
vent.
5. Fit hinge covers and tighten Torx screws.
1. Remove 2 Torx screws securing vent hinge
covers.
2. Remove covers from hinges.
3. Remove 2 screws securing hinges to vent.
4. Remove hinges from vent.
5. Remove nuts from vent and discard sealing
washers.
6. With assistance remove screw securing vent
catch to body.
7. Remove vent.
EXTERIOR FITTINGS
17
BODY
SUN VISOR
FINISHER - ’A’ POST
Service repair no - 76.10.47
Service repair no - 76.13.07
Remove
Remove
1. Release sun visor from retaining clip.
2. Remove 2 screws securing sun visor.
3. Remove sun visor.
Refit
1. Fit sun visor and secure with screws.
2. Secure sun visor in clip.
1. Release seal from door aperture.
2. Release 4 clips and remove ’A’ post finisher.
3. Remove clips from finisher.
Refit
1. Fit clips to ’A’ post finisher.
2. Fit finisher to ’A’ post and secure with clips.
3. Fit seal to door aperture.
INTERIOR TRIM COMPONENTS
1
BODY
CASING - REAR QUARTER LOWER - 3 DOOR
Service repair no - 76.13.12
Remove
1. Release rear seat squab and fold seat forward.
2. Release load space lamp from trim casing.
3. Disconnect 2 Lucars and remove load space
lamp.
4. Remove 6 Torx screws securing luggage
compartment carpet retainer.
5. Remove carpet retainer.
6. Release 4 turn buckles securing trim casing.
7. Release and remove trim casing from luggage
compartment.
2
INTERIOR TRIM COMPONENTS
Refit
1. Position casing in luggage compartment.
2. Fit turn buckles
3. Fit luggage compartment carpet retainer and fit
Torx screws.
4. Position load space lamp to casing, connect
Lucars and secure lamp in casing.
5. Reposition rear seat.
BODY
CASING - REAR QUARTER LOWER - 5 DOOR
Service repair no - 76.13.12
Remove
10. Remove 5 retaining clips from casing.
Refit
1. Release back of rear seat and fold forward.
2. Remove bolt securing rear seat belt lower
mounting and position seat belt aside.
3. Release load space cover from retainers and
remove cover.
4. Remove screw securing load space cover
retainer and remove retainer.
5. Release load space lamp from trim casing.
Disconnect 2 Lucars and remove load space
lamp.
6. Remove 2 screws securing casing to load
space carpet retainer.
7. Release 4 turn buckles securing trim casing.
8. Release trim casing from 5 retaining clips.
9. Remove trim casing from load space.
1. Fit retaining clips to casing.
2. Position casing in load space, locate and
secure retaining clips.
3. Fit turn buckles
4. Fit screws securing casing to carpet retainer.
5. Position load space lamp to casing, connect
Lucars and secure lamp in casing.
6. Position load space cover retainer and secure
with screw.
7. Fit load space cover and secure in retainers.
8. Position rear seat belt and tighten bolt to 40
Nm
9. Lower seats and secure back of seat in
position.
INTERIOR TRIM COMPONENTS
3
BODY
CASING - REAR QUARTER UPPER - 3 DOOR
Service repair no - 76.13.13
Remove
1. Remove rear quarter lower casing. See this
section.
2. Remove body rear side casing. See this
section.
3. Remove screw and release rear vent catch.
4. Remove seat belt access cover from upper
casing.
5. Release 4 clips securing upper casing.
6. Remove upper casing.
7. Remove 4 retaining clips from casing
4
INTERIOR TRIM COMPONENTS
Refit
1. Fit retaining clips to casing.
2. Position casing, align seat belt and secure
casing retaining clips.
3. Fit seat belt access cover.
4. Position rear vent sealing rubber to upper
casing.
5. Position rear vent catch and tighten screw.
6. Fit side casing. See this section.
7. Fit lower casing. See this section.
BODY
CASING - REAR QUARTER UPPER - 5 DOOR
Service repair no - 76.13.13
Remove
1. Remove rear quarter lower casing. See this
section.
Refit
1. Fit retaining clips to casing.
2. Position casing to body and secure retaining
clips.
3. Fit screws securing bottom of casing.
4. Fit rear quarter lower casing. See this section.
2. Remove 3 screws securing upper casing to
body.
3. Release casing from 8 retaining clips.
4. Remove upper casing from load space.
5. Remove 8 retaining clips from casing
INTERIOR TRIM COMPONENTS
5
BODY
Do not carry out further dismantling if
component is removed for access only.
FINISHER - ’B/C’ POST UPPER - 5 DOOR
Service repair no - 76.13.28
Remove
1. Remove seat base finisher. See this section.
4.
5.
6.
7.
Remove 6 clips from finisher.
Remove seat belt slide.
Fit seat belt slide to replacement finisher.
Fit clips to replacement finisher.
Refit
2. Remove Torx bolt retaining seat belt lower
mounting and position seat belt aside.
3. Release finisher from 6 retaining clips and
remove finisher.
6
INTERIOR TRIM COMPONENTS
1. Position finisher and engage retaining clips.
2. Position seat belt lower mounting. Fit and
tighten Torx bolt to 40 Nm.
3. Fit seat base finisher. See this section.
BODY
FINISHER -’B/C’ POST LOWER - 5 DOOR
Service repair no - 76.13.29
Remove
1. Remove cushion side finisher. See Seats and
seat belts.
6. Remove scrivet from front of B/C’ post lower
finisher.
7. Remove Torx screw from rear of B/C’ post
lower finisher.
8. Release and remove B/C’ post lower finisher
from seat base finisher.
Refit
2. Remove scrivet and 5 Torx screws from carpet
retainer.
3. Remove front carpet retainer.
4. Release B/C’ post upper finisher and position
aside.
1. Locate B/C’ post lower finisher under seat
base finisher and rear carpet retainer.
2. Fit Torx screw to rear of B/C’ post lower
finisher.
3. Fit scrivet to B/C’ post lower finisher.
4. Fit Torx screws to seat base finisher.
5. Align and secure B/C’ post upper finisher.
6. Fit cushion side finisher. See Seats and seat
belts.
7. Fit front carpet retainer and secure with Torx
screws and scrivet.
5. Remove 3 Torx screws from top of seat base
finisher.
INTERIOR TRIM COMPONENTS
7
BODY
CASING - BODY SIDE - REAR
Service repair no - 76.13.57
Remove
1. Remove rear seat. See Seats and seat belts.
2. Remove Torx bolt securing rear seat belt lower
to body and position seat belt aside.
3. Release 6 trim clips and remove trim casing.
4. Remove 6 trim fasteners from body panel.
Do not carry out further dismantling if
component is removed for access only.
5. Noting the position of the 3 long screws,
remove 10 Torx screws and remove pocket
from trim casing.
6. Remove 3 screws and remove pocket finisher.
7. Release 6 tags and remove speaker grille.
8. Position speaker grille on replacement casing
and secure tags.
9. Position pocket finisher and tighten screws.
10. Position pocket and tighten Torx screws
8
INTERIOR TRIM COMPONENTS
Refit
1. Fit trim fasteners to trim casing.
2. Position trim casing and secure clips.
3. Position seat belt and tighten Torx bolt to 50
Nm.
4. Fit rear seat. See Seats and seat belts.
BODY
CONSOLE - FRONT
Service repair no - 76.25.01
8. Remove 4 screws securing switch pack to
console.
9. Remove 3 screws from centre and sides of
console.
Remove
1. Remove rear console. See this section.
2. Remove radio. See ELECTRICAL, Repairs.
10. Release 5 multiplugs and bulb holder from
switch pack.
11. Remove console.
3. Remove 3 heater control knobs.
4. Remove 2 screws from heater control panel.
5. Remove heater control panel.
6. Release tags and remove radio cage.
7. Remove 2 screws from top of console.
INTERIOR TRIM COMPONENTS
9
BODY
12. Remove 4 screws from switch pack assembly
and remove assembly.
Refit
1. Position switch pack assembly, fit and tighten
screws.
2. Position console to fascia.
3. Connect multiplugs and bulb holder to switch
pack.
4. Fit and tighten screws securing centre and
sides of console.
5. Fit and tighten screws securing switch pack to
console.
6. Fit and tighten screws to top of console.
7. Position radio cage to console and secure with
retaining tags.
8. Position heater control panel, fit and tighten
screws.
9. Fit heater control knobs.
10. Fit radio. See ELECTRICAL, Repairs.
11. Fit rear console. See this section.
10
INTERIOR TRIM COMPONENTS
BODY
CONSOLE - REAR
Service repair no - 76.25.04
Remove
Refit
1. Fit cigar lighter.
2. Fit ashtray lid.
3. Position rear console and connect Lucar and
multiplug to cigar lighter.
4. Fit and tighten screws.
5. Fit ashtray and screw cover.
1. Remove ashtray and screw cover.
2. Remove 4 screws from console.
3. Raise console and disconnect Lucar and
multiplug from cigar lighter.
4. Remove rear console.
5. Remove ashtray lid.
6. Remove cigar lighter.
INTERIOR TRIM COMPONENTS
11
BODY
FASCIA
Service repair no - 76.46.23
Remove
1. Remove front console. See this section.
2. Remove rotary coupler. See RESTRAINT
SYSTEMS, Repairs.
6. Open driver’s glove box lid and remove fuse
box cover.
3. Disconnect 4 multiplugs from wiper/ indicator
switch.
7.
8.
9.
10.
Disconnect 2 multiplugs from fuse box.
Close glove box lid.
Remove clock. See ELECTRICAL, Repairs.
Remove both ’A’ post finishers See this
section.
11. Models without passenger airbag:
Remove fascia stowage box. See this section.
Models with passenger airbag:
Remove passenger airbag. See RESTRAINT
SYSTEMS, Repairs.
4. Loosen clamping screw and remove wiper/
indicator switch.
5. Remove 2 screws from steering column lower
finisher and remove finisher.
12
INTERIOR TRIM COMPONENTS
BODY
All models:
12. Remove 12 bolts securing fascia.
13. With assistance remove fascia.
Do not carry out further dismantling if
component is removed for access only.
14. Remove 4 screws, disconnect 3 multiplugs
from switches, and remove instrument bezel
finisher.
16. Disconnect 3 multiplugs from instrument pack.
17. Release mirror and headlamp leveling
switches.
18. Disconnect multiplugs from mirror switch and
headlamp leveling switch.
15. Remove 2 screws from instrument upper cover
and remove cover.
INTERIOR TRIM COMPONENTS
13
BODY
22. Remove 4 screws from instrument pack and
remove instrument pack.
19. Disconnect 4 Lucars from glove box lamp and
switch.
23. Remove 6 screws from instrument pack lower
cover and remove cover.
20. Release 9 harness clips.
21. Feed harness through fascia and remove
harness.
14
INTERIOR TRIM COMPONENTS
BODY
Models without passenger airbag:
24. Remove 4 nuts from grab handle and remove
handle.
Models with passenger airbag:
25. Remove 2 screws from airbag lower finisher
and remove finisher.
All models:
27. Remove 4 face level vents and collect seals.
28. Remove glove box hinge pins and remove
glove box lids.
29. Remove glove box lamp and mat.
30. Remove 4 screws from glove box and remove
glove box.
31. Remove 2 screws from each glove box lock
and remove locks.
32. Remove switch blank.
33. Noting their fitted positions, remove 11 spire
nuts and 3 harness clips.
34. Remove fascia and coin tray mats.
26. Remove 4 screws from centre bracket and
remove bracket.
INTERIOR TRIM COMPONENTS
15
BODY
35. Fit fascia and coin tray mats to replacement
fascia. Ensure mats are fully located in
position.
36. Fit spire nuts and harness clips.
37. Fit switch blank.
38. Fit glove box locks and secure with screws.
39. Fit glove box and secure with screws.
40. Fit glove box lamp and mat.
41. Fit glove box lids and secure hinge pins.
42. Position seals to face level vents and fit vents.
43. Fit centre bracket and secure with screws.
Models without passenger airbag:
44. Fit grab handle and secure with nuts.
Models with passenger airbag:
45. Fit airbag lower finisher and secure with
screws.
All models:
46. Fit instrument pack lower cover and secure
with screws.
47. Fit instrument pack and secure with screws.
48. Position harness and secure harness in clips.
49. Fit mirror and headlamp leveling switches.
50. Feed harness through fascia and connect
multiplugs to instrument pack, mirror switch
and headlamp leveling switch.
51. Connect Lucars to glove box lamp and switch.
52. Fit instrument upper cover and secure with
screws.
53. Position instrument bezel finisher, connect
multiplugs and secure finisher with screws.
16
INTERIOR TRIM COMPONENTS
Refit
1. With assistance position fascia.
2. Fit and tighten screws.
Models without passenger airbag:
3. Fit fascia stowage box. See this section.
Models with passenger airbag:
4. Fit passenger airbag. See RESTRAINT
SYSTEMS, Repairs.
All models:
5. Fit ’A’ post finishers. See this section.
6. Fit clock. See ELECTRICAL, Repairs.
7. Open driver’s glove box lid and connect
multiplugs to fuse box.
8. Fit fuse box cover and close glove box lid.
9. Fit steering column lower finisher and secure
with screws.
10. Fit wiper/indicator switch and tighten clamping
screw.
11. Connect multiplugs to wiper/indicator switch.
12. Fit rotary coupler. See RESTRAINT
SYSTEMS, Repairs.
13. Fit front console See this section.
BODY
STOWAGE BOX - FASCIA
Service repair no - 76.46.45
Remove
1. Remove mat from stowage box to access
screws.
2. Remove 2 screws.
3. Remove stowage box form fascia.
Refit
1. Position stowage box and secure with screws.
2. Fit mat to stowage box.
INTERIOR TRIM COMPONENTS
17
BODY
CARPET - LOADSPACE
Service repair no - 76.49.04
Remove
1. Remove both rear quarter lower trim casings.
See this section.
2.
3.
4.
5.
6.
Open lid on security box.
Remove 6 screws securing lid.
Remove lid.
Remove 4 screws securing lid latch strikers.
Remove both strikers.
7. Release carpet from rear seat strikers and
lashing eyes.
8. Remove 4 buckles from rear carpet.
9. Remove carpet.
18
INTERIOR TRIM COMPONENTS
Refit
1.
2.
3.
4.
5.
6.
Position carpet in loadspace.
Fit buckles to rear carpet.
Fit lid latch strikers and secure with screws.
Fit lid and secure with screws.
Close lid.
Fit rear quarter lower trim casings. See this
section.
BODY
GLOVE BOX
HEADLINING - 5 DOOR
Service repair no - 76.52.03
Service repair no - 76.64.01
Service repair no - 76.64.15
Remove
Remove
1. Open glove box lid.
1. Remove both A’ post trims. See this section.
2. Remove both rear quarter upper trim casings.
See this section.
3. Remove both sun visors. See this section.
2. Release illumination lamp from glove box.
3. Remove 4 screws and remove glove box.
Refit
1. Position glove box and tighten screws.
2. Position and secure illumination lamp.
3. Close glove box lid.
4. Remove screw from each sun visor clip and
collect clips.
5. Remove screw covers and screws from grab
handles and remove grab handles.
6. Remove grab handle blanking plugs.
INTERIOR TRIM COMPONENTS
19
BODY
Models with sun roof:
10. Release and remove sun roof surround finisher
from sunroof aperture.
7. Release roof lamps, disconnect multiplugs and
remove roof lamps.
All models:
11. Remove 5 retaining studs from headlining.
12. With assistance remove headlining through tail
door.
8. Release both B/C’ post upper finishers and
position aside.
9. Release headlining from front and rear door
aperture seals.
20
INTERIOR TRIM COMPONENTS
BODY
Refit
1. With assistance, position headlining and
secure with retaining studs.
Models with sun roof:
2. Position sunroof surround finisher and secure
in position.
All models:
3. Locate headlining to front and rear door
aperture seals.
4. Fit and secure ’B/C’ post upper finishers.
5. Connect multiplugs and fit roof lamps.
6. Fit grab handle blanking plugs.
7. Fit grab handles, tighten screws and fit screw
covers.
8. Fit sun visor clips and tighten screws.
9. Fit both sun visors. See this section.
10. Fit both ’A’ post trims. See this section.
11. Fit rear quarter upper trim casings. See this
section.
13.
14.
15.
16.
Do not carry out further dismantling if
component is removed for access only.
Release 8 tags securing front roof lamp
support and remove support.
Remove 14 nuts from stowage pockets, collect
backing plates and remove stowage pockets.
Position stowage pockets and backing plates
on replacement headlining and secure with
nuts.
Position roof lamp support on replacement
headlining and secure retaining tags.
INTERIOR TRIM COMPONENTS
21
BODY
HEADLINING - 3 DOOR
Service repair no - 76.64.15
Remove
1. Fold front seat squabs forward.
2. Remove both sun visors. See this section.
3. Remove both ’A’ post trims. See this section.
4. Remove 2 screws from both sun visor clips and
collect clips.
5. Remove 2 screws securing headlining to front
end of roof panel.
22
INTERIOR TRIM COMPONENTS
6. Remove roof lamp lens.
7. Remove 2 screws, release roof lamp and
disconnect multiplug.
8. Release headlining rear finisher from roof
panel and remove finisher.
BODY
Refit
9. Release door aperture seals to release
headlining.
10. Release 3 studs securing rear edge of
headlining to roof panel.
11. Remove 4 screws securing headlining to ’B’
posts.
12. Release 2 studs at LH and RH side of
headlining.
13. Lower front edge of headlining.
14. Release sun roof seal and remove headlining.
1. Fit pocket to headlining and secure with
screws.
2. Fit studs to headlining.
3. Position headlining and secure studs to roof
panel.
4. Fit and tighten screws to ’B’ posts and roof
panel.
5. Secure headlining behind rear vent rubbers.
6. Fit headlining rear finisher.
7. Refit door aperture seals.
8. Position sun roof seal to headlining.
9. Position roof lamp and connect multiplug.
10. Tighten roof lamp screws and fit lens.
11. Position sun visor clips and tighten screws.
12. Fit sun visors. See this section.
13. Fit both ’A’ post finishers. See this section.
14. Reposition front seat squabs.
15. Remove studs from headlining.
16. Remove 3 screws and remove pocket from
headlining.
INTERIOR TRIM COMPONENTS
23
BODY
WINDSCREEN
Service repair no - 76.81.01
NOTE: The following equipment is
required:
Cutting wire and handles
Windscreen repair kit
Sealer applicator gun
Suction cups
WARNING: Wear protective gloves when
handling glass, solvents and primers.
WARNING: Wear suitable eye protection
when removing and refitting glass.
Remove
1. Remove air intake panel and wipers. See
HEATING & VENTILATION, Repairs.
2. Remove sun visors and sun visor retaining
clips.
3. Remove ’A’ post trims. See Interior trim
components.
4. Remove retaining stud from front of headlining.
5. Remove interior mirror. See Interior trim
components.
6. Fit protection to bonnet and areas around
screen.
7. Cover heater ducts with masking tape.
8. Cover interior of vehicle with protective sheet.
9. Make knife cut in sealant at bottom of ’A’ post.
10. Insert cutting wire through previously made
knife cut and fit handles as shown, with
approximately 200 mm of wire between
handles.
11. Using suitable cutting wire, with assistance if
required, carefully cut sealer. Ensure that glass
is retained as last sealant is cut.
NOTE: If multi-strand cutting wire is used,
a sawing action can be used to cut
through heavy sealant deposits around
corners.
CAUTION: Use of a sawing action may
overheat and break single strand wire.
SCREENS
1
BODY
12. Attach suction cups and use assistance to
remove glass from body.
CAUTION: Lay glass on felt covered
supports. Do not stand on edge. Any
chipping of glass edge may develop into
cracks.
13. Collect screen support blocks.
Refit
8. Clean frame and edge of screen with solvent.
CAUTION: Do not touch cleaned or primed
surfaces with fingers.
9. Apply etch primer to any bare metal on frame.
10. Apply bonding agent to screen and allow to
cure.
11. Apply primer over etch primer on frame.
12. Apply activator over old sealer on frame.
13. Allow activator to cure.
14. Fit pre-cut nozzle to sealer cartridge, remove
lid and shake out crystals, and install in
applicator gun.
NOTE: Nozzle will need modification to
achieve required bead section.
1. Carefully remove excess sealer from body
leaving a smooth surface.
2. Use a vacuum cleaner to clear away any
waste.
3. Original glass: Carefully cut back old sealer to
obtain a smooth surface without damaging
obscuration band on glass.
4. Fit spacer blocks to body.
5. With assistance, locate screen to body.
6. Apply masking tape reference marks to aid
fitment.
7. With assistance, remove screen and place
aside.
15. Apply a continuous bead of sealer around edge
of frame as shown.
16. Check for breaks and air bubbles in sealer.
2
SCREENS
BODY
17. With assistance, lift screen into place and align
to screen supports and tape. Raise screen up
to roof on ratchet support blocks. Lightly press
glass to fully seat sealer.
18. Remove protective covers and tape.
19. Test sealer for leaks, apply additional sealer if
necessary. If water is used, allow sealer to dry
before testing. Spray water around glass and
check for leaks. Mark any area that leaks. Dry
glass and sealer then apply additional sealer.
20. Fit ’A’ post trims. See Repairs.
21. Fit headlining retaining stud.
22. Fit sun visor retaining clips and sun visors.
23. Fit interior mirror. See Repairs.
24. Fit air intake panel and wipers. See HEATING
& VENTILATION, Repairs.
CAUTION: A curing time of 6 hours is
desirable, during this time leave a window
open and do not slam the doors. If the car
must be used, drive slowly.
SCREENS
3
BODY
GLASS - BODY SIDE - REAR
Service repair no - 76.81.18
NOTE: The following equipment is
required:
•
•
•
•
Cutting wire and handles.
Windscreen repair kit.
Sealer applicator gun.
Suction cups.
NOTE: If multi-strand cutting wire is used,
a sawing action can be used to cut
through heavy sealant deposits around
corners.
WARNING: Wear protective gloves when
handling glass, solvents and primers.
CAUTION: Use of a sawing action may
overheat and break single strand wire.
WARNING: Wear suitable eye protection
when removing and refitting glass.
6. Attach suction cup and remove glass body.
Remove
1. Remove rear quarter upper casing. See
Interior trim components.
2. Cover interior of vehicle with protective sheet.
3. Make knife cut in sealant at bottom of ’D’ post.
4. Insert cutting wire through previously made
knife cut and fit handles as shown, with
approximately 200 mm of wire between
handles.
4
5. With assistance, wedge tube of handle A
between glass and body, ahead of cutting
position, and carefully cut sealer using a
continuous pull on handle B from the outside.
Ensure that glass is retained as last sealant is
cut.
SCREENS
CAUTION: Lay glass on felt covered
supports. Do not stand on edge. Any
chipping of glass edge may develop into
cracks.
7. Collect 4 spacer blocks.
BODY
Refit
14. Fit pre-cut nozzle to sealer cartridge, remove
lid and shake out crystals. Install cartridge in
applicator gun.
NOTE: Nozzle will need modification to
achieve required bead section.
1. Carefully remove excess sealer from body
leaving a smooth surface.
2. Use a vacuum cleaner to clear away any
waste.
3. Original glass: Carefully cut back old sealer to
obtain a smooth surface without damaging
obscuration band on glass.
4. Fit rubber spacer blocks to body.
5. With assistance, locate screen to body.
6. Apply masking tape reference marks to aid
fitment.
7. Remove screen and place aside.
8. Clean frame and edge of screen with solvent.
CAUTION: Do not touch cleaned or primed
surfaces with fingers.
9. Apply etch primer to any bare metal on frame.
10. Apply bonding agent to screen and allow to
cure.
11. Apply primer over etch primer on frame.
12. Apply activator over old sealer on frame.
13. Allow activator to cure.
15. Apply a continuous bead of sealer around edge
of frame as shown. Make bead slightly thicker
at each corner.
16. Check for breaks and air bubbles in sealer.
17. Position glass to body and align to reference
tape.
18. Lightly press glass to fully seat sealer.
19. Secure glass with tape until sealer has cured.
20. Remove protective covers and tape.
21. Test sealer for leaks, apply additional sealer if
necessary. If water is used, allow sealer to dry
before testing. Spray water around glass and
check for leaks. Mark leakage points and apply
additional sealer as necessary when area is
completely dry.
22. Fit rear quarter upper casing. See Interior
trim components.
SCREENS
5
BODY
SEAT - FRONT
Service repair no - 78.10.44/99
WARNING: See GENERAL INFORMATION,
SRS Precautions.
Remove
Refit
1. Position seat and secure with screws. Tighten
screws to 45 Nm.
2. Fit cover to rear bolt.
3. Connect pretensioner multiplug. Secure
pretensioner multiplug to seat frame.
4. Fit seat base finisher. See this section.
1. Make the SRS system safe. See GENERAL
INFORMATION, SRS Precautions.
2. Remove seat base finisher. See this section.
3. Release pretensioner multiplug from seat
frame. Disconnect pretensioner multiplug.
4. Remove cover from rear securing bolt.
5. Remove 4 Torx screws securing seat.
6. Remove seat.
SEATS AND SEAT BELTS
1
BODY
SEAT - RH REAR - 5 DOOR
Service repair no - 78.10.49/99
Remove
1. Release carpet from heel board and remove 2
Torx bolts from seat hinges.
2. Fold seat forward and remove 2 Torx bolts
from seat hinges.
3. Remove seat.
2
SEATS AND SEAT BELTS
Refit
1. Position seat in vehicle and align hinges.
2. Fit Torx bolts to seat hinges. Tighten Torx bolts
to 25 Nm..
3. Lower seat.
4. Fit Torx bolts to heel board. Tighten Torx bolts
to 25 Nm..
5. Reposition carpet.
BODY
CUSHION AND SQUAB - REAR SEAT - 3 DOOR
Service repair no - 78.10.57/99
Remove
Refit
1. With assistance, position seat in vehicle and
align hinges.
2. Fit Torx bolts and lower seat. Tighten Torx
bolts to 25 Nm..
3. Fit Torx bolts to heel board. Tighten Torx bolts
to 25 Nm..
1. Remove 2 Torx bolts securing seat to heel
board.
2. Fold seat forward and remove 2 Torx bolts
from seat hinges.
3. With assistance, remove seat.
SEATS AND SEAT BELTS
3
BODY
CUSHION COVER - FRONT SEAT
Service repair no - 78.30.01
Remove
1. Remove front seat. See this section.
5. Release sides of cushion cover from frame.
6. Release front of cushion cover from frame.
2. Remove recline control knob.
3. Release retaining studs from side covers and
remove covers.
4. Remove 4 Torx bolts from squab frame and
remove squab frame from cushion frame.
4
SEATS AND SEAT BELTS
7. Release rear of cushion cover from frame.
8. Release rear of cushion pad from frame.
9. Remove cushion cover and pad.
BODY
10. Remove and discard 12 hog rings holding
cushion cover to cushion pad.
11. Remove cushion cover.
Refit
1. Position cushion cover to pad.
2. Pull cover into position and secure with NEW
hog rings.
3. Position cushion cover and pad and secure to
frame.
4. Fit squab frame to cushion frame and tighten
Torx bolts to 45etorq>.
5. Fit side covers and secure retaining studs.
6. Fit recline control knob.
7. Fit front seat. See this section.
SEATS AND SEAT BELTS
5
BODY
CUSHION COVER - RH REAR SEAT - 5 DOOR
Service repair no - 78.40.04
Remove
1. Remove RH rear seat. See this section.
4. Remove 5 screws and remove both end
covers.
5. Remove 3 Torx bolts and remove squab from
cushion.
2. Remove 2 screws and remove seat belt reel
cover.
6. Release rear of cushion cover from frame.
7. Release sides and front of cushion cover from
frame.
8. Release cover and pad from frame.
3. Remove nut and release seat belt belt reel.
6
SEATS AND SEAT BELTS
BODY
Refit
1. Position cover to pad and secure with NEW
hog rings.
2. Position seat belt/seat belt buckle on frame
and tighten Torx bolts to 40 Nm.
3. Fit cover and pad to frame.
4. Fit front and sides of cushion cover to frame.
5. Fit rear of cushion cover to frame.
6. Fit cushion to squab and tighten Torx bolts.
7. Fit end covers and tighten screws.
8. Position seat belt reel in seat squab and
tighten nut to 32 Nm.
9. Fit seat belt reel cover and tighten screws.
10. Fit rear seat. See this section.
9. Remove 2 Torx bolts from seat belt/seat belt
buckle. Remove seat belt/seat belt buckle from
frame.
10. Remove cover and pad from frame.
11. Remove and discard 17 hog rings and remove
cover from pad.
SEATS AND SEAT BELTS
7
BODY
CUSHION COVER - REAR SEAT - 3 DOOR
Service repair no - 78.40.05
Remove
1. Remove rear seat assembly. See this section.
6. Release back board assembly from squab
frame and remove back board.
2. Remove 2 screws securing console cover and
remove cover.
3. Remove 4 screws securing rear seat console
and remove console.
4. Remove 4 screws securing end covers and
remove covers.
5. Remove 4 Torx bolts and remove squab
assembly from cushion assembly.
8
SEATS AND SEAT BELTS
7. Release rear of cushion cover from frame.
8. Release sides and front of cushion cover from
frame.
BODY
Refit
1. Position cover to pad and secure with NEW
hog rings.
2. Fit cover to pad.
3. Position cover and pad and secure to frame.
4. Fit cushion to squab and tighten Torx bolts to
45 Nm.
5. Position back board and secure to frame.
6. Fit end covers and tighten screws.
7. Position rear seat console, fit and tighten
screws.
8. Position console cover, fit and tighten screws.
9. Fit rear seat. See this section.
9. Remove cover and pad from frame.
10. Release cushion cover from pad.
11. Remove and discard 13 hog rings and remove
cover from pad.
SEATS AND SEAT BELTS
9
BODY
CUSHION COVER - LH REAR SEAT - 5 DOOR
Service repair no - 78.40.05
Remove
1. Remove LH rear seat. See this section.
4. Release rear of cushion cover from frame.
5. Release sides and front of cushion cover from
frame.
6. Remove cover and pad from frame.
7. Remove and discard 16 hog rings and remove
cover from pad.
Refit
2. Remove 5 screws and remove both end
covers.
3. Remove 3 Torx bolts and remove squab from
cushion.
10
SEATS AND SEAT BELTS
1. Position cover to pad and secure with NEW
hog rings.
2. Fit cover and pad to frame.
3. Fit front and sides of cushion cover to frame.
4. Fit rear of cushion cover to frame.
5. Fit cushion to squab and tighten Torx bolts to
45 Nm.
6. Fit end covers and tighten screws.
7. Fit rear seat. See this section.
BODY
FINISHER - SEAT BASE - FRONT SEAT
Service repair no - 78.55.01
Remove
1. Remove front seat cushion side finisher. See
this section.
Refit
1. Position finisher to seat runner.
2. Fit and tighten Torx screws.
3. Fit and tighten Torx screw under front seat and
close cover.
4. Fit front carpet retainer and secure with scrivet
and Torx screws.
5. Fit front seat cushion side finisher. See this
section.
2. Remove scrivet and 5 Torx screws from carpet
retainer.
3. Remove front carpet retainer.
4. Release cover to access Torx screw under
front seat, remove Torx screw.
5. Remove 2 Torx screws securing finisher to
seat runner.
6. Remove finisher.
SEATS AND SEAT BELTS
11
BODY
FINISHER - CUSHION SIDE - FRONT SEAT
LUMBAR SUPPORT - FRONT SEAT
Service repair no - 78.55.06
Service repair no - 78.60.07
Remove
Remove
1. Remove front seat. See this section.
1. Remove 2 covers to access screws.
2. Remove 3 screws securing finisher.
3. Release catches at front and side of seat and
remove finisher.
2. Release and remove head restraint.
3. Remove recline control knob.
4. Release retaining studs from side covers and
remove covers.
5. Remove 4 Torx bolts from squab frame and
remove squab frame from cushion frame.
6. Remove lumbar control knob.
Refit
1. Position finisher to seat, locate catches, fit and
tighten securing screws.
2. Fit screw covers.
7. Release squab cover at base of seat frame.
12
SEATS AND SEAT BELTS
BODY
8. Release squab cover from squab frame and
squab pad.
9. Remove and discard 2 hog rings from rear of
cover.
10. Drill out 2 pop rivet from squab frame.
13. Remove 2 bolts from cable control and release
cable control.
14. Release 8 lumbar support retainers from squab
frame and collect 4 hook retainers
15. Remove lumbar support mechanism.
Refit
11. Remove head restraint guide tubes.
12. Remove squab cover and pad.
1. Position lumbar support to squab frame, locate
hook retainers.
2. Fit lumbar support retainers to squab frame.
3. Position cable control and tighten bolts.
4. Fit squab cover and pad to frame.
5. Fit head restraint guide tubes.
6. Fit new hog rings to rear of cover.
7. Position straps and secure with pop rivets.
8. Fit squab cover to squab pad and frame.
9. Secure squab cover at base of frame.
10. Fit lumbar support control knob.
11. Fit squab frame to cushion frame and tighten
Torx bolts.
12. Fit side covers and secure retaining studs.
13. Fit head restraint.
14. Fit recline control knob.
15. Fit front seat. See this section.
SEATS AND SEAT BELTS
13
BODY
LATCH ASSEMBLY - REAR SQUAB - RH
LATCH ASSEMBLY - REAR SQUAB - LH
Service repair no - 78.80.05
Service repair no - 78.80.16
Remove
Remove
1. Remove rear seat squab cover. See this
section.
1. Remove rear seat squab cover. See this
section.
2. Remove 2 Torx screws from squab lock.
3. Release cable from abutment and remove from
lock.
4. Release cable from lever abutment and
remove from lever.
Refit
2.
3.
4.
5.
Remove 3 screws from lock button.
Remove 2 Torx screws from squab lock.
Release lock button from lock.
Release cable from abutment and remove from
lock.
6. Release cable from lever abutment and
remove from lever.
Refit
1.
2.
3.
4.
5.
6.
14
Position cable to lever and locate in abutment.
Fit cable to lock and locate in abutment.
Fit lock button to lock.
Fit Torx screws to squab lock.
Fit screws to lock button.
Fit squab cover. See this section.
SEATS AND SEAT BELTS
1.
2.
3.
4.
Position cable to lever and locate in abutment.
Fit cable to lock and locate in abutment.
Fit and tighten Torx screws to lock.
Fit squab cover. See this section.
BODY
SQUAB COVER - FRONT SEAT
Service repair no - 78.90.08
Remove
1. Remove front seat. See this section.
8. Release squab cover from squab frame and
squab pad.
9. Remove and discard 2 hog rings from rear of
cover.
10. Drill out 2 pop rivet from squab frame.
2. Release and remove head restraint.
3. Remove recline control knob.
4. Release retaining studs from side covers and
remove covers.
5. Remove 4 Torx bolts from squab frame and
remove squab frame from cushion frame.
6. Remove lumbar control knob.
11. Remove head restraint guide tubes.
12. Remove squab cover and pad from frame.
13. Remove and discard 10 hog rings holding
cover to squab pad.
14. Remove squab cover.
7. Release squab cover at base of seat frame.
SEATS AND SEAT BELTS
15
BODY
Refit
SQUAB COVER - REAR SEAT - 3 DOOR
1. Position squab cover to pad.
2. Pull cover into position and secure with NEW
hog rings.
3. Fit squab cover and pad to frame.
4. Fit head restraint guide tubes.
5. Fit NEW hog rings to rear of cover.
6. Position straps and secure with pop rivets.
7. Fit squab cover to squab pad and squab frame.
8. Secure squab cover at base of squab frame.
9. Fit lumbar support control knob.
10. Fit squab frame to cushion frame and tighten
Torx bolts.
11. Fit side covers and secure retaining studs.
12. Fit recline control knob.
13. Fit head restraint.
14. Fit front seat. See this section.
Service repair no - 78.90.12
Remove
1. Remove rear seat assembly. See this section.
2. Remove 2 screws securing console cover and
remove cover.
3. Remove 4 screws securing rear seat console
and remove console.
4. Remove 4 screws securing end covers and
remove covers.
5. Remove 4 Torx bolts and remove squab
assembly from cushion assembly.
16
SEATS AND SEAT BELTS
BODY
6. Release back board assembly from squab
frame and remove back board.
10. Raise cover and pad to access head restraint
guide tubes.
11. Remove guide tubes.
12. Release cover from top of frame.
13. Remove cover and pad.
7. Remove head restraint.
8. Release bottom of squab cover from frame.
9. Release sides of squab cover from frame.
SEATS AND SEAT BELTS
17
BODY
SQUAB COVER - LH REAR SEAT - 5 DOOR
Service repair no - 78.90.12
Remove
1. Fold LH rear seat forward.
14. Release cover from pad, remove and discard 5
Hog rings.
15. Remove cover from pad.
Refit
1. Locate cover to pad and secure with NEW hog
rings.
2. Fit cover to pad.
3. Secure cover to top of frame.
4. Fit guide tubes.
5. Secure sides and bottom of cover to frame.
6. Fit head restraint.
7. Fit cushion to squab and tighten Torx bolts to
45 Nm.
8. Position back board and secure to frame.
9. Fit end covers and tighten screws.
10. Position rear seat console, fit and tighten
screws.
11. Position console cover, fit and tighten screws.
12. Fit rear seat. See this section.
2. Remove 5 screws from end covers and remove
covers.
3. Remove 3 bolts from seat squab and remove
squab from cushion.
4. Remove head restraint.
18
SEATS AND SEAT BELTS
BODY
Refit
1. Position squab cover to pad and secure hog
rings.
2. Fit cover and pad to squab frame.
3. Fit head restraint guide tubes.
4. Fit cover to sides and bottom of frame.
5. Fit cover to rear of frame .
6. Fit back cloth and secure latch escutcheon.
7. Fit head restraint.
8. Fit squab to cushion and tighten bolts.
9. Fit side covers and tighten screws.
10. Secure rear seat in locked position.
5. Release squab from sides and bottom of
frame.
6. Release latch escutcheon and remove seat
frame back cloth.
7. Release cover from rear of frame.
8. Release and remove 2 head restraint guide
tubes.
9. Remove cover and pad from frame.
10. Remove 9 hog rings and remove cover from
pad.
SEATS AND SEAT BELTS
19
BODY
SQUAB COVER - RH REAR SEAT - 5 DOOR
Service repair no - 78.90.13
Remove
1. Fold RH rear seat forward.
2. Remove 2 screws from seat belt reel cover and
remove cover.
4. Remove 5 screws from end covers and remove
covers.
5. Remove 3 bolts from seat squab and remove
squab from cushion.
6. Remove both head restraints.
7. Remove arm rest aperture trim.
8. Remove 2 screws from arm rest and remove
arm rest.
3. Remove nut from seat belt reel, release reel
and position aside.
20
SEATS AND SEAT BELTS
BODY
9. Release squab from arm rest aperture.
10. Release squab from seat belt aperture and
from rear of frame.
12. Release and remove 4 head restraint guide
tubes.
13. Release squab lock warning button
escutcheon.
11. Release squab from sides and bottom of
frame. Release latch escutcheon and remove
back cloth.
14. Remove cover and pad from frame.
SEATS AND SEAT BELTS
21
BODY
15. Remove 12 hog rings and remove cover from
pad.
Refit
1. Position squab cover to pad and secure hog
rings.
2. Fit cover and pad to squab frame.
3. Fit head restraint guide tubes and seat lock
warning button escutcheon.
4. Fit cover to sides and bottom of frame.
5. Fit cover to rear of frame and seat belt
aperture.
6. Fit back cloth and secure latch escutchion.
7. Fit cover to arm rest aperture.
8. Fit arm rest and tighten screws.
9. Fit arm rest aperture trim.
10. Fit head restraints.
11. Fit squab to cushion and tighten bolts.
12. Fit side covers and tighten screws.
13. Position seat belt reel and tighten nut to 32
Nm.
14. Fit seat belt reel cover and tighten screws.
15. Secure rear seat in locked position.
22
SEATS AND SEAT BELTS
BODY
SUN ROOF ASSEMBLY - 3 DOOR
Service repair no - 76.83.01
Remove
WARNING: Wear protective gloves when
handling solvents and primers.
WARNING: Wear suitable eye protection
when cutting out sun roof.
1. Remove headlining. See Interior trim
components.
5. Remove glass panels and ’T’ bar.
6. Remove 8 screws securing wind deflectors.
7. Remove wind deflectors.
2. Disconnect drain tubes from sun roof.
3. Remove and discard cable ties.
4. Loosen 4 Torx screws securing clamping
plates and remove plates.
SUNROOF
1
BODY
Refit
1. Clean surrounding area with solvent.
2. Use a vacuum cleaner to clear away dust and
debris.
3. Cut sealer on roof flange down to a smooth
even finish.
4. Etch prime and paint any damaged areas.
5. Apply primer over etch primer on flange.
6. Apply activator over old sealer on flange.
7. Allow activator to cure.
8. Fit pre-cut nozzle to sealer cartridge, remove
lid and shake out crystals, install in applicator
gun.
NOTE: Modify nozzle as required.
9. Apply a continuous bead of sealer around roof
flange as shown. Make bead slightly thicker at
the corners.
8.
9.
10.
11.
Remove sun roof tray seal. See this section.
Mask up roof and sun roof aperture.
Cover interior trim with protective sheet.
Make a cut through the sealer at the back of
the sun roof, a 90° bend in the cutting tool will
help.
CAUTION: Take care not to damage paint
or roof aperture flange when cutting out
sunroof.
12. Using suitable cutting wire, cut through PU
sealer securing sunroof to roof.
NOTE: Multi-strand cutting wire is advised,
as a sawing action may be required on the
corners. Single strand wire may overheat
and break during sawing action.
13. Remove section of sunroof.
2
SUNROOF
NOTE: Sealer bead should be 8 mm by 8
mm.
10. Check for breaks and air bubbles in the sealer.
11. With assistance position sunroof and align to
roof aperture.
12. Fit sun roof tray seal. See this section.
13. Position sunroof clamping plates, fit and tighten
screws.
14. Connect drain tubes and secure with NEW
cable ties.
15. Remove body and trim protection.
16. Position wind deflectors, fit and tighten screws.
17. Fit ’T’ bar and glass panels.
18. Fit headlining. See Interior trim components.
BODY
WIND DEFLECTOR - GLASS SUN ROOF - 3
DOOR
Service repair no - 76.83.28
Remove
1. Release and remove sun roof glass panel.
2. Remove 4 screws securing hinges, and
remove wind deflector.
3. Collect hinges.
NOTE: Hinges are handed.
Refit
1. Locate hinges to wind deflector, position wind
deflector, fit and tighten screws.
2. Position glass panel and secure catch.
SUNROOF
3
BODY
SEAL - SUN ROOF TRAY
Service repair no - 76.83.61
Remove
Refit
1. Position seal to roof.
CAUTION: Do not use sharp tools to
locate seal
2. Locate seal to corners of tray and fit between
roof and tray.
3. Fit seal to inner part of tray.
4. Fit ’T’ bar.
5. Fit roof glass.
6. Fit roof finishers.
7. Ensure gaskets are in position on side rails.
Tighten Torx bolts to 22 Nm. to secure side
rails.
8. Fit side rail end covers.
1. Remove side rail front end covers.
2. Unscrew 4 Torx bolts securing front of side
rails and side rails.
3. Remove front and rear roof finishers.
4. Remove roof glass.
5. Remove ’T’ bar.
6. Release seal from inner part of tray.
7. Release seal from corners of tray and ease
from between roof and tray.
8. Remove tray seal.
4
SUNROOF
BODY
SUN ROOF ASSEMBLY - 5 DOOR
PANEL GLASS - SUN ROOF - 5 DOOR
Service repair no - 76.84.01
Service repair no - 76.84.03
Remove
Remove
1. Remove headlining. See Interior trim
components.
1. Open sun roof blind.
2. Disconnect drain tubes from sun roof.
3. Disconnect multiplug from sun roof motor.
4. With assistance, remove 6 nuts and 2 bolts
securing sun roof.
5. Remove sun roof assembly.
Refit
1. Ensure plastic washers and tray seal are in
position.
2. With assistance position sun roof assembly, fit
and tighten nuts and bolts.
3. Connect multiplug to sun roof.
4. Connect drain tubes to sun roof and secure
with cable ties.
5. Fit headlining. See Interior trim components.
2. Remove covers from glass securing screws.
3. Remove 6 screws securing glass.
4. Remove glass.
Refit
1. Position glass, fit screws but do not tighten at
this stage.
2. Align glass to roof and tighten screws.
3. Fit screw covers.
4. Operate sun roof to check alignment.
5. Close sun roof blind.
SUNROOF
5
BODY
SEAL - PANEL GLASS - SUN ROOF - 5 DOOR
MOTOR - SUN ROOF
Service repair no - 76.84.05
Service repair no - 76.84.07
Remove
Remove
1. Remove glass panel. See this section.
1. Remove front roof lamp. See ELECTRICAL,
Repairs.
2. Remove headlining to sun roof finisher. See
Repairs.
3. Carefully lower front of headlining to access
motor.
2. Release ends of seal from glass and remove
seal .
Refit
1. Clean adhesive from glass.
2. Position seal; apply adhesive to ends of seal
and secure to glass panel.
3. Fit glass panel. See this section.
4. Remove 3 Torx screws securing motor.
5. Release motor from gearbox, lower through
headlining, disconnect 4 Lucars and remove
motor.
Refit
1. Position motor, connect Lucars and fit motor to
gearbox.
2. Position sun roof in tilt mode, power motor
forward to the first stop (motor and lifting
assemblies are then timed together).
3. Fit and tighten Torx screws.
4. Carefully reposition headlining.
5. Fit sun roof finisher. See Repairs.
6. Fit roof lamp. See ELECTRICAL, Repairs.
6
SUNROOF
BODY
DRIVE CABLES & SLIDE ASSEMBLIES
Service repair no - 76.84.09
Remove
1.
2.
3.
4.
5.
Remove sun roof motor. See this section.
Remove glass panel. See this section.
Open sun roof.
Release and remove wind deflector.
Position sun roof in tilt mode.
Refit
1. Ensure cable tubes are in position, lightly
grease the end of cable tube.
2. Engage cable in tube and fit lifting assembly to
roof.
3. Fit cable guide clamp, place lifting assembly in
tilt mode.
4. Fit rear cam guide.
5. Fit and tighten Torx screws.
6. Fit sun roof motor. See this section.
7. Open sun roof.
8. Position wind deflector and secure to sun roof.
9. Fit glass panel. See this section.
6. Remove 4 Torx screws securing lifting
assembly to roof.
7. Collect rear cam guide.
8. Slide assembly forward, remove cable guide
clamp.
9. Remove lifting assembly and cable.
SUNROOF
7
BODY
DRAIN TUBE - SUN ROOF - FRONT - 5 DOOR
Service repair no - 76.84.20
Remove
1. Remove headlining. See Interior trim
components.
4. Disconnect drain tube from sun roof, discard
cable tie.
5. Attach draw string and remove drain tube.
Refit
1. Attach draw string to NEW drain tube and pull
into position.
2. Connect drain tube to sun roof and secure with
NEW cable tie.
3. Connect drain tube to wheel arch grommet.
4. Secure wheel arch grommet.
5. Position carpet retainer, fit and tighten Torx
screws.
6. Fit headlining. See Interior trim components.
2. Remove 5 Torx screws securing carpet
retainer and remove retainer.
3. Release drain tube from wheel arch grommet.
8
SUNROOF
BODY
DRAIN TUBE - SUN ROOF - REAR - 5 DOOR
FINISHER - SUN ROOF FLANGE TO HEADLINING
Service repair no - 76.84.21
Service repair no - 76.84.25
Remove
Remove
1. Remove headlining. See Interior trim
components.
1. Release sun roof surround finisher from
sunroof aperture and remove finisher.
2. Release drain tube from wheel arch grommet
and 3 securing clips.
3. Disconnect drain tube from sun roof and
discard cable tie.
4. Remove drain tube.
Refit
1. Position sunroof surround finisher and secure
in position ensure locating lug is in position at
the front of finisher.
Refit
1. Position NEW drain tube.
2. Connect drain tube to sun roof and secure with
NEW cable tie.
3. Connect drain tube to wheel arch grommet and
secure in clips.
4. Secure wheel arch grommet.
5. Fit headlining. See Interior trim components.
SUNROOF
9
BODY
WIND DEFLECTOR - SUN ROOF - 5 DOOR
BLIND - SUN ROOF - 5 DOOR
Service repair no - 76.84.28
Service repair no - 76.84.30
Remove
Remove
1. Remove sun roof. See this section.
2. Carefully release wind deflector retaining pegs
from roof.
3. Release wind deflector from lifting assemblies.
4. Remove wind deflector.
Refit
1. Position wind deflector to lifting assemblies and
secure in position.
2. Carefully locate retaining pegs under roof.
3. Fit sun roof. See this section.
10
SUNROOF
1. Remove headlining. See Interior trim
components.
2. Remove 2 blind stops.
3. Remove 2 rubber buffers.
4. Slide blind to the rear of sun roof and remove
from guides.
Refit
1.
2.
3.
4.
Lubricate guides with isoflex grease.
Fit blind to guides and slide into position.
Fit blind stops and rubber buffers.
Fit headlining. See Interior trim components.
BODY
SWITCH - SUN ROOF
SEAL - SUN ROOF TRAY - 5 DOOR
Service repair no - 76.84.40
Service repair no - 76.84.61
Remove
Remove
1. Remove front console. See Interior trim
components.
2. Remove switch from console.
1. Remove sun roof assembly. See this section.
Refit
1. Fit switch to console.
2. Fit front console. See Interior trim
components.
2. Remove seal from tray.
Refit
1. Clean old adhesive from tray.
2. Remove backing from NEW seal and fit seal to
tray.
3. Fit sun roof assembly. See this section.
SUNROOF
11
PANEL REPAIRS
CONTENTS
Page
SEALING AND CORROSION PROTECTION
CORROSION PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
STRUCTURAL ADHESIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SEAM SEALERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SOUND DAMPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
PANELS
PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SERVICEABLE PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PROCEDURES
GENERAL WELDING PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
PANEL REPLACEMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REPAIRS
BODY REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FRONT BULKHEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BONNET LOCKING PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HEADLAMP MOUNTING PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FRONT LOWER CROSSMEMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FRONT SIDEMEMBER (COMPLETE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FRONT SIDEMEMBER (FRONT SECTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FRONT VALANCE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
VALANCE UPPER FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
VALANCE FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
VALANCE OUTER REINFORCEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
’A’ POST - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
’A’ POST - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
SILL REINFORCEMENT - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SILL REINFORCEMENT - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
’B/C’ POST REINFORCEMENT - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
’B/C’ POST REINFORCEMENT - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
COMPLETE REAR QUARTER - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
COMPLETE REAR QUARTER - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
OUTER REAR WHEEL ARCH - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
OUTER REAR WHEEL ARCH - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
INNER ’E’ POST - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INNER ’E’ POST - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REAR FLOOR CROSSMEMBER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REAR FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
FLOOR LONGITUDINAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
FRONT ROOF ASSEMBLY - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
REAR ROOF ASSEMBLY - 3 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
ROOF ASSEMBLY - 5 DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
OUTER BODY SIDE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
TIME SCHEDULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
PANEL REPAIRS
CORROSION PREVENTION
Factory treatments
During production, vehicle bodies are treated with
the following anti-corrosion materials:
• An application of cavity wax which is sprayed into
the sill panels and the lower areas of the door
panels.
• A PVC-based underbody sealer which is sprayed
onto the underside of the main floor and sills, the
exterior of the safe well and the forward face of
the lower dash crossmember.
• A coating of underbody wax which is applied to
the entire underbody inboard of the sill vertical
flanges, and covers all moving and flexible
components EXCEPT for wheels, tyres, brakes
and exhaust.
• A coat of protective wax applied to the engine
bay area.
Whenever body repairs are carried out, ensure the
anti-corrosion materials in the affected area are
repaired or renewed as necessary using the
approved materials. See INFORMATION, Sealing
and corrosion protection.
Cavity wax injection
Areas treated with cavity wax are shown in the
following Figures. After repairs, always re-treat these
areas with an approved cavity wax. In addition, treat
all interior surfaces which have been disturbed
during repairs whether they have been treated in
production or not. This includes all box members,
cavities and door interiors. It is permissible to drill
extra holes for access where necessary, provided
these are not positioned in load-bearing members.
Ensure that such holes are treated with a suitable
zinc rich primer, brushed with wax and then sealed
with a rubber grommet.
During application, ensure that the wax covers all
flange and seam areas and that it is adequately
applied to all repaired areas of both new and
existing panels.
It should be noted that new panel assemblies and
complete body shells are supplied without wax
injection treatment. Ensure that such treatment is
carried out after repairs.
Effective cavity wax protection is vital. Always
observe the following points:
• Complete all paint refinish operations before wax
application.
• Clean body panel areas and blow-clean cavities
if necessary, before treatment.
• Maintain a temperature of 18°C during
application and drying.
• Check the spray pattern of injection equipment.
• Mask off all areas not to be wax coated and
which could be contaminated by wax overspray.
• Remove body fixings, such as seat belt
retractors, if contamination is at all likely.
• Move door glasses to fully closed position before
treating door interiors.
• Treat body areas normally covered by trim before
refitting items.
• Check that body and door drain holes are clear
after the protective wax has dried.
• Keep all equipment clean, especially wax
injection nozzles.
Before wax injection, ensure that the cavity to be
treated is free from any contamination or foreign
matter. Where necessary, clear out any debris using
compressed air.
CAUTION: Ensure that cavity wax is
applied AFTER the final paint process and
BEFORE refitting any trim components.
SEALING AND CORROSION PROTECTION
1
PANEL REPAIRS
Cavity wax treatment areas and injection holes - 3 door
All areas symmetrically opposite to those shown are also treated.
2
SEALING AND CORROSION PROTECTION
PANEL REPAIRS
Key to Figure, cavity wax treatment areas and injection holes - 3 door
1. Injection hole for inner sill
2. Injection hole for area between tail door outer
panel and reinforcing panel
3. Tail door inner panel
4. Tail door reinforcing panel
5. Tail door outer panel
6. Injection hole for sill
Sill cavity wax injection holes - 5 door
All areas symmetrically opposite to those shown are also treated.
1. Injection hole for inner sill
2. Rear injection hole for sill
3. Front injection hole for sill
SEALING AND CORROSION PROTECTION
3
PANEL REPAIRS
Door cavity wax treatment areas and injection hole - 5 door
All areas symmetrically opposite to those shown are also treated.
4
SEALING AND CORROSION PROTECTION
PANEL REPAIRS
Key to Figure, door cavity wax treatment areas and injection holes - 5 door
1. Injection hole for area between tail door outer
panel and reinforcing panel
2. Tail door inner panel
3. Tail door reinforcing panel
4. Tail door outer panel
Underbody sealer
Underfloor areas and sill outer panels are treated
with a Plastisol PVC underbody sealer. This material
is not suitable for re-treatment. When repairing areas
of underbody sealer, strip the factory-applied
underbody sealer back to a suitable break point.
Ensure that a clean metal surface is exposed and
that the edge of the existing sealer adheres soundly
to the panel.
Apply new underbody sealer between primer and
surfacer paint operations. Apply seam sealer as
necessary before application of underbody sealer.
Ensure that blanking plugs and grommets in the
floor pan (except those used for wax injection) are
fitted before underbody sealer application. Refit any
heat-fusible plugs which have been disturbed in
repair with the aid of a hot air blower, or replace with
rubber grommets.
CAUTION: Ensure that suspension units,
wheels, tyres, power unit, driveshafts,
exhaust and brakes (including all
mounting points) are shielded prior to
application of fresh underbody sealer.
SEALING AND CORROSION PROTECTION
5
PANEL REPAIRS
Underbody sealer treatment areas
6
SEALING AND CORROSION PROTECTION
PANEL REPAIRS
Underbody wax
The underbody wax must be reinstated following all
repairs affecting floor panels. The wax is applied
over paints and underbody sealers.
CAUTION: Remove old underbody wax
completely from a zone extending at least
200mm beyond the area where new
underbody sealer is to be applied.
Engine bay wax
Reinstate all protective engine bay wax disturbed
during repairs using an approved material.
Where repairs have involved replacement of engine
bay panels, treat the entire engine compartment
including all components, clips and other fixtures
with an approved underbonnet lacquer or wax.
Precautions during body repairs and handling
Take care when handling the vehicle in the
workshop. Underbody sealers, seam sealers,
underbody wax and body panels may be damaged if
the vehicle is carelessly lifted. See INFORMATION,
Lifting and towing.
Do not attach painted metal surfaces of any
accessory directly to the vehicle’s bodywork unless
suitably protected. Where metal faces are bolted
together always interpose a suitable interface
material such as weldable zinc rich primer, extruded
strip, or zinc tape.
Steam cleaning and dewaxing
Due to the high temperatures generated by steam
cleaning equipment, there is a risk that certain trim
components could be damaged and some
adhesives and corrosion prevention materials
softened or liquified.
Adjust the equipment so that the nozzle temperature
does not exceed 90°C (194°F). Take care not to
allow the steam jet to dwell on one area, and keep
the nozzle at least 300mm from panel surfaces.
DO NOT remove wax or lacquer from underbody or
underbonnet areas during repairs. Should it be
necessary to steam clean these areas, apply a new
coating of wax or underbody protection as soon as
possible.
Proprietary anti-corrosion treatments
The application of proprietary anti-corrosion
treatments in addition to the factory-applied
treatment could invalidate the Corrosion Warranty
and should be discouraged. This does not apply to
approved, compatible, preservative waxes which
may be applied on top of existing coatings.
Fitting approved accessories
When fitting accessories ensure that the vehicle’s
corrosion protection is not affected, either by
breaking the protective coating or by introducing a
moisture trap.
Do not screw self-tapping screws directly into body
panels. Fit suitable plastic inserts to the panel
beforehand. Always ensure that the edges of holes
drilled into panels, chassis members and other body
parts are protected with a suitable zinc rich or acid
etch primer, and follow with a protective wax coating
brushed onto the surrounding area.
SEALING AND CORROSION PROTECTION
7
PANEL REPAIRS
Inspections during maintenance servicing
It is a requirement of the Corrosion Warranty that the
vehicle body is checked for corrosion by an
authorised Land Rover Dealer at least once a year,
to ensure that the factory-applied protection remains
effective.
Service Job Sheets include the following operations
to check bodywork for corrosion:
• With the vehicle on a lift, carry out visual check of
underbody sealer for damage.
• With the vehicle lowered, inspect exterior
paintwork for damage and body panels for
corrosion.
NOTE: The vehicle must be washed and
free from deposits prior to inspection. It is
part of the owner’s responsibility to
ensure that the vehicle is kept free of
accumulations of mud which could accelerate
the onset of corrosion. It will be necessary for
the vehicle to be washed by the Dealer prior to
inspection of bodywork if the customer has
offered the vehicle in a dirty condition. Particular
attention should be paid to areas where access
is difficult.
NOTE: The checks described above are
intended to be visual only. It is not
intended that the operator should remove
trim panels, finishers, rubbing strips or
sound-deadening materials when checking the
vehicle for corrosion and paint damage.
With the vehicle on a lift, and using an inspection or
spot lamp, visually check for the following:
• Corrosion damage and damaged paintwork,
condition of underbody sealer on front and rear
lower panels, sills and wheel arches.
• Damage to underbody sealer. Corrosion in areas
adjacent to suspension mountings and fuel tank
fixings.
NOTE: The presence of small blisters in
underbody sealer is acceptable, providing
they do not expose bare metal.
Pay special attention to signs of damage caused to
panels or corrosion protection material by incorrect
jack positioning.
CAUTION: It is essential to follow the
correct jacking and lifting procedures. See
INFORMATION, Lifting and towing.
8
SEALING AND CORROSION PROTECTION
With the vehicle lowered, visually check for evidence
of damage and corrosion on all visible painted
areas, in particular the following:
• Front edge of bonnet.
• Visible flanges in engine compartment.
• Lower body and door panels.
Rectify any bodywork damage or evidence of
corrosion found during inspection as soon as is
practicable, both to minimise the extent of the
damage and to ensure the long term effectiveness of
the factory-applied corrosion prevention treatment.
Where the cost of rectification work is the owner’s
responsibility, the Dealer must advise the owner and
endorse the relevant documentation accordingly.
Where corrosion has become evident and is
emanating from beneath a removable component
(e.g. trim panel, window glass, seat etc.), remove the
component as required to permit effective
rectification.
PANEL REPAIRS
Underbody protection repairs
Whenever body repairs are carried out, ensure that
full sealing and corrosion protection treatments are
reinstated. This applies both to the damaged areas
and also to areas where protection has been
indirectly impaired, as a result either of accident
damage or repair operations.
Remove corrosion protection from the damaged
area before straightening or panel beating. This
applies in particular to panels coated with wax, PVC
underbody sealer, sound deadening pads etc.
WARNING: DO NOT use oxy-acetylene gas
equipment to remove corrosion
prevention materials. Large volumes of
fumes and gases are liberated by these materials
when they burn.
Equipment for the removal of tough anti-corrosion
sealers offers varying degrees of speed and
effectiveness. The compressed air-operated scraper
(NOT an air chisel) offers a relatively quiet
mechanical method using an extremely rapid
reciprocating action. Move the operating end of the
tool along the work surface to remove the material.
4. Replace all heat-fusible plugs which have been
disturbed. Where such plugs are not available
use rubber grommets of equivalent size,
ensuring that they are embedded in sealer.
5. Mask off all mounting faces from which
mechanical components, hoses and pipe clips,
have been removed. Underbody sealer must
be applied before such components are
refitted.
6. Brush sealer into all exposed seams.
7. Spray the affected area with an approved
service underbody sealer.
8. Remove masking from component mounting
faces, and touch-in where necessary. Allow
adequate drying time before applying
underbody wax.
After refitting mechanical components, including
hoses and pipes and other fixtures, mask off the
brake discs and apply a coat of approved underbody
wax.
NOTE: Where repairs include the
application of finish paint coats in the
areas requiring underbody wax, carry out
paint operations before applying wax.
The most common method of removal is by means
of a hot air blower with integral scraper.
NOTE: High temperatures can be
generated with this equipment which may
cause fumes. Take care during its use.
Another tool, and one of the most efficient methods,
is the rapid-cutting ’hot knife’. This tool uses a wide
blade and is quick and versatile, able to be used
easily in profiled sections where access is otherwise
difficult.
Use the following procedure when repairing
underbody coatings:
1. Remove existing underbody coatings.
2. After panel repair, clean the affected area with
a solvent wipe, and treat bare metal with an
etch phosphate material.
3. Re-prime the affected area.
CAUTION: DO NOT, under any
circumstances, apply underbody sealer
directly to bare metal surfaces.
SEALING AND CORROSION PROTECTION
9
PANEL REPAIRS
STRUCTURAL ADHESIVES
Metal-to-metal adhesive is applied to critical joint
areas during factory assembly. The material used is
a high-temperature, heat cured, nitrile phenolic
which serves to bond two metal surfaces and also to
seal the joint against ingress of dust, moisture and
fumes. This material is not suitable for service use
and, during repair, should be substituted by an
approved Structural Adhesive. See INFORMATION,
Sealing and corrosion protection.
Those joints which require the application of
structural adhesive are detailed in the following
Figures. Only joints applicable to service panels are
included. Apply structural adhesive where indicated
or to the mating panel surface.
CAUTION: When separating a joint treated
with metal-to-metal adhesive, it is
important to avoid distortion. Heat the
joint gradually until the bond weakens
sufficiently to permit panel separation.
NOTE: When spot welding through
metal-to-metal adhesive, take particular
care to adjust the transformer setting to
ensure a reliable weld.
10
SEALING AND CORROSION PROTECTION
PANEL REPAIRS
Adhesive on front valance
Joints symmetrically opposite to those shown are also treated
1. Apply 3 mm diameter beads
2. Apply with brush
3. Apply with brush
SEALING AND CORROSION PROTECTION
11
PANEL REPAIRS
Adhesive on ’A’ post, sill and rear quarter - 3 door
Joints symmetrically opposite to those shown are also treated. Apply 3 mm diameter beads to all joints shown.
Leave sill drain points free of adhesive.
12
SEALING AND CORROSION PROTECTION
PANEL REPAIRS
Adhesive on ’A’ post, sill and rear quarter - 5 door
Joints symmetrically opposite to those shown are also treated. Apply 3 mm diameter beads to all joints shown.
Leave sill drain points free of adhesive.
SEALING AND CORROSION PROTECTION
13
PANEL REPAIRS
Adhesive on rear wheel arch reinforcement - 3 door
Joints symmetrically opposite to those shown are also treated. Apply 3 mm diameter beads to all joints shown.
14
SEALING AND CORROSION PROTECTION
PANEL REPAIRS
Adhesive on body side and roof - 3 door
Joints symmetrically opposite to those shown are also treated. Apply 3 mm diameter beads except where detailed
otherwise (below).
1. Apply 4 x 10 mm diameter spots
2. Apply 3 x 4 mm diameter beads
3. Apply 3 x 10 mm diameter spots
4. Apply 6 mm diameter bead (fuel resistant seam
sealer)
SEALING AND CORROSION PROTECTION
15
PANEL REPAIRS
Adhesive on body side - 5 door
Joints symmetrically opposite to those shown are also treated. Apply 3 mm diameter beads except where detailed
otherwise (below).
1.
2.
3.
4.
16
Apply 4 x 10 mm diameter spots
Apply 3 x 4 mm diameter beads
Apply 3 x 10 mm diameter spots
Apply 4 x 10 mm diameter spots
SEALING AND CORROSION PROTECTION
5. Apply 3 x 4 mm diameter beads
6. Apply 3 x 10 mm diameter spots
7. Apply 6 mm diameter bead (fuel resistant seam
sealer)
PANEL REPAIRS
Adhesive on roof - 5 door
Joints symmetrically opposite to those shown are also treated. Apply 3 mm diameter beads to all joints shown.
SEALING AND CORROSION PROTECTION
17
PANEL REPAIRS
SEAM SEALERS
A heat cured, PVC based sealant is applied to
specific joint seams during factory assembly. This
material is not suitable for service use and, during
repair, should be substituted by an approved Seam
Sealer. See INFORMATION, Sealing and
corrosion protection.
Seams to which seam sealer is applied during
factory assembly are detailed in the following
Figures.
Apply seam sealers after the application of primer
and before the application of surfacer and top coat.
The seam sealer must form a continuous bead, with
the profile of the bead dependant on the type of
seam. If seam sealer is applied with a brush, take
particular care to maintain the required coverage of
the seam. Where shaping of the seam sealer is
required, use a cloth soaked with solvent such as
white spirit or Shell SBP3 to achieve the required
finish.
Ensure that ALL accessible repair seams are sealed
following a repair. Damage to a vehicle often flexes
areas of the body remote from the impact. As a
result, the seam sealer in these areas may be
disturbed by subsequent straightening and repair
operations. Check all seams in the vicinity of the
area undergoing repair for evidence of cracked
seam sealer, then clean out as required and apply
fresh seam sealer using the following procedure:
• Clean the affected seam and re-treat any
exposed metal areas with a suitable etch
phosphate primer.
• Treat affected area with an etch-acid primer.
• Apply appropriate seam sealer as necessary.
• Apply appropriate colour coat (and underbody
sealer as applicable).
Where seams are inaccessible following the
reassembly or fitting of components, ensure that a
paste-type seam sealer is applied to such seams.
Certain seams also become inaccessible after the
completion of panel repairs. In such instances apply
seam sealer and paint before final assembly.
Provided access is adequate, apply seam sealer to
both sides of a repair joint. Where access is limited
to one side only (e.g. box sections), treat the
affected box member with cavity wax.
18
SEALING AND CORROSION PROTECTION
PANEL REPAIRS
Seam sealer on underside
Seams symmetrically opposite to those shown are also treated.
SEALING AND CORROSION PROTECTION
19
PANEL REPAIRS
Seam sealer on rear wheelarch
Seams symmetrically opposite to those shown are also treated.
20
SEALING AND CORROSION PROTECTION
PANEL REPAIRS
Seam sealer on bonnet and doors
Seams symmetrically opposite to those shown are also treated. Front door of 5 door model shown, front door of 3
door model similar. Ensure drain holes in doors are not blocked by sealant.
SEALING AND CORROSION PROTECTION
21
PANEL REPAIRS
Seam sealer on fuel filler and roof - 3 door
Seams symmetrically opposite to those shown are also treated. On roof seams, sealant to be finished flush to
surface forward of points ’A’ and rearward of points ’B’.
22
SEALING AND CORROSION PROTECTION
PANEL REPAIRS
Seam sealer on fuel filler and roof - 5 door
Seams symmetrically opposite to those shown are also treated. On roof seam, sealant to be finished flush to
surface forward of point ’A’.
SEALING AND CORROSION PROTECTION
23
PANEL REPAIRS
Sealed seams in front wheelarch, engine compartment and screen rail
Seams symmetrically opposite to those shown are also treated. Use putty on seams marked ’A’. On windscreen rail,
sealant to be finished flush to adjacent surfaces over length ’B’. On front suspension turrets, ensure damper
mounting holes are kept free of sealant.
24
SEALING AND CORROSION PROTECTION
PANEL REPAIRS
Seam sealer on vehicle interior and rear quarter - 3 door
Seams symmetrically opposite to those shown are also treated. Sealant to be wiped to a smooth finish over length
’A’ (rear load floor to rear heelboard underframe).
SEALING AND CORROSION PROTECTION
25
PANEL REPAIRS
Seam sealer on vehicle interior and rear quarter - 5 door
Seams symmetrically opposite to those shown are also treated. Sealant to be wiped to a smooth finish over length
’A’ (rear load floor to rear heelboard underframe).
26
SEALING AND CORROSION PROTECTION
PANEL REPAIRS
SOUND DAMPENING
During production, expanded foam is incorporated
into some body cavities to reduce noise or prevent
the ingress of moisture, dust and fumes. After a
repair that involves replacement of a section
containing expanded foam, the new section must be
injected with an approved sound dampening foam.
See INFORMATION, Sealing and corrosion
protection. The sound dampening foam should be
injected after paint refinishing and application of
cavity wax.
Accessible cavities that must be injected with sound
dampening foam are detailed in the following
Figures. When injecting the foam, ensure the foam
fills a complete cross section of the cavity.
Sound dampening foam injection points - 3 door
Cavities symmetrically opposite to those shown must also be treated.
1. ’A’ post reinforcement to sill
reinforcement/inner sill
2. ’B’ post reinforcement to sill
reinforcement/inner sill
3. End of rear lower body closing assembly inject through either hole, angle applicator
nozzle to fill outboard end of assembly
SEALING AND CORROSION PROTECTION
27
PANEL REPAIRS
Sound dampening foam injection points - 5 door
Cavities symmetrically opposite to those shown must also be treated.
1. ’A’ post reinforcement to sill
reinforcement/inner sill
2. ’B/C’ post reinforcement to sill
reinforcement/inner sill
28
SEALING AND CORROSION PROTECTION
3. Outer wheelarch to outer body side
4. End of rear lower body closing assembly inject through either hole, angle applicator
nozzle to fill outboard end of assembly
PANEL REPAIRS
PAINT
Sectioned panels
Replacement panels
When replacing part or sectioned panels, the basic
procedure is the same as for welded panels
described above, with the following variations:
Replacement panels are supplied with a cathodic
primer coating as part of the panel protection and in
compliance with the vehicle’s Corrosion Warranty,
where applicable. DO NOT remove the primer
before paint refinishing. In the event of localized
surface damage or imperfections, ensure that
only the minimum of primer is removed during
rectification work for effective repair.
Rectify damage as far as possible by panel beating
or straightening. To remove corrosion or paint runs
on outer surfaces, abrade the primer coat in the
affected area as necessary using the following
procedure:
1. Clean the panel using a solvent wipe.
2. Treat exposed areas of metal with an etch
phosphate process.
3. Re-treat the affected area using either a
separate acid-etch primer and two-pack
surfacer, or an integrated etch primer/filler.
1. Remove primer from both new and existing
joint faces, cleaning to a bright metal finish.
2. Where an overlap joint with the existing panel
is to be spot welded, apply weld-through, zinc
rich primer to both joint faces and spot weld
while the primer is still wet, or according to the
manufacturer’s instructions.
3. MIG weld butt joints where applicable.
4. Clean the panel with a solvent wipe.
5. Treat bare metal areas using an etch
phosphate process.
6. Re-prime affected areas as necessary as for
rectifying transit damage.
7. Treat the inner faces of lap or butt joints with a
suitable cavity wax. See Sealing and
corrosion protection.
Panel preparation
Welded panels
1. Remove primer from the immediate vicinity of
new and existing panel flanges, cleaning to
bright metal finish.
2. On joints to be spot welded, apply
weld-through zinc rich primer to joint faces of
both flanges. Make spot welds while primer is
still wet or according to the manufacturer’s
instructions.
3. Dress accessible weld joints.
4. Clean panel using solvent wipe.
5. Treat bare metal with an etch phosphate
process.
6. Re-treat repaired areas.
PANELS
1
PANEL REPAIRS
Clinched panels
1. Abrade primer on new and existing panel joint
faces, and clean using a solvent wipe.
2. Apply metal-to-metal adhesive where
applicable.
3. Where joints are to be spot welded, apply
suitable weld-through, zinc rich primer to weld
areas.
4. Where joints are to be MIG, arc or gas welded,
apply zinc rich primer in adjacent areas but
leave the welded area untreated.
5. To retain the panel while clinching the flanges,
tack spot weld or plug weld as appropriate.
6. Clean the panel with a solvent wipe.
7. Treat bare metal areas with a suitable etch
phosphate process.
8. Re-prime affected areas as necessary as for
rectifying transit damage.
Paint refinishing
1. Seal required exterior and interior seams with
an approved seam sealer. See Sealing and
corrosion protection.
2. Apply a two-pack paint refinishing system.
3. Repair any damage to underbody sealers
either at this stage or before paint operations.
See Sealing and corrosion protection.
4. Apply cavity wax to all interior surfaces which
have not received refinish paint.
Paint repairs
Before carrying out paintwork repairs, clean the
vehicle thoroughly using either a steam cleaner or
high-pressure washer.
Wash locally repaired areas using a mild
water-mixable detergent and wipe them clean with
solvent, immediately before paint application.
Ensure that damaged paintwork which has led to
exposed metal is abraded until the metal is clean,
extending beyond the area of the original damage.
Treat the bare metal with an etch phosphate to
remove all traces of rust and to provide a key for
new paint coats. Re-treat the affected area using
either a separate acid-etch primer and two-pack
surfacer or an integrated etch primer/filler, and follow
with a two-pack paint system. Treat those surfaces
not receiving paint using an approved cavity wax,
following paint operations. See Sealing and
corrosion protection.
2
PANELS
A. Two-pack top coat
B. Two-pack primer filler and etch primer
C. Etch phosphate
PANEL REPAIRS
SERVICEABLE PANELS
The following Figures show the service panels which
feature in the Body Repairs procedures. Additional
panels and full body shells are also available. See
Parts Fiche for details.
Front end panels
1.
2.
3.
4.
5.
Bonnet locking platform and weldnut assembly
LH headlamp mounting panel
Lower closing panel
Front lower crossmember assembly
LH crossmember to sidemember gusset plate
6.
7.
8.
9.
RH crossmember to sidemember gusset plate
Front bulkhead assembly
RH headlamp mounting panel
Bonnet locking platform assembly
PANELS
3
PANEL REPAIRS
Inner front end panels
1. Valance outer reinforcement assembly
2. Front valance assembly
3. Front sidemember assembly
4
PANELS
4. Front sidemember closing panel
5. Valance front assembly
6. Valance upper front assembly
PANEL REPAIRS
Outer body side panels - 3 door
1. Outer body side assembly
2. Rear outer body side panel
3. Lower outer body side panel
4. Front outer body side panel
PANELS
5
PANEL REPAIRS
Outer body side panels - 5 door
1. Outer body side assembly
2. Rear outer body side panel
6
PANELS
3. Lower outer body side panel
4. Front outer body side panel
PANEL REPAIRS
Front inner body side panels - 3 door
1. A post reinforcement
2. Inner A post
3. Inner sill reinforcement
4. Lower A post reinforcement
PANELS
7
PANEL REPAIRS
Front inner body side panels - 5 door
1. Inner A post
2. A post reinforcement
3. Inner (B/C post) panel
8
PANELS
4. B/C post reinforcement
5. Inner sill reinforcement
6. Lower A post reinforcement
PANEL REPAIRS
Rear inner body side panels - 3 door
1.
2.
3.
4.
Complete rear quarter assembly
Squab side reinforcement
Rear body side reinforcement assembly
Lower inner E post assembly
5. Outer rear wheelarch assembly
6. Rear quarter front lower reinforcement
7. B/C post reinforcement
PANELS
9
PANEL REPAIRS
Rear inner body side panels - 5 door
1. Complete rear quarter assembly
2. Inner E post assembly
10
PANELS
3. Rear body side reinforcement assembly
4. Outer rear wheelarch assembly
PANEL REPAIRS
Roof assemblies - 3 door
1. Front roof assembly
2. Rear roof assembly
PANELS
11
PANEL REPAIRS
Roof assembly - 5 door
1. Roof assembly (with sunroof)
2. Roof assembly (without sunroof)
12
PANELS
PANEL REPAIRS
Rear end panels
1.
2.
3.
4.
5.
Rear floor crossmember assembly
Inner panel
Bumper mounting bracket
Safe well assembly
Gusset, rear floor to quarter inner LH
6.
7.
8.
9.
LH floor longitudinal
Rear floor assembly
RH floor longitudinal
Gusset, rear floor to quarter inner RH
PANELS
13
PANEL REPAIRS
Door assemblies
1. Front door outer (3 door)
2. Front door assembly (3 door)
3. Rear door assembly
14
PANELS
4. Rear door outer
5. Front door assembly (5 door)
6. Front door outer (5 door)
PANEL REPAIRS
GENERAL WELDING PRECAUTIONS
For ease of reference, the diagrams on the following
pages show only the type of weld used in repair
where it varies from that used in production.
The replacement welds in the welding diagrams are
denoted by the following symbols:
• MIG plug welds must be used in repair joints
where there is no access for a resistance spot
welder. To replace each production spot weld a
hole must be drilled and/or punched, and a MIG
plug weld then made in its place. The number of
plug welds must match exactly the number of
spot welds which have been removed.
• Where holes are left in an existing panel after
removal of the spot welds, a single MIG plug
weld will be made in each hole as appropriate.
A = Single/Multiple thickness plug welds
B = MIG seam weld
When carrying out welding operations the following
criteria must be observed:
• Where resistance spot welds have been used in
production, these must be reproduced with new
spot welds in replacement where possible. All
such reproduction spot welds must be spaced
30mm apart.
• When spot welding, it is recommended that test
coupons of the same metal gauges and materials
are produced to carry out peel tests to ensure
that welding equipment being used can produce
a satisfactory joint. Plug welds must be used if a
satisfactory spot weld cannot be produced.
• The electrode arms on hand-held spot welding
guns must not exceed 300mm in length.
• Single-side spot welding is not acceptable.
• Brazing and gas welding are not acceptable
EXCEPT where they have been specified in
production.
• Where 3 metal thicknesses or more are to be
welded together it is imperative to use MIG plug
welds to ensure joint strength.
PROCEDURES
1
PANEL REPAIRS
Seat belt anchorages
Seat belt anchorages are safety critical. When
making repairs in these areas, it is essential to follow
design specifications. Note that High Strength Low
Alloy (HSLA) steel may be used for seat belt
anchorages.
Where possible, the original production assembly
should be used, complete with its seat belt
anchorages, or the cut line should be so arranged
that the original seat belt anchorage is not disturbed.
All welds within 250mm of seat belt anchorages
must be carefully checked for weld quality, including
spacing of spot welds.
WARNING: Body parts incorporating seat
belt anchorages MUST be renewed
completely if damaged beyond repair, as
the welds in these areas are safety critical and
cannot be disturbed.
2
PROCEDURES
PANEL REPAIRS
PANEL REPLACEMENT PROCEDURE
This procedure is designed to explain the basic
panel removal and replacement method. The main
criterion in removal and replacement of body panels
is that the original standard is maintained as far as
possible. While individual repairs will differ in detail,
this procedure has been devised placing emphasis
on ease of repair and the elimination of unnecessary
work.
Body panels are being increasingly manufactured in
high strength steels to meet design requirements for
safety and weight saving. As panels in high strength
steels cannot be visually identified, and as they are
more sensitive to excess heat than panels
manufactured from low carbon steel, it is advisable
that the following procedure be observed at all
times.
2. Cut out welds using a cobalt drill.
Remove panel
3. Alternatively, use a clamp-type spot weld
remover.
1. Expose resistance spot welds. For those spot
welds which are not obviously visible, use a
rotary impregnated wire brush fitted to an air
drill, or alternatively a hand held wire brush.
NOTE: In wheel arch areas it may be
necessary to soften underbody coating,
using a hot air gun, prior to exposing spot
welds.
PROCEDURES
3
PANEL REPAIRS
Prepare old surfaces
1. Remove any remaining sealant using a hot air
gun to minimise the risk of toxic fumes caused
by heat generated during welding.
CAUTION: CARE MUST BE TAKEN TO
AVOID EXCESSIVE HEAT BUILD-UP
WHEN USING THE HOT AIR GUN.
4. Cut away the bulk of the panel as necessary
using an air saw.
NOTE: On certain panel joints MIG welds
and braze should be removed using a
sander where possible, before cutting out
the panel bulk.
2. Clean all panel joint edges to a bright smooth
finish, using a belt-type sander.
NOTE: As an alternative, a disc sander
may be used.
5. Separate spot welded joints and remove panel
remnants using hammer, bolster chisel and
pincers.
3. Straighten existing panel joint edges using
shaping block and hammer.
4
PROCEDURES
PANEL REPAIRS
Prepare new surfaces
1. Mark out bulk of new panel and trim to size,
leaving approximately 50mm overlap with
existing panel. Offer up new panel/section,
align with associated panels (e.g. new rear
quarter aligned with door and tailgate). Clamp
into position.
2. Cut new and existing panels as necessary to
form butt, joggle or brace joint as required.
Remove all clamps and metal remnants.
3. Prepare new panel joint edges for welding by
sanding to a bright finish. This must include
inner as well as outer faces.
4. Apply suitable weld-through primer, to panel
joint surfaces to be welded, using brush or
aerosol can.
PROCEDURES
5
PANEL REPAIRS
Welding
5. Apply seam sealer or structural adhesive, as
applicable, to panel joint surfaces. See
INFORMATION, Sealing and corrosion
protection.
Offer up and align
Offer up new panel and align with associated
panels. Clamp into position using welding clamps or
Mole grips. Where a joggle or brace joint is being
adopted, make a set in the original panel joint edge
or insert a brace behind the joint.
1. Select arms for resistance spot welding and
shape electrode tips using a tip trimmer.
CAUTION: Use arms not exceeding
300mm in length.
NOTE: To maintain efficiency, the tips will
require regular cleaning with emery cloth.
NOTE: In cases where access for welding
clamps is difficult, it may be necessary to
use tack welds.
2. Fit resistance spot welding arms and test
equipment for satisfactory operation, using test
coupons. Where monitoring equipment is not
available, verify weld strength by checking that
metal around the weld puddle pulls apart under
tension during pulling.
6
PROCEDURES
PANEL REPAIRS
5. Dress MIG tack welds using a sander with 36
grit disc, or a belt-type sander where access is
limited.
3. Use a resistance spot welder where access
permits. Try to ensure weld quality by using a
welding monitor where possible.
4. MIG tack weld butt joints and re-check
alignment and panel contours where
necessary. Ensure that a gap is maintained to
minimise welding distortion, by inserting a
hacksaw blade as an approximate guide.
PROCEDURES
7
PANEL REPAIRS
6. MIG seam weld butt joints.
8. Dress all welds using either a sander with 36
grit disc, or a belt-type sander and/or
impregnated wire brush.
NOTE: Brazing operations, if required,
must be carried out at this point.
7. Always use MIG plug welds where excessive
metal thickness or limited access make
resistance spot welding impractical. Make plug
welds either by using holes left by the spot
weld cutter, or through holes punched and
drilled for the purpose.
8
PROCEDURES
PANEL REPAIRS
BODY REPAIR
FRONT BULKHEAD ASSEMBLY
The following panel repair operations itemize
components which must be removed for access
during repair of a base model vehicle.
NOTE: In this procedure, the
crossmember to sidemember gusset
plates are replaced in conjunction with the
front bulkhead assembly.
Because of the unpredictable nature of accident
damage, the items listed make no allowance for any
difficulties which may be found in removal and only
apply to an undamaged vehicle. All damaged
components should be renewed following panel
repairs.
Remove
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove front bumper valance. See BODY,
Exterior fittings.
5. Remove front bumper armature.
6. Remove radiator. See COOLING SYSTEM,
Repairs.
7. Remove PAS fluid cooler. See STEERING,
Repairs.
8. Remove LH and RH headlamps. See
ELECTRICAL, Repairs.
9. Release wiring to headlamps and position
aside.
10. Remove LH and RH engine bay shields.
11. Remove bumper valance LH and RH
attachment brackets.
12. Remove battery. See ELECTRICAL, Repairs.
13. Remove air intake hose.
14. Remove horn. See ELECTRICAL, Repairs.
15. Remove windscreen washer reservoir. See
WIPERS & WASHERS, Repairs.
16. Remove bonnet lock.
17. Support bonnet in open position.
18. Remove bonnet stay.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
REPAIRS
1
PANEL REPAIRS
Refit
1. Fit bonnet stay.
2. Fit bonnet lock.
3. Fit windscreen washer reservoir. See WIPERS
& WASHERS, Repairs.
4. Fit horn. See ELECTRICAL, Repairs.
5. Fit air intake hose.
6. Fit battery. Do not connect earth lead. See
ELECTRICAL, Repairs.
7. Fit bumper valance LH and RH attachment
brackets.
8. Fit LH and RH engine bay shields.
9. Fit LH and RH headlamps. See
ELECTRICAL, Repairs. Secure headlamps
wiring.
2
REPAIRS
10. Fit PAS fluid cooler. See STEERING,
Repairs.
11. Fit radiator. See COOLING SYSTEM,
Repairs.
12. Fit front bumper armature.
13. Fit front bumper valance. See BODY, Exterior
fittings.
14. Connect all ECUs.
15. Connect alternator. See ELECTRICAL,
Repairs.
16. Connect battery earth lead.
PANEL REPAIRS
BONNET LOCKING PLATFORM
Remove
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove front bumper valance. See BODY,
Exterior fittings.
5. Remove radiator. See COOLING SYSTEM,
Repairs.
6. Remove both headlamp assemblies. See
ELECTRICAL, Repairs.
7. Remove horn. See ELECTRICAL, Repairs.
8. Remove battery. See ELECTRICAL, Repairs.
9. Remove air intake hose.
10. Remove bonnet lock.
11. Support bonnet in open position.
12. Remove bonnet stay.
Refit
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Fit bonnet stay.
Fit bonnet lock.
Fit air intake hose.
Fit battery. Do not connect earth lead. See
ELECTRICAL, Repairs.
Fit horn. See ELECTRICAL, Repairs.
Fit both headlamp assemblies. See
ELECTRICAL, Repairs.
Fit radiator. See COOLING SYSTEM,
Repairs.
Fit front bumper valance. See BODY, Exterior
fittings.
Connect all ECUs.
Connect alternator. See ELECTRICAL,
Repairs.
Connect battery earth lead.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure.
REPAIRS
3
PANEL REPAIRS
HEADLAMP MOUNTING PANEL
Refit
Remove
For LH side
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove front bumper valance. See BODY,
Exterior fittings.
5. Remove front bumper armature.
6. Remove radiator. See COOLING SYSTEM,
Repairs.
7. Remove headlamp assembly. See
ELECTRICAL, Repairs.
8. Release wiring to headlamp and position aside.
1. Fit air intake hose.
2. Fit horn. See ELECTRICAL, Repairs.
3. Fit battery. Do not connect earth lead. See
ELECTRICAL, Repairs.
4. Fit front bumper LH support bracket.
For RH side
5. Fit PAS fluid cooler. See STEERING,
Repairs.
6. Fit windscreen washer reservoir. See WIPERS
& WASHERS, Repairs.
7. Fit front bumper LH support bracket.
For LH side
For both sides
9.
10.
11.
12.
Remove front bumper LH support bracket.
Remove battery. See ELECTRICAL, Repairs.
Remove horn. See ELECTRICAL, Repairs.
Remove air intake hose.
For RH side
13. Remove front bumper RH support bracket.
14. Remove windscreen washer reservoir. See
WIPERS & WASHERS, Repairs.
15. Remove PAS fluid cooler. See STEERING,
Repairs.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
4
REPAIRS
8. Fit headlamp assembly. See ELECTRICAL,
Repairs. Secure headlamp wiring.
9. Fit radiator. See COOLING SYSTEM,
Repairs.
10. Fit front bumper armature.
11. Fit front bumper valance. See BODY, Exterior
fittings.
12. Connect all ECUs.
13. Connect alternator. See ELECTRICAL,
Repairs.
14. Connect battery earth lead.
PANEL REPAIRS
FRONT LOWER CROSSMEMBER
NOTE: In this procedure, the
crossmember to sidemember gusset
plates are replaced in conjunction with the
front lower crossmember.
If required, the lower closing panel can be
replaced separately.
Remove
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove LH and RH engine bay shields.
5. Remove front bumper valance. See BODY,
Exterior fittings.
6. Remove front bumper armature.
7. Remove radiator. See COOLING SYSTEM,
Repairs.
8. Remove PAS fluid cooler. See STEERING,
Repairs.
9. Release wiring for LH and RH headlamps and
position aside.
Refit
1. Secure wiring to LH and RH headlamps.
2. Fit PAS fluid cooler. See STEERING,
Repairs.
3. Fit radiator. See COOLING SYSTEM,
Repairs.
4. Fit front bumper armature.
5. Fit front bumper valance. See BODY, Exterior
fittings.
6. Fit LH and RH engine bay shields.
7. Connect all ECUs.
8. Connect alternator. See ELECTRICAL,
Repairs.
9. Connect battery earth lead.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
REPAIRS
5
PANEL REPAIRS
FRONT SIDEMEMBER (COMPLETE)
NOTE: In this procedure, the front
sidemember closing panel and the related
crossmember to sidemember gusset plate
are replaced in conjunction with the front
sidemember.
Remove
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Disconnect battery earth lead.
Disconnect all ECUs.
Remove road wheel(s).
Remove underbelly panel. See BODY,
Exterior fittings.
Remove front bumper valance. See BODY,
Exterior fittings.
Remove front bumper armature.
Remove radiator. See COOLING SYSTEM,
Repairs.
Remove PAS fluid cooler. See STEERING,
Repairs.
Remove headlamp. See ELECTRICAL,
Repairs.
Release wiring to headlamp and position aside.
Remove engine bay shield.
Remove front wheel arch liner. See BODY,
Exterior fittings.
Remove front suspension rear beam.
Remove engine and gearbox. See ENGINE,
Repairs.
Remove PAS rack. See STEERING, Repairs.
Remove fascia. See BODY, Interior trim
components.
For LH side
17.
18.
19.
20.
21.
Remove front bumper LH support bracket.
Remove LH engine mounting from body.
Remove battery. See ELECTRICAL, Repairs.
Remove air intake hose.
Remove horn. See ELECTRICAL, Repairs.
For RH side
22. Remove front bumper RH support bracket.
23. Remove RH engine mounting from body.
24. Remove windscreen washer reservoir. See
WIPERS & WASHERS, Repairs.
6
REPAIRS
For driver’s side
25. Remove passenger compartment fuse box.
26. Remove brake pedal box and brake servo. See
BRAKES, Repairs.
27. Remove clutch pedal box. See CLUTCH,
Repairs.
For both sides
28. Remove treadplate from front door aperture.
Release front carpet and position aside.
29. Remove insulation pads from engine bulkhead.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
PANEL REPAIRS
22. Fit radiator. See COOLING SYSTEM,
Repairs.
23. Fit front bumper armature.
24. Fit front bumper valance. See BODY, Exterior
fittings.
25. Fit underbelly panel. See BODY, Exterior
fittings.
26. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque wrench
settings.
27. Connect all ECUs.
28. Connect battery earth lead.
Refit
1. Fit insulation pads to engine bulkhead.
2. Position front carpet and fit treadplate to front
door aperture.
For driver’s side
3. Fit clutch pedal box. See CLUTCH, Repairs.
4. Fit brake pedal box and brake servo. See
BRAKES, Repairs.
5. Fit passenger compartment fuse box.
For LH side
6. Fit horn. See ELECTRICAL, Repairs.
7. Fit air intake hose.
8. Fit battery. Do not connect battery earth lead.
See ELECTRICAL, Repairs.
9. Fit LH engine mounting to body.
10. Fit front bumper LH support bracket.
For RH side
11. Fit windscreen washer reservoir. See WIPERS
& WASHERS, Repairs.
12. Fit RH engine mounting to body.
13. Fit front bumper RH support bracket.
For both sides
14. Fit fascia. See BODY, Interior trim
components.
15. Fit PAS rack. See STEERING, Repairs.
16. Fit engine and gearbox. See ENGINE,
Repairs.
17. Fit front suspension rear beam.
18. Fit front wheel arch liner. See BODY, Exterior
fittings.
19. Fit engine bay shield.
20. Fit headlamp. See ELECTRICAL, Repairs.
Secure headlamp wiring.
21. Fit PAS fluid cooler. See STEERING,
Repairs.
REPAIRS
7
PANEL REPAIRS
FRONT SIDEMEMBER (FRONT SECTION)
NOTE: In this procedure, the front section
of the front sidemember closing panel and
the related crossmember to sidemember
gusset plate are replaced in conjunction with the
front sidemember.
Remove
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Disconnect battery earth lead.
Disconnect all ECUs.
Remove road wheel(s).
Remove underbelly panel. See BODY,
Exterior fittings.
Remove front bumper valance. See BODY,
Exterior fittings.
Remove radiator. See COOLING SYSTEM,
Repairs.
Remove PAS fluid cooler. See STEERING,
Repairs.
Remove headlamp. See ELECTRICAL,
Repairs.
Release wiring to headlamp and position aside.
Remove engine bay shield.
Remove front wheel arch liner. See BODY,
Exterior fittings.
For LH side
12. Remove front bumper LH support bracket.
13. Remove ECM.
14. Remove battery carrier. See ELECTRICAL,
Repairs.
15. Remove air cleaner.
16. Remove air intake hose.
17. Remove horn. See ELECTRICAL, Repairs.
For RH side
18. Remove front bumper RH support bracket.
19. Remove windscreen washer reservoir. See
WIPERS & WASHERS, Repairs.
20. Remove alternator. See ELECTRICAL,
Repairs.
21. Remove PAS pump. See STEERING,
Repairs.
8
REPAIRS
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
PANEL REPAIRS
Refit
For LH side
Fit horn. See ELECTRICAL, Repairs.
Fit air intake hose.
Fit air cleaner.
Fit battery carrier. Do not connect battery earth
lead. See ELECTRICAL, Repairs.
5. Fit ECM.
6. Fit front bumper LH support bracket.
1.
2.
3.
4.
For RH side
7. Fit PAS pump. See STEERING, Repairs.
8. Fit alternator. See ELECTRICAL, Repairs.
9. Fit windscreen washer reservoir. See WIPERS
& WASHERS, Repairs.
10. Fit front bumper RH support bracket.
For both sides
11. Fit front wheel arch liner. See BODY, Exterior
fittings.
12. Fit engine bay shield.
13. Fit headlamp. See ELECTRICAL, Repairs.
Secure headlamp wiring.
14. Fit PAS fluid cooler. See STEERING,
Repairs.
15. Fit radiator. See COOLING SYSTEM,
Repairs.
16. Fit front bumper valance. See BODY, Exterior
fittings.
17. Fit underbelly panel. See BODY, Exterior
fittings. See
18. Connect all ECUs.
19. Connect battery earth lead.
REPAIRS
9
PANEL REPAIRS
FRONT VALANCE ASSEMBLY
Remove
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Disconnect battery earth lead.
Disconnect all ECUs.
Remove road wheel(s).
Remove underbelly panel. See BODY,
Exterior fittings.
Remove front bumper valance. See BODY,
Exterior fittings.
Remove front bumper armature.
Remove radiator. See COOLING SYSTEM,
Repairs.
Remove PAS fluid cooler. See STEERING,
Repairs.
Remove headlamp. See ELECTRICAL,
Repairs.
Release wiring to headlamp and position aside.
Remove engine bay shield.
Remove front wheel arch liner. See BODY,
Exterior fittings.
Remove front wing. See BODY, Exterior
fittings.
Remove front suspension rear beam.
Remove engine and gearbox. See ENGINE,
Repairs.
Remove front damper. See FRONT
SUSPENSION, Repairs.
Remove PAS rack. See STEERING, Repairs.
Remove fascia. See BODY, Interior trim
components.
For LH side
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
10
Remove front bumper LH support bracket.
Remove tool kit.
Remove air cleaner.
Remove air intake hose.
Remove ECM.
Remove relay module. See ELECTRICAL,
Repairs.
Remove battery carrier. See ELECTRICAL,
Repairs.
Remove engine compartment fuse box and
related wiring.
Remove LH engine mounting from body.
On models with ’L’ series engine, remove fuel
filter. See FUEL DELIVERY SYSTEM - ’L’
SERIES, Repairs.
Remove LH front brake pipe.
REPAIRS
For RH side
30. Remove front bumper RH support bracket.
31. Remove windscreen washer reservoir. See
WIPERS & WASHERS, Repairs.
32. Remove coolant expansion tank. See
COOLING SYSTEM, Repairs.
33. Remove RH engine mounting from body.
34. Remove PAS fluid reservoir. See STEERING,
Repairs.
35. Remove RH front brake pipe.
36. Remove pressure conscious reducing valve
and related brake pipes. See BRAKES,
Repairs.
For driver’s side
37. Remove passenger compartment fuse box.
38. Remove brake pedal box and brake servo. See
BRAKES, Repairs.
39. Remove clutch pedal box. See CLUTCH,
Repairs.
For both sides
40. Release vehicle harness from valance and
position aside.
41. Remove treadplate from front door aperture.
Release front carpet and position aside.
42. Remove insulation pads from engine bulkhead.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
PANEL REPAIRS
For RH side
18. Fit pressure conscious reducing valve and
related brake pipes. See BRAKES, Repairs.
19. Fit RH front brake pipe. Bleed brake system.
See BRAKES, Adjustments.
20. Fit PAS fluid reservoir. See STEERING,
Repairs.
21. Fit RH engine mounting to body.
22. Fit coolant expansion tank. See COOLING
SYSTEM, Repairs.
23. Fit windscreen washer reservoir. See WIPERS
& WASHERS, Repairs.
24. Fit front bumper RH support bracket.
Refit
1. Fit insulation pads to front and rear sides of
engine bulkhead.
2. Position front carpet and fit treadplate to front
door aperture.
3. Secure vehicle harness to valance.
For driver’s side
4. Fit clutch pedal box. See CLUTCH, Repairs.
5. Fit brake pedal box and brake servo. See
BRAKES, Repairs.
6. Fit passenger compartment fuse box.
For LH side
7. Fit LH front brake pipe. Bleed brake system.
See BRAKES, Adjustments.
8. On models with ’L’ series engine, fit fuel filter.
See FUEL DELIVERY SYSTEM - ’L’ SERIES,
Repairs.
9. Fit LH engine mounting to body.
10. Fit engine compartment fuse box and related
wiring.
11. Fit battery carrier. Do not connect battery earth
lead. See ELECTRICAL, Repairs.
12. Fit relay module. See ELECTRICAL, Repairs.
13. Fit ECM.
14. Fit air intake hose.
15. Fit air cleaner.
16. Fit tool kit.
17. Fit front bumper LH support bracket.
For both sides
25. Fit fascia. See BODY, Interior trim
components.
26. Fit PAS rack. See STEERING, Repairs.
27. Fit front damper. See FRONT SUSPENSION,
Repairs.
28. Fit engine and gearbox. See ENGINE,
Repairs.
29. Fit front suspension rear beam.
30. Fit front wing. See BODY, Exterior fittings.
31. Fit front wheel arch liner. See BODY, Exterior
fittings.
32. Fit engine bay shield.
33. Fit headlamp. See ELECTRICAL, Repairs.
Secure headlamp wiring.
34. Fit PAS fluid cooler. See STEERING,
Repairs.
35. Fit radiator. See COOLING SYSTEM,
Repairs.
36. Fit front bumper armature.
37. Fit front bumper valance. See BODY, Exterior
fittings.
38. Fit underbelly panel. See BODY, Exterior
fittings.
39. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque wrench
settings.
40. Connect all ECUs.
41. Connect battery earth lead.
REPAIRS
11
PANEL REPAIRS
VALANCE UPPER FRONT
Refit
Remove
For LH side
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove road wheel(s).
5. Remove front wheel arch liner. See BODY,
Exterior fittings.
6. Remove front wing. See BODY, Exterior
fittings.
7. Remove front bumper valance. See BODY,
Exterior fittings.
8. Remove headlamp. See ELECTRICAL,
Repairs.
9. Release wiring from valance and position
aside.
For LH side
10. Remove ECM.
11. Remove battery. See ELECTRICAL, Repairs.
For RH side
12. Remove PAS fluid reservoir. See STEERING,
Repairs.
13. Remove brake pipes from valance.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
12
REPAIRS
1. Fit battery. Do not connect earth lead. See
ELECTRICAL, Repairs.
2. Fit ECM.
For RH side
3. Fit PAS fluid reservoir. See STEERING,
Repairs.
4. Fit brake pipes to valance. Bleed brakes. See
BRAKES, Adjustments.
For both sides
5. Secure wiring to valance.
6. Fit headlamp. See ELECTRICAL, Repairs.
7. Fit front bumper valance. See BODY, Exterior
fittings.
8. Fit front wing. See BODY, Exterior fittings.
9. Fit front wheel arch liner. See BODY, Exterior
fittings.
10. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque wrench
settings.
11. Connect all ECUs.
12. Connect alternator. See ELECTRICAL,
Repairs.
13. Connect battery earth lead.
PANEL REPAIRS
VALANCE FRONT
Remove
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove road wheel(s).
5. Remove front wheel arch liner. See BODY,
Exterior fittings.
6. Remove engine bay shield.
7. Remove front wing. See BODY, Exterior
fittings.
8. Remove front bumper valance. See BODY,
Exterior fittings.
9. Remove front bumper support bracket.
10. Remove radiator. See COOLING SYSTEM,
Repairs.
11. Remove headlamp. See ELECTRICAL,
Repairs.
12. Release wiring to headlamp and position aside.
For LH side
13.
14.
15.
16.
17.
Remove tool kit.
Remove air cleaner.
Remove air intake hose.
Remove ECM.
Remove battery carrier. See ELECTRICAL,
Repairs.
18. Remove engine compartment fuse box and
related wiring.
19. Remove LH front brake pipe.
For RH side
20. Remove PAS fluid reservoir. See STEERING,
Repairs.
21. Remove RH front brake pipe.
22. Remove pressure conscious reducing valve
and related brake pipes. See BRAKES,
Repairs.
23. Remove windscreen washer reservoir. See
WIPERS & WASHERS, Repairs.
24. Remove PAS fluid cooler. See STEERING,
Repairs.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
For LH side
1. Fit LH front brake pipe. Bleed brake system.
See BRAKES, Adjustments.
2. Fit engine compartment fuse box and related
wiring.
3. Fit battery carrier. Do not connect battery earth
lead. See ELECTRICAL, Repairs.
4. Fit ECM.
5. Fit air intake hose.
6. Fit air cleaner.
7. Fit tool kit.
For RH side
8. Fit PAS fluid cooler. See STEERING,
Repairs.
9. Fit windscreen washer reservoir. See WIPERS
& WASHERS, Repairs.
10. Fit pressure conscious reducing valve and
related brake pipes. See BRAKES, Repairs.
11. Fit RH front brake pipe. Bleed brake system.
See BRAKES, Adjustments.
12. Fit PAS fluid reservoir. See STEERING,
Repairs.
REPAIRS
13
PANEL REPAIRS
For both sides
13. Fit headlamp. See ELECTRICAL, Repairs.
Secure headlamp wiring.
14. Fit PAS fluid cooler. See STEERING,
Repairs.
15. Fit radiator. See COOLING SYSTEM,
Repairs.
16. Fit front bumper support bracket.
17. Fit front bumper valance. See BODY, Exterior
fittings.
18. Fit front wing. See BODY, Exterior fittings.
19. Fit front wheel arch liner. See BODY, Exterior
fittings.
20. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque wrench
settings.
21. Connect all ECUs.
22. Connect alternator. See ELECTRICAL,
Repairs.
23. Connect battery earth lead.
VALANCE OUTER REINFORCEMENT
Remove
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove road wheel(s).
5. Remove front wheel arch liner. See BODY,
Exterior fittings.
6. Remove front wing. See BODY, Exterior
fittings.
7. Remove front bumper valance. See BODY,
Exterior fittings.
8. Remove headlamp. See ELECTRICAL,
Repairs.
9. Release wiring from valance and position
aside.
For LH side
Remove battery. See ELECTRICAL, Repairs.
Remove tool kit.
Remove ECM.
Remove relay module. See ELECTRICAL,
Repairs.
14. Remove battery carrier. See ELECTRICAL,
Repairs.
15. Remove engine compartment fuse box and
related wiring.
10.
11.
12.
13.
For RH side
16. Remove PAS fluid reservoir. See STEERING,
Repairs.
17. Remove brake pipes from valance.
14
REPAIRS
PANEL REPAIRS
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
For both sides
9. Secure wiring to valance.
10. Fit headlamp. See ELECTRICAL, Repairs.
11. Fit front bumper valance. See BODY, Exterior
fittings.
12. Fit front wing. See BODY, Exterior fittings.
13. Fit front wheel arch liner. See BODY, Exterior
fittings.
14. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque wrench
settings.
15. Connect all ECUs.
16. Connect alternator. See ELECTRICAL,
Repairs.
17. Connect battery earth lead.
Refit
For LH side
1. Fit engine compartment fuse box and related
wiring.
2. Fit battery carrier. See ELECTRICAL,
Repairs.
3. Fit relay module. See ELECTRICAL, Repairs.
4. Fit ECM.
5. Fit tool kit.
6. Fit battery. Do not connect earth lead. See
ELECTRICAL, Repairs.
For RH side
7. Fit PAS fluid reservoir. See STEERING,
Repairs.
8. Fit brake pipes to valance. Bleed brakes. See
BRAKES, Adjustments.
REPAIRS
15
PANEL REPAIRS
’A’ POST - 3 DOOR
NOTE: In this procedure, the front outer
body side panel is replaced in conjunction
with the inner ’A’ post and the ’A’ post
reinforcements.
Remove
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove road wheel(s).
5. Remove front wheel arch liner. See BODY,
Exterior fittings.
6. Remove front wing. See BODY, Exterior
fittings.
7. Remove front door. See BODY, Doors.
8. Remove front seat. See BODY, Seats and
seat belts.
9. Remove fascia. See BODY, Interior trim
components.
10. Remove duct of outboard face level ventilator.
11. Remove headlining. See BODY, Interior trim
components.
12. Remove windscreen. See BODY, Screens.
13. Remove treadplate from front door aperture.
Release front carpet and position aside.
14. Remove front door aperture seal.
15. Remove engine bulkhead insulation.
For driver’s side
16. Remove passenger compartment fuse box.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
16
REPAIRS
PANEL REPAIRS
Refit
’A’ POST - 5 DOOR
For driver’s side
NOTE: In this procedure, the front outer
body side panel is replaced in conjunction
with the inner ’A’ post and the ’A’ post
reinforcements.
1. Fit passenger compartment fuse box.
For both sides
Remove
2. Fit insulation pads to engine bulkhead.
3. Fit front door aperture seal.
4. Position front carpet and fit treadplate to front
door aperture.
5. Fit windscreen. See BODY, Screens.
6. Fit headlining. See BODY, Interior trim
components.
7. Fit duct of outboard face level ventilator.
8. Fit fascia. See BODY, Interior trim
components.
9. Fit front seat. See BODY, Seats and seat
belts.
10. Fit front door. See BODY, Doors.
11. Fit front wing. See BODY, Exterior fittings.
12. Fit front wheel arch liner. See BODY, Exterior
fittings.
13. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque wrench
settings.
14. Connect all ECUs.
15. Connect alternator. See ELECTRICAL,
Repairs.
16. Connect battery earth lead.
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove road wheel(s).
5. Remove front wheel arch liner. See BODY,
Exterior fittings.
6. Remove front wing. See BODY, Exterior
fittings.
7. Remove front door. See BODY, Doors.
8. Remove front seat. See BODY, Seats and
seat belts.
9. Remove fascia. See BODY, Interior trim
components.
10. Remove duct of outboard face level ventilator.
11. Remove headlining. See BODY, Interior trim
components.
12. Remove windscreen. See BODY, Screens.
13. Remove treadplate from front door aperture.
Release front carpet and position aside.
14. Remove front door aperture seal.
15. Remove engine bulkhead insulation.
For driver’s side
16. Remove passenger compartment fuse box.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
REPAIRS
17
PANEL REPAIRS
Refit
For driver’s side
1. Fit passenger compartment fuse box.
For both sides
2. Fit insulation pads to engine bulkhead.
3. Fit front door aperture seal.
4. Position front carpet and fit treadplate to front
door aperture.
5. Fit headlining. See BODY, Interior trim
components.
6. Fit windscreen. See BODY, Screens.
7. Fit duct of outboard face level ventilator.
8. Fit fascia. See BODY, Interior trim
components.
9. Fit front seat. See BODY, Seats and seat
belts.
10. Fit front door. See BODY, Doors.
11. Fit front wing. See BODY, Exterior fittings.
12. Fit front wheel arch liner. See BODY, Exterior
fittings.
13. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque wrench
settings.
14. Connect all ECUs.
15. Connect alternator. See ELECTRICAL,
Repairs.
16. Connect battery earth lead.
18
REPAIRS
PANEL REPAIRS
SILL REINFORCEMENT - 3 DOOR
NOTE: In this procedure, the lower outer
body side panel is replaced in conjunction
with the sill reinforcement.
Remove
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove road wheel(s).
5. Remove front wing. See BODY, Exterior
fittings.
6. Remove front door. See BODY, Doors.
7. Remove front seat. See BODY, Seats and
seat belts.
8. Remove rear seat. See BODY, Seats and
seat belts.
9. Remove treadplate from front door aperture.
10. Remove side door aperture seal.
11. Remove rear body side casing. See BODY,
Interior trim components.
12. Release carpet from inner sill and position
aside.
13. Release vehicle harness from inner sill and
position aside.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1. Secure vehicle harness to inner sill.
2. Position carpet to inner sill.
3. Fit rear body side casing. See BODY, Interior
trim components.
4. Fit side door aperture seal(s).
5. Fit treadplate to side door aperture(s).
6. Fit rear seat. See BODY, Seats and seat
belts.
7. Fit front seat. See BODY, Seats and seat
belts.
8. Fit front door. See BODY, Doors.
9. Fit front wing. See BODY, Exterior fittings.
10. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque wrench
settings.
11. Connect all ECUs.
12. Connect alternator. See ELECTRICAL,
Repairs.
13. Connect battery earth lead.
REPAIRS
19
PANEL REPAIRS
SILL REINFORCEMENT - 5 DOOR
NOTE: In this procedure, the lower outer
body side panel is replaced in conjunction
with the sill reinforcement.
Remove
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove road wheel(s).
5. Remove front wing. See BODY, Exterior
fittings.
6. Remove front door. See BODY, Doors.
7. Remove rear door. See BODY, Doors.
8. Remove B/C post lower finisher. See BODY,
Interior trim components.
9. Remove front seat. See BODY, Seats and
seat belts.
10. Remove rear seat. See BODY, Seats and
seat belts.
11. Remove treadplate from side door apertures.
12. Remove side door aperture seals.
13. Release carpet from inner sill and position
aside.
14. Release vehicle harness from inner sill and
position aside.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
20
REPAIRS
Refit
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Secure vehicle harness to inner sill.
Position carpet to inner sill.
Fit side door aperture seals.
Fit treadplate to side door apertures.
Fit rear seat. See BODY, Seats and seat
belts.
Fit front seat. See BODY, Seats and seat
belts.
Fit B/C post lower finisher. See BODY,
Interior trim components.
Fit rear door. See BODY, Doors.
Fit front door. See BODY, Doors.
Fit front wing. See BODY, Exterior fittings.
Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque wrench
settings.
Connect all ECUs.
Connect alternator. See ELECTRICAL,
Repairs.
Connect battery earth lead.
PANEL REPAIRS
’B/C’ POST REINFORCEMENT - 3 DOOR
NOTE: In this procedure, the rear outer
body side panel and the rear quarter front
lower reinforcement are replaced in
conjunction with the ’B/C’ post reinforcement.
Remove
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove road wheel(s).
5. Remove rear wheel arch extension. See
BODY, Exterior fittings.
6. Remove rear wheel arch liner.
7. Remove front seat belt. See RESTRAINT
SYSTEMS, Repairs.
8. Remove front door striker from B/C post.
9. Remove rear seat. See BODY, Seats and
seat belts.
10. Remove rear body side casing. See BODY,
Interior trim components.
11. Remove treadplate from side door aperture.
12. Remove side door aperture seal.
13. Release carpet from inner sill and position
aside.
14. Remove rear quarter vent and seal. See
BODY, Exterior fittings.
15. Remove rear roof panel finisher.
16. Remove headlining. See BODY, Interior trim
components.
17. Release vehicle harness from inner sill and
position aside.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
REPAIRS
21
PANEL REPAIRS
Refit
’B/C’ POST REINFORCEMENT - 5 DOOR
1. Secure vehicle harness to inner sill.
2. Fit headlining. See BODY, Interior trim
components.
3. Fit rear roof panel finisher.
4. Fit seal and rear quarter vent. See BODY,
Exterior fittings.
5. Secure carpet to inner sill.
6. Fit side door aperture seal.
7. Fit treadplate from side door aperture.
8. Fit rear body side casing. See BODY, Interior
trim components.
9. Fit rear seat. See BODY, Seats and seat
belts.
10. Fit front door striker to B/C post.
11. Fit front seat belt. See RESTRAINT
SYSTEMS, Repairs.
12. Fit rear wheel arch liner.
13. Fit rear wheel arch extension. See BODY,
Exterior fittings.
14. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque wrench
settings.
15. Connect all ECUs.
16. Connect alternator. See ELECTRICAL,
Repairs.
17. Connect battery earth lead.
NOTE: In this procedure, the rear outer
body side panel and the inner panel are
replaced in conjunction with the ’B/C’ post
reinforcement.
Remove
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove rear door. See BODY, Doors.
5. Remove headlining. See BODY, Interior trim
components.
6. Remove front seat belt. See RESTRAINT
SYSTEMS, Repairs.
7. Remove B/C post lower finisher. See BODY,
Interior trim components.
8. Remove front door striker from B/C post.
9. Remove front seat. See BODY, Seats and
seat belts.
10. Remove rear seat. See BODY, Seats and
seat belts.
11. Remove treadplate from side door aperture(s).
12. Remove side door aperture seal(s).
13. Release carpet from inner sill and position
aside.
14. Release vehicle harness from inner sill and
position aside.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
22
REPAIRS
PANEL REPAIRS
Refit
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Secure vehicle harness to inner sill.
Position carpet to inner sill.
Fit side door aperture seal(s).
Fit treadplate from side door aperture(s).
Fit rear seat. See BODY, Seats and seat
belts.
Fit front seat. See BODY, Seats and seat
belts.
Fit front door striker to B/C post.
Fit B/C post lower finisher. See BODY,
Interior trim components.
Fit front seat belt. See RESTRAINT
SYSTEMS, Repairs.
Fit headlining. See BODY, Interior trim
components.
Fit rear door. See BODY, Doors.
Connect all ECUs.
Connect alternator. See ELECTRICAL,
Repairs.
Connect battery earth lead.
REPAIRS
23
PANEL REPAIRS
COMPLETE REAR QUARTER - 3 DOOR
NOTE: In this procedure, the rear outer
body side panel is replaced in conjunction
with the complete rear quarter.
Remove
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove road wheel(s).
5. Remove sill lower finisher. See BODY,
Exterior fittings.
6. Remove rear bumper valance. See BODY,
Exterior fittings.
7. Remove rear wheel arch liner.
8. Remove door striker from ’B’ post.
9. Remove treadplate from front door aperture.
10. Remove front door aperture seal.
11. Release carpet from inner sill and rear
heelboard and position aside.
12. Remove soft/hard top.
13. Remove tail door aperture seal.
14. Remove rear roof panel finisher. See BODY,
Exterior fittings.
15. Remove tail lamp. See ELECTRICAL,
Repairs.
16. Remove rear quarter lower casing. See
BODY, Interior trim components.
17. Remove rear quarter upper casing. See
BODY, Interior trim components.
18. Remove rear side seat belt. See RESTRAINT
SYSTEMS, Repairs.
19. Remove loadspace carpet. See BODY,
Interior trim components.
20. Remove rear seat. See BODY, Seats and
seat belts.
21. Remove rear body side casing. See BODY,
Interior trim components.
22. Remove headlining. See BODY, Interior trim
components.
23. Remove rear quarter vent and seal. See
BODY, Exterior fittings.
24. Remove rear damper. See REAR
SUSPENSION, Repairs.
25. Release vehicle harness from rear quarter and
position aside.
For LH side
26. Remove tail door striker from ’E’ post.
24
REPAIRS
For RH side
27. Remove tail door. See BODY, Doors.
28. Remove fuel filler neck. See FUEL DELIVERY
SYSTEM, Repairs.
29. Remove fuel tank. See FUEL DELIVERY
SYSTEM, Repairs.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
2. Arrow A is shown to highlight the fact that there
are plug welds on the other side of the inner
wheelarch as well. These are to weld the rear
longitudinal to the inner wheelarch.
PANEL REPAIRS
Refit
For LH side
1. Fit tail door striker to ’E’ post.
For RH side
2. Fit fuel tank. See FUEL DELIVERY SYSTEM,
Repairs.
3. Fit fuel filler neck. See FUEL DELIVERY
SYSTEM, Repairs.
4. Fit tail door. See BODY, Doors.
REPAIRS
25
PANEL REPAIRS
For both sides
5. Secure vehicle harness to rear quarter.
6. Fit rear damper. See REAR SUSPENSION,
Repairs.
7. Fit seal and rear quarter vent. See BODY,
Exterior fittings.
8. Fit headlining. See BODY, Interior trim
components.
9. Fit rear body side casing. See BODY, Interior
trim components.
10. Fit rear seat. See BODY, Seats and seat
belts.
11. Fit loadspace carpet. See BODY, Interior trim
components.
12. Fit rear side seat belt. See RESTRAINT
SYSTEMS, Repairs.
13. Fit rear quarter upper casing. See BODY,
Interior trim components.
14. Fit rear quarter lower casing. See BODY,
Interior trim components.
15. Fit tail lamp. See ELECTRICAL, Repairs.
16. Fit rear roof panel finisher. See BODY,
Exterior fittings.
17. Fit tail door aperture seal.
18. Fit soft/hard top.
19. Secure carpet to inner sill and rear heelboard.
20. Fit front door aperture seal.
21. Fit treadplate to front door aperture.
22. Fit door striker to ’B’ post.
23. Fit rear wheel arch liner.
24. Fit rear bumper valance. See BODY, Exterior
fittings.
25. Fit sill lower finisher. See BODY, Exterior
fittings.
26. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque wrench
settings.
27. Connect all ECUs.
28. Connect alternator. See ELECTRICAL,
Repairs.
29. Connect battery earth lead.
26
REPAIRS
COMPLETE REAR QUARTER - 5 DOOR
NOTE: In this procedure, the rear outer
body side panel is replaced in conjunction
with the complete rear quarter.
Remove
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove road wheel(s).
5. Remove sill lower finisher. See BODY,
Exterior fittings.
6. Remove rear bumper valance. See BODY,
Exterior fittings.
7. Remove rear wheel arch liner.
8. Remove rear door striker from ’D’ post.
9. Remove treadplate from rear door aperture.
10. Remove rear door aperture seal.
11. Release carpet from inner sill and rear
heelboard and position aside.
12. Remove tail door glass upper finisher. See
BODY, Doors.
13. Remove tail door glass side finisher. See
BODY, Doors.
14. Remove tail door aperture seal.
15. Remove roof panel finisher. See BODY,
Exterior fittings.
16. Remove tail lamp. See ELECTRICAL,
Repairs.
17. Remove rear quarter lower casing. See
BODY, Interior trim components.
18. Remove rear quarter upper casing. See
BODY, Interior trim components.
19. Remove rear side seat belt. See RESTRAINT
SYSTEMS, Repairs.
PANEL REPAIRS
20. Remove loadspace carpet. See BODY,
Interior trim components.
21. Remove rear seat. See BODY, Seats and
seat belts.
22. Remove headlining. See BODY, Interior trim
components.
23. Remove rear body side glass. See BODY,
Screens.
24. Remove rear damper. See REAR
SUSPENSION, Repairs.
25. Release vehicle harness from rear quarter and
position aside.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
2. Arrow A is shown to highlight the fact that there
are plug welds on the other side of the inner
wheelarch as well. These are to weld the rear
longitudinal to the inner wheelarch.
For LH side
26. Remove tail door striker from ’E’ post.
For RH side
27. Remove tail door. See BODY, Doors.
28. Remove fuel filler neck. See FUEL DELIVERY
SYSTEM, Repairs.
29. Remove fuel tank. See FUEL DELIVERY
SYSTEM, Repairs.
REPAIRS
27
PANEL REPAIRS
Refit
For LH side
1. Fit tail door striker to ’E’ post.
For RH side
2. Fit fuel tank. See FUEL DELIVERY SYSTEM,
Repairs.
3. Fit fuel filler neck. See FUEL DELIVERY
SYSTEM, Repairs.
4. Fit tail door. See BODY, Doors.
For both sides
5. Secure vehicle harness to rear quarter.
6. Fit rear damper. See REAR SUSPENSION,
Repairs.
7. Fit rear body side glass. See BODY, Screens.
8. Fit headlining. See BODY, Interior trim
components.
9. Fit rear seat. See BODY, Seats and seat
belts.
10. Fit loadspace carpet. See BODY, Interior trim
components.
11. Fit rear side seat belt. See RESTRAINT
SYSTEMS, Repairs.
12. Fit rear quarter upper casing. See BODY,
Interior trim components.
13. Fit rear quarter lower casing. See BODY,
Interior trim components.
14. Fit tail lamp. See ELECTRICAL, Repairs.
15. Fit roof panel finisher. See BODY, Exterior
fittings.
28
REPAIRS
16. Fit tail door aperture seal.
17. Fit tail door glass side finisher. See BODY,
Doors.
18. Fit tail door glass upper finisher. See BODY,
Doors.
19. Secure carpet to inner sill and rear heelboard.
20. Fit rear door aperture seal.
21. Fit treadplate to rear door aperture.
22. Fit rear door striker to ’D’ post.
23. Fit rear wheel arch liner.
24. Fit rear bumper valance. See BODY, Exterior
fittings.
25. Fit sill lower finisher. See BODY, Exterior
fittings.
26. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque wrench
settings.
27. Connect all ECUs.
28. Connect alternator. See ELECTRICAL,
Repairs.
29. Connect battery earth lead.
PANEL REPAIRS
OUTER REAR WHEEL ARCH - 3 DOOR
NOTE: In this procedure, the squab side
reinforcement is replaced in conjunction
with the outer rear wheel arch.
Remove
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove road wheel(s).
5. Remove rear bumper valance. See BODY,
Exterior fittings.
6. Remove rear wheel arch liner.
7. Remove rear quarter lower casing. See
BODY, Interior trim components.
8. Remove rear seat. See BODY, Seats and
seat belts.
9. Remove rear body side casing. See BODY,
Interior trim components.
10. Remove rear damper. See REAR
SUSPENSION, Repairs.
For RH side
11. Remove fuel filler neck. See FUEL DELIVERY
SYSTEM, Repairs.
12. Remove fuel tank. See FUEL DELIVERY
SYSTEM, Repairs.
REPAIRS
29
PANEL REPAIRS
Refit
OUTER REAR WHEEL ARCH - 5 DOOR
For RH side
Remove
1. Fit fuel tank. See FUEL DELIVERY SYSTEM,
Repairs.
2. Fit fuel filler neck. See FUEL DELIVERY
SYSTEM, Repairs.
For both sides
3. Fit rear damper. See REAR SUSPENSION,
Repairs.
4. Fit rear body side casing. See BODY, Interior
trim components.
5. Fit rear seat. See BODY, Seats and seat
belts.
6. Fit rear quarter lower casing. See BODY,
Interior trim components.
7. Fit rear wheel arch liner.
8. Fit rear bumper valance. See BODY, Exterior
fittings.
9. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque wrench
settings.
10. Connect all ECUs.
11. Connect alternator. See ELECTRICAL,
Repairs.
12. Connect battery earth lead.
30
REPAIRS
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove road wheel(s).
5. Remove rear bumper valance. See BODY,
Exterior fittings.
6. Remove rear wheel arch liner.
7. Remove rear quarter lower casing. See
BODY, Interior trim components.
8. Remove rear seat. See BODY, Seats and
seat belts.
9. Remove rear damper. See REAR
SUSPENSION, Repairs.
For RH side
10. Remove fuel filler neck. See FUEL DELIVERY
SYSTEM, Repairs.
11. Remove fuel tank. See FUEL DELIVERY
SYSTEM, Repairs.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
PANEL REPAIRS
Refit
For RH side
1. Fit fuel tank. See FUEL DELIVERY SYSTEM,
Repairs.
2. Fit fuel filler neck. See FUEL DELIVERY
SYSTEM, Repairs.
For both sides
3. Fit rear damper. See REAR SUSPENSION,
Repairs.
4. Fit rear seat. See BODY, Seats and seat
belts.
5. Fit rear quarter lower casing. See BODY,
Interior trim components.
6. Fit rear wheel arch liner.
7. Fit rear bumper valance. See BODY, Exterior
fittings.
8. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque wrench
settings.
9. Connect all ECUs.
10. Connect alternator. See ELECTRICAL,
Repairs.
11. Connect battery earth lead.
REPAIRS
31
PANEL REPAIRS
INNER ’E’ POST - 3 DOOR
NOTE: In this procedure, the rear outer
body side panel and the rear body side
reinforcement assembly is replaced in
conjunction with the inner ’E’ post assembly.
Remove
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove road wheel(s).
5. Remove rear bumper valance. See BODY,
Exterior fittings.
6. Remove rear wheel arch liner.
7. Remove tail lamp. See ELECTRICAL,
Repairs.
8. Remove soft/hard top.
9. Remove tail door aperture seal.
10. Remove rear quarter lower casing. See
BODY, Interior trim components.
11. Remove loadspace carpet. See BODY,
Interior trim components.
12. Release vehicle harness from ’E’ post and
position aside.
For LH side
13. Remove tail door striker.
For RH side
14. Remove tail door. See BODY, Doors.
15. Remove fuel filler neck. See FUEL DELIVERY
SYSTEM, Repairs.
16. Remove fuel tank. See FUEL DELIVERY
SYSTEM, Repairs.
32
REPAIRS
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
PANEL REPAIRS
Refit
For LH side
1. Fit tail door striker.
For RH side
2. Fit fuel tank. See FUEL DELIVERY SYSTEM,
Repairs.
3. Fit fuel filler neck. See FUEL DELIVERY
SYSTEM, Repairs.
4. Fit tail door. See BODY, Doors.
For both sides
5. Secure vehicle harness to ’E’ post.
6. Fit loadspace carpet. See BODY, Interior trim
components.
7. Fit rear quarter lower casing. See BODY,
Interior trim components.
8. Fit tail door aperture seal.
9. Fit soft/hard top.
10. Fit tail lamp. See ELECTRICAL, Repairs.
11. Fit rear wheel arch liner.
12. Fit rear bumper valance. See BODY, Exterior
fittings.
13. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque wrench
settings.
14. Connect all ECUs.
15. Connect alternator. See ELECTRICAL,
Repairs.
16. Connect battery earth lead.
REPAIRS
33
PANEL REPAIRS
INNER ’E’ POST - 5 DOOR
NOTE: In this procedure, the rear outer
body side panel and the rear body side
reinforcement assembly is replaced in
conjunction with the inner ’E’ post assembly.
Remove
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove road wheel(s).
5. Remove rear bumper valance. See BODY,
Exterior fittings.
6. Remove rear wheel arch liner.
7. Remove tail lamp. See ELECTRICAL,
Repairs.
8. Remove roof panel finisher. See BODY,
Exterior fittings.
9. Remove tail door glass upper finisher. See
BODY, Doors.
10. Remove tail door glass side finisher. See
BODY, Doors.
11. Remove tail door aperture seal.
12. Remove rear quarter lower casing. See
BODY, Interior trim components.
13. Remove rear quarter upper casing. See
BODY, Interior trim components.
14. Remove loadspace carpet. See BODY,
Interior trim components.
15. Remove rear body side glass. See BODY,
Screens.
16. Release vehicle harness from ’E’ post and
position aside.
For LH side
17. Remove tail door striker.
For RH side
18. Remove tail door. See BODY, Doors.
19. Remove fuel filler neck. See FUEL DELIVERY
SYSTEM, Repairs.
20. Remove fuel tank. See FUEL DELIVERY
SYSTEM, Repairs.
34
REPAIRS
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
PANEL REPAIRS
Refit
For LH side
1. Fit tail door striker.
For RH side
2. Fit fuel tank. See FUEL DELIVERY SYSTEM,
Repairs.
3. Fit fuel filler neck. See FUEL DELIVERY
SYSTEM, Repairs.
4. Fit tail door. See BODY, Doors.
For both sides
5. Secure vehicle harness to ’E’ post.
6. Fit rear body side glass. See BODY, Screens.
7. Fit loadspace carpet. See BODY, Interior trim
components.
8. Fit rear quarter upper casing. See BODY,
Interior trim components.
9. Fit rear quarter lower casing. See BODY,
Interior trim components.
10. Fit tail door aperture seal.
11. Fit tail door glass side finisher. See BODY,
Doors.
12. Fit tail door glass upper finisher. See BODY,
Doors.
13. Fit roof panel finisher. See BODY, Exterior
fittings.
14. Fit tail lamp. See ELECTRICAL, Repairs.
15. Fit rear wheel arch liner.
16. Fit rear bumper valance. See BODY, Exterior
fittings.
17. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque wrench
settings.
18. Connect all ECUs.
19. Connect alternator. See ELECTRICAL,
Repairs.
20. Connect battery earth lead.
REPAIRS
35
PANEL REPAIRS
REAR FLOOR CROSSMEMBER ASSEMBLY
Remove
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove tail door. See BODY, Doors.
5. Remove tail door aperture seal.
6. Remove LH and RH rear quarter lower
casings. See BODY, Interior trim
components.
7. Remove loadspace carpet. See BODY,
Interior trim components.
8. Release vehicle harness from rear body lower
closing and position aside.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
36
REPAIRS
Refit
1. Secure vehicle harness to rear body lower
closing.
2. Fit loadspace carpet. See BODY, Interior trim
components.
3. Fit LH and RH rear quarter lower casings. See
BODY, Interior trim components.
4. Fit tail door aperture seal.
5. Fit tail door. See BODY, Doors.
6. Connect all ECUs.
7. Connect alternator. See ELECTRICAL,
Repairs.
8. Connect battery earth lead.
PANEL REPAIRS
REAR FLOOR
Remove
NOTE: In this procedure, the inner quarter
to rear floor gussets are replaced in
conjunction with the rear floor.
If required, the safe well can be replaced
separately.
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove tail exhaust pipe. See MANIFOLD &
EXHAUST SYSTEMS, Repairs.
5. Remove tail door. See BODY, Doors.
6. Remove tail door aperture seal.
7. Remove LH and RH rear quarter lower
casings. See BODY, Interior trim
components.
8. Remove loadspace carpet. See BODY,
Interior trim components.
9. Remove fuel tank. See FUEL DELIVERY
SYSTEM, Repairs.
10. Release vehicle harness from rear body lower
closing and position aside.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1. Secure vehicle harness to rear body lower
closing.
2. Fit fuel tank. See FUEL DELIVERY SYSTEM,
Repairs.
3. Fit loadspace carpet. See BODY, Interior trim
components.
4. Fit LH and RH rear quarter lower casings. See
BODY, Interior trim components.
5. Fit tail door aperture seal.
6. Fit tail door. See BODY, Doors.
7. Fit tail exhaust pipe. See MANIFOLD &
EXHAUST SYSTEMS, Repairs.
8. Connect all ECUs.
9. Connect alternator. See ELECTRICAL,
Repairs.
10. Connect battery earth lead.
REPAIRS
37
PANEL REPAIRS
FLOOR LONGITUDINAL
Remove
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove tail exhaust pipe. See MANIFOLD &
EXHAUST SYSTEMS, Repairs.
5. Remove tail door. See BODY, Doors.
6. Remove tail door aperture seal.
7. Remove LH and RH rear quarter lower
casings. See BODY, Interior trim
components.
8. Remove loadspace carpet. See BODY,
Interior trim components.
9. Remove fuel tank. See FUEL DELIVERY
SYSTEM, Repairs.
10. Release vehicle harness from rear body lower
closing and position aside.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
38
REPAIRS
Refit
1. Secure vehicle harness to rear body lower
closing.
2. Fit fuel tank. See FUEL DELIVERY SYSTEM,
Repairs.
3. Fit loadspace carpet. See BODY, Interior trim
components.
4. Fit LH and RH rear quarter lower casings. See
BODY, Interior trim components.
5. Fit tail door aperture seal.
6. Fit tail door. See BODY, Doors.
7. Fit tail exhaust pipe. See MANIFOLD &
EXHAUST SYSTEMS, Repairs.
8. Connect all ECUs.
9. Connect alternator. See ELECTRICAL,
Repairs.
10. Connect battery earth lead.
PANEL REPAIRS
FRONT ROOF ASSEMBLY - 3 DOOR
REAR ROOF ASSEMBLY - 3 DOOR
Remove
Remove
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove LH and RH front roof panel finishers.
5. Remove headlining. See BODY, Interior trim
components.
6. Remove sunroof assembly. See BODY,
Sunroof.
7. Remove windscreen. See BODY, Screens.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure.
Refit
1. Fit windscreen. See BODY, Screens.
2. Fit sunroof. See BODY, Sunroof.
3. Fit headlining. See BODY, Interior trim
components.
4. Fit LH and RH front roof panel finishers.
5. Connect all ECUs.
6. Connect alternator. See ELECTRICAL,
Repairs.
7. Connect battery earth lead.
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove soft/hard top.
5. Remove LH and RH rear roof panel finishers.
6. Remove headlining. See BODY, Interior trim
components.
7. Remove sunroof. See BODY, Sunroof.
8. Remove aerial. See ELECTRICAL, Repairs.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure.
Refit
1. Fit aerial. See ELECTRICAL, Repairs.
2. Fit sunroof. See BODY, Sunroof.
3. Fit headlining. See BODY, Interior trim
components.
4. Fit LH and RH rear roof panel finishers.
5. Fit soft/hard top.
6. Connect all ECUs.
7. Connect alternator. See ELECTRICAL,
Repairs.
8. Connect battery earth lead.
REPAIRS
39
PANEL REPAIRS
ROOF ASSEMBLY - 5 DOOR
Remove
1. Disconnect battery earth lead.
2. Disconnect alternator. See ELECTRICAL,
Repairs.
3. Disconnect all ECUs.
4. Remove tail door glass upper finisher. See
BODY, Doors.
5. Remove LH and RH roof panel finishers. See
BODY, Exterior fittings.
6. Remove headlining. See BODY, Interior trim
components.
7. If applicable, remove sunroof. See BODY,
Sunroof.
8. Remove aerial. See ELECTRICAL, Repairs.
9. Remove windscreen. See BODY, Screens.
Repair
1. Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
40
REPAIRS
Refit
1.
2.
3.
4.
5.
6.
7.
8.
9.
Fit windscreen. See BODY, Screens.
Fit aerial. See ELECTRICAL, Repairs.
If applicable, fit sunroof. See BODY, Sunroof.
Fit headlining. See BODY, Interior trim
components.
Fit LH and RH roof panel finishers. See
BODY, Exterior fittings.
Fit tail door glass upper finisher. See BODY,
Doors.
Connect all ECUs.
Connect alternator. See ELECTRICAL,
Repairs.
Connect battery earth lead.
PANEL REPAIRS
OUTER BODY SIDE ASSEMBLY
For weld details, and components to remove for
access during replacement, of the outer body side
assembly, see ’A’ post, ’B/C post, sill and rear
quarter repair procedures.
REPAIRS
41
PANEL REPAIRS
TIME SCHEDULES
Panel/assembly panel replacement times
The following information shows the total time taken
to replace single panels and complete assemblies.
This time includes removal of Mechanical, Electrical
and Trim (MET) items, plus paint times based on
Metallic Clear Over Base Paint.
5 Door
The times shown were generated by Thatcham (the
Motor Insurance Repair and Research Centre) and
are to be used as a guide only.
42
REPAIRS
Panel Description
Total time
Body side LH
29.4
Body side RH
31.5
Bonnet
7.2
Bonnet locking platform
7.0
Door front - each
8.4
Door rear - each
8.1
Door skin front - each
12.2
Door skin rear - each
11.2
Front bulkhead assembly
12.7
Front lower crossmember
8.5
Headlamp mounting panel
6.4
Rear floor crossmember assembly
9.5
Roof assembly
23.5
Bodyside lower outer LH
16.8
Bodyside lower outer RH
16.9
Taildoor
9.0
Wing
6.9
Bodyside rear outer LH
19.3
Bodyside rear outer RH
21.5
PANEL REPAIRS
Combination panel replacement times
The following panel combination times show the
total time to remove/refit body panels, MET items
and any paint processes.
5 Door - Front end combination panel times
Panel Description
Total Time
Bonnet locking platform
Bumper front
Headlamp mounting panel
Wing
15.3
Bumper front
Front Panel assembly
Wing RH & LH
20.6
Bonnet locking platform
Bumper front
Sidemember closing panel
Sidemember front section
Front crossmember lower
Headlamp mounting panel
Wing
Valance upper assembly section
Valance outer reinforcement section
35.7 LH
37.9 RH
Bumper front
Sidemember closing panel LH front
Sidemember closing panel RH front
Sidemember complete assembly LH
Sidemember complete assembly RH
Front bulkhead assembly
Wing LH & RH
Valance upper assembly LH & RH
Valance outer reinforcement section
LH & RH
49.1
Bonnet locking platform
Bumper front
Sidemember closing panel section
Sidemember front section
Front crossmember lower
Headlamp mounting panel
Valance front section
Wing
Valance upper assembly section
Valance outer reinforcement section
27.1 LH
27.7 RH
REPAIRS
43
PANEL REPAIRS
5 door - Bodyside combination panel times
Panel description
5 door - Rear end combination panel times
Total time
Panel description
11.6
Rear bumper
Rear outer bodyside panel
E-post inner assembly
Gusset rear floor
Crossmember assembly rear floor
Front door
Wing
Rear door
Rear outer bodyside panel
31.2 LH
33.4 RH
23.4 LH
25.7 RH
Front door
Rear door
Lower outer bodyside panel
26.1 LH
26.2 RH
Front door
Rear door
Bodyside assembly
Wing
40.5 LH
42.9 RH
Front door
Front outer bodyside panel
A-post reinforcement
Windscreen
Wing
Valance outer reinforcement rear
section
Total time
Rear bumper
Rear outer bodyside panel LH & RH
E-post inner assembly LH & RH
Gusset rear floor LH & RH
Crossmember assembly rear floor
51.2
Rear bumper
Rear outer bodyside panel
E-post inner assembly
Quarter complete rear assembly
Gusset rear floor
Crossmember assembly rear floor
Longitudinal rear section
Rear floor panel
44.7 LH
46.8 RH
34.1 LH
35.5 RH
Rear bumper
Rear outer bodyside panel LH & RH
E-post inner assembly LH & RH
Quarter complete rear assembly LH
& RH
Gusset rear floor LH & RH
Crossmember assembly rear floor
Longitudinal rear section LH & RH
Rear floor panel
69.2
44
REPAIRS
PANEL REPAIRS
Panel/assembly replacement times
Combination panel replacement times
3 Door
3 Door - Front end combination times will be the
same as 5 door models.
Panel Description
Total time
Body side LH
30.1
Body side RH
31.9
Door front - each
8.9
Door rear - each
8.1
Door skin front - each
12.9
Front bulkhead assembly
12.6
Crossmember assembly rear floor
12.1
Roof assembly
19.9
Bodyside lower outer LH
14
Bodyside lower outer RH
14.1
Bodyside rear outer LH
22.4
Bodyside rear outer RH
24.3
3 Door - Bodyside combination panel times
Panel description
Total time
Front door
Wing
12.2
Front door
Rear outer bodyside panel
27.2 LH
29.7 RH
Front door
Bodyside assembly
34.6 LH
36.4 RH
Front door
Bodyside assembly
Wing
37.7 LH
40.2 RH
Front door
Front outer bodyside panel
A-post reinforcement
Windscreen
Wing
Valance outer reinforcement rear
section
33.8 LH
35.1 RH
REPAIRS
45
PANEL REPAIRS
3 Door - Rear end combination panel times
Panel description
Total time
Rear bumper
Rear outer bodyside panel
E-post inner assembly
Gusset rear floor
Crossmember assembly rear floor
34.4 LH
36.7 RH
Rear bumper
Rear outer bodyside panel LH & RH
E-post inner assembly LH & RH
Gusset rear floor LH & RH
Crossmember assembly rear floor
54.8
Rear bumper
Rear outer bodyside panel
E-post inner assembly
Quarter complete rear assembly
Gusset rear floor
Crossmember assembly rear floor
Longitudinal rear section
Rear floor panel
49 LH
50.6 RH
Rear bumper
Rear outer bodyside panel LH & RH
E-post inner assembly LH & RH
Quarter complete rear assembly LH
& RH
Gusset rear floor LH & RH
Crossmember assembly rear floor
Longitudinal rear section LH & RH
Rear floor panel
75.3
46
REPAIRS
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