Page 558 of 976
57STEERING
16
REPAIR
7.Remove bulb holder from steering column lock
shroud.
8.Tap head of shear bolts anti-clockwise to release
them.
9.Remove and discard shear bolts.
10.Detach saddle.
11.Remove steering column lock assembly.
Refit
12.Position steering lock saddle on column, locating
spigot in hole provided.
13.Place lower lock assembly into column.
14.Fit but do not fully tighten new shear bolts.
15.Connect multiplugs.
16.Insert bulb holder into steering column lock
shroud.
17.Reconnect battery negative lead.
18.Check steering column lock for correct
operation, tighten shear bolts until heads shear
off.
19.Fit steering column shroud.
See Steering
Column Shroud
20.If fitted - fit knee bolster, fit and tighten screws.
21.Raise driver's access panel, secure turnbuckles.DROP ARM
Service repair no - 57.50.14
Remove
1.Place vehicle on a hoist, or support front axle on
axle stands.
2.Disconnect drag link ball joint from drop arm,
using extractor LRT-57-018.
Page 568 of 976

STEERING
7
OVERHAUL Fitting sector shaft cover
73.Fit new sealing ring to cover.
74.Align cover with casing.
75.Screw cover assembly fully on to sector shaft
adjuster screw.
76.If necessary back off sector shaft adjuster screw.
Tap cover in place to allow cover to joint fully
with casing.
NOTE: Before tightening fixings, rotate
input shaft to ensure sector shaft roller is
free to move in valve worm. If initial
resistance is left, turn adjuster screw
approximately two turns in a clockwise direction.
77.Fit cover bolts. Tighten to
75 Nm.
Fitting cylinder cover
78.Fit new square section seal to cover.
79.Remove slave bolt fitted at instruction 68. Press
cover into cylinder just to clear retainer ring
groove.
80.Fit retaining ring to groove with one end of ring
positioned 12 mm from extractor hole.
Adjusting sector shaft
NOTE: Refit drop arm and tighten nut
sufficiently to ensure that no backlash
exists between drop arm and sector shaft.
81.To set worm on centre, rotate input shaft to full
inner-lock (full right lock for a left hand drive
vehicle, full left lock for a right hand drive
vehicle). Rotate input shaft back towards centre
two full turns.
82.The box is now on centre and can be adjusted.
Page 569 of 976

57STEERING
8
OVERHAUL 83.Hold input shaft and rock drop arm to establish
backlash is present. Continue rocking and slowly
turn sector shaft adjusting screw clockwise.
Continue rotating adjuster screw until backlash
has almost been eliminated.
84.Refit locknut and tighten.
NOTE: It is important steering box is
centralised before any adjustments are
made.
85.Check maximum rolling torque one and a quarter
turns either side of centre position, using a
torque wrench and spline socket LRT-57-025.
Rotate adjuster screw to obtain across centre
torque of 0.34 Nm plus torque figure at one and
a quarter turns. Tighten adjuster locknut to
60
Nm.
Adjusting rack adjuster.
86.Turn in rack adjuster to increase figure
measured in instruction 85. by 0.23 - 0.34 Nm.
The final figure may be less, but must not
exceed 1.35 Nm.
87.Lock rack adjuster in position with grub screw.
Tighten to
5 Nm.
Torque peak check
With input shaft rotated from lock to lock, rolling
torque figures should be greatest across centre
position and equally disposed about centre position.
The condition depends on value of shimming fitted
between valve and worm assembly inner bearing cup
and casing. The original shim washer value will give
correct torque peak position unless major components
have been replaced.Procedure
88.With input coupling shaft toward the operator,
turn shaft fully counter-clockwise.
89.Check torque figures obtained from lock to lock
using torque wrench and spline socket
LRT-57-025.
90.Check also for equal engagement either side of
centre.
Adjustments
91.Note where greatest figures are recorded
relative to steering position.If greatest figures are
not recorded across centre of travel (steering
straight-ahead), adjust as follows:
If torque peak occursbeforecentre position,addto
shim washer value; if torque peak occursaftercentre
position,subtractfrom shim washer value,
refer to
fitting valve and worm assembly
.
Shim washers are available as follows:
0.03mm, 0.07mm, 0.12mm and 0.24mm.
NOTE: Adjustment of 0.07mm to shim
value will move torque peak area by 1/4
turn on the shaft.
CAUTION: When reshimming valve and
worm, extreme caution must be exercised
to prevent seal damage during
reassembly.
Page 652 of 976

SUPPLEMENTARY RESTRAINT SYSTEM
7
REPAIR ROTARY COUPLER CENTRALISE
Fitting a rotary coupler which has not been centralised
could result in tape breakage. If the tape is broken, a
new rotary coupler must be fitted.
Providing the removal procedure has been correctly
followed this operation should not be necessary. If
however there is evidence of tampering, it is
imperative that the coupler is centralised.
CAUTION: Ensure wheels are positioned
straight ahead before fitting the rotary
coupler.
1.Correctly fit rotary coupler to column switch
assembly but do not fit steering wheel or make
any electrical connections.
See rotary coupler.
2.Depress rotary coupler locking peg and without
using undue force, rotate coupler anti-clockwise
as far as inner tape will allow. Releasing peg will
lock coupler in its current position.
NOTE: Do not apply excessive force when
limit is reached as this may result in tape
breakage. If no limit can be found, tape
has already broken and rotary coupler must be
replaced.
3.Having turned rotary coupler fully anti-clockwise
to limit position, proceed to turn coupler 2.5 turns
clockwise to obtain central position. (Coupler will
normally rotate a full five turns from
anti-clockwise limit to clockwise limit).
4.Make necessary electrical connections and refit
steering wheel.
See steering wheel.
5.Refit driver's airbag module.See driver's
airbag module.
COLUMN SWITCH ASSEMBLY
Service repair no - Indicator/lighting - 86.65.55
Service repair no - Wash/wipe - 84.15.34
Remove
1.Remove steering wheel.
See steering wheel.
2.Release 2 turnbuckles and remove lower dash
panel.
Page 673 of 976
76CHASSIS AND BODY
6
REPAIR ADJUSTMENT-FRONT DOOR LOCK AND HANDLE
ASSEMBLY
Service repair no - 76.37.47
Inside door release handle to lock
1.Refit the inside door release handle surround
before any adjustment is made, allowing the
handle to be set from the correct operating
position.
2.At the lock end of the interior handle connecting
rod, rotate the spring tensioned nyloc nut
clockwise or counter-clockwise, as necessary to
shorten or extend the operating length of the rod.Outside door release handle to lock
3.Disconnect the connecting rod from the plastic
ferrule at the rear of the outer door release
handle. Rotate the rod clockwise or
counter-clockwise to shorten or extend the
operating length as necessary.
NOTE: Door release should be effective
before the total handle movement is
exhausted to provide a small overthrow
movement.
Page 677 of 976

76CHASSIS AND BODY
10
REPAIR ADJUSTMENT-REAR SIDE DOOR LOCK AND
HANDLE
Service repair no - 76.37.47
Outside door release handle to lock
1.Disconnect the short off-set connecting rod at
the rear of the outer release handle, rotate the
rod clockwise or counter clockwise to shorten or
extend the operating length of the rod as
required.
NOTE: Door release should occur before
the total handle movement is achieved to
provide a small overthrow movement.
REAR SIDE DOOR GLASS AND REGULATOR
Service repair no - 76.31.45
Remove
1.Ensure that the window is in the fully closed
position and secure it with adhesive tape over
the top of the door to prevent the glass from
dropping down.
2.Disconnect battery negative lead.
3.Remove the door trim panel.
See rear side
door - trim panel.
4.Remove the plastic vapour barrier.
5.Where applicable remove the door actuator and
window lift motor.
See ELECTRICAL, Repair,
window lift motor - rear. See ELECTRICAL,
Repair, rear side door actuator units.
6.Remove the four window regulator securing
screws and shakeproof washers from the inner
door panel.
7.Carefully disengage the lifting arm stud from the
glass lifting channel and remove the window
regulator from the lower opening in the inner
door panel.
8.Remove the waist rail seal from the top of the
door panel.
9.Remove the single bolt, spring and plain
washers from inside the door, securing the
bottom of the short glass run channel.
10.Remove the two bolts, spring and plain washers
from the hinge face of the door.
Page 713 of 976
76CHASSIS AND BODY
46
REPAIR DASH PANEL CENTRAL LOUVRE PANEL
Service repair no - 76.46.42
Remove
1.Disconnect battery negative lead.
2.Remove radio.
See ELECTRICAL, Repair,
radio.
3.Release tags securing radio cage to louvre
panel and remove cage.
4.Remove clock.
See ELECTRICAL, Repair,
clock.
5.Release 4 coin tray securing tags.
6.Remove coin tray.
7.Remove 3 heater control and blower switch
knob.
8.Remove 2 screws securing heater graphic
display panel and remove panel.
9.Remove 4 screws securing heater control unit to
panel.
10.Working through coin tray aperture, remove
screw securing panel.
11.Working through clock aperture, remove screw
securing panel.
12.Loosen 2 uppermost panel retaining screws.
NOTE: On some models the panel is fitted
with an LED. In this case, manoeuvre LED
from panel and disconnect.
13.Remove panel retaining screw cover.
Page 714 of 976

CHASSIS AND BODY
47
REPAIR
14.Remove 2 screws securing louvre panel.
15.Remove louvre panel from dash panel.
Refit
16.Position louvre panel, feed harness connectors
through their correct apertures,and align to dash
panel.
CAUTION: When refitting avoid trapping of
electrical wiring.
17.Fit and tighten screws securing louvre panel.
18.Fit panel retaining screw cover.
19.Position heater control unit to panel and secure
with screws.
20.Fit heater graphic display panel and secure with
screws.
21.Fit heater control and blower switch knobs.
22.Fit clock.
See ELECTRICAL, Repair, clock.
23.Position coin tray and secure to tags.
24.Position radio cage, feed electrical connectors
and aerial through cage, and position to panel.
25.Bend back radio cage retaining tags.
26.Fit radio.
See ELECTRICAL, Repair, radio.
27.Connect battery negative lead.DASH PANEL ASSEMBLY
Service repair no - 76.46.23
Remove
1.Move front seats to rearmost position.
2.Disconnect battery negative lead.
3.Disconnect air bag multiplugs under dash panel.
CAUTION: When air bags are fitted,
reference must be made to the Airbag
Supplementary Restraint System section.
4.Remove passenger glove box.
5.Remove driver's side access panel.
6.Remove centre console assembly.
See centre
console.
7.Remove airbag from steering wheel.See
SUPPLEMENTARY RESTRAINT SYSTEM,
Repair, driver's airbag module.
8.Remove passenger's airbag from dash panel.
See SUPPLEMENTARY RESTRAINT SYSTEM,
Repair, passenger's airbag module.
9.Release clamp and lower steering column.
10.Remove steering wheel.
See STEERING,
Repair, steering wheel.
11.Remove column switch.See
SUPPLEMENTARY RESTRAINT SYSTEM,
Repair, column switch assembly.
12.Remove instrument binnacle.See
ELECTRICAL, Repair, instrument binnacle.
13.Remove radio.See ELECTRICAL, Repair,
radio.
14.Remove exterior mirrors switch panel.
15.Remove coin tray.
16.Remove switch panel.
17.Remove clock.
18.Undo screw securing mounting bracket and
position passenger's side relay assembly aside.
19.Set heater controls fully clockwise.