Page 568 of 873

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 673 of 873
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 873

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 714 of 873

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.
Page 745 of 873
HEATING AND VENTILATION
3
REPAIR Air direction
3.Set control fully clockwise
4.Release outer cable from 2 clips on unit.
5.Release cable from stud on flap lever.
6.Remove control cable from control lever.
Temperature
7.Set RH control fully clockwise, LH control fully
anti-clockwise
8.Release outer cable from 2 clips on unit.
9.Release cable from stud on flap lever.
10.Remove control cable from control lever.
Refit
11.Reverse removal procedure. Check the
satisfactory function of the controls before fitting
louvre vent panel.RESISTOR UNIT
Service repair no - 80.20.17
Remove
1.Open glove box, manoeuvre side springs
through cut-outs and lower lid.
2.Remove 2 screws securing resistor unit to
trunking.
3.Disconnect multiplug and remove resistor unit.
Refit
4.Reverse removal procedure.
Page 826 of 873

86ELECTRICAL
6
REPAIR Refit
NOTE: If a new distributor is being fitted,
mark body in same relative position as
distributor removed.
8.Leads for distributor cap should be connected as
illustrated.
Figures 1 to 8 inclusive indicate plug lead
numbers.
RH-Right hand side of engine, when viewed
from rear.
LH-Left hand side of engine, when viewed from
rear.
9.If engine has not been turned while distributor
has been removed, carry out instructions 10. to
17. Alternatively proceed to instruction 18.
10.Fit new 'O' ring seal to distributor housing.
11.Turn distributor drive until centre line of rotor arm
is 30Ê anti-clockwise from mark made on top
edge of distributor body.
12.Fit distributor in accordance with alignment
markings.
NOTE: It may be necessary to align oil
pump drive shaft to enable distributor
drive shaft to engage in slot.
13.Fit clamp and bolt. Secure distributor in exact
original position.
14.Connect vacuum hose to distributor and low
tension lead to coil.
15.Fit distributor cap.
16.Reconnect battery.
17.Using suitable electronic equipment, set ignition
timing.
See Adjustment, Ignition timing
18.If engine has been turned with distributor
removed, carry out instructions 19 to 30.
19.Set engine-No. 1 piston to static ignition timing
figure
See ENGINE TUNING DATA,
Information, Engine 3.9 V8i
20.Turn distributor drive until rotor arm is
approximately 30Ê anti-clockwise from number
one sparking plug lead position on cap.
21.Fit distributor to engine.
22.Check that centre line of rotor arm is now in line
with number one sparking plug lead on cap.
Reposition distributor if necessary.
23.If distributor does not seat correctly in front
cover, oil pump drive is not engaged. Engage by
lightly pressing down distributor while turning
engine.
24.Fit clamp and bolt, do not tighten.
25.Set ignition timing statically to 6Ê B.T.D.C.
26.Connect vacuum hose to distributor.
27.Fit low tension lead to coil.
28.Fit distributor cap.
29.Reconnect battery.
30.Using suitable electronic equipment set the
ignition timing.
See Adjustment, Ignition
timing