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REPAIR REAR FOLD DOWN SEATS
Service repair no - 76.71.23
Seat and squab
Remove
1.Locate the seat in the down position, release the
seat belt strap and buckle from their stowed
positions.
2.Remove 4 Torx screws from the lower brackets.
3.Fold the seat up and remove the 2 Torx screws
from the upper brackets. Collect 4 washers.
4.Remove seat assembly.
Refit
5.Position seat assembly, align upper brackets,
and secure with Torx screws tightened to
13 Nm
(10 lbf ft)
.
NOTE: Ensure washers are fitted in their
correct positions.
6.Align lower brackets, fit Torx screws and tighten
to
13 Nm (10 lbf ft).
7.Secure the seat belt strap and buckle to their
stowed positions.
Seat squab
Remove
8.Remove the seat assembly from the vehicle.
9.Remove the pivot bolts and washers securing
the seat squab to the frame.
NOTE: The pivot bolts, securing the seat
squab and cushion, are fitted with a wavy
washer under the head and a plain washer
between the link or bracket. Ensure that these
washers are fitted in the correct locations when
reassembling the seat.
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CHASSIS AND BODY
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REPAIR SUNROOF ELECTRIC MOTORS
Service repair no - 76.82.84/85
FRONT MOTOR
Remove
1.Disconnect battery negative lead.
2.Ensure sunroof is in normally closed position
NOTE: If the electric motor has failed the
sunroof can be closed manually using an
allen key to turn motor spindle A.
3.Remove switch panel from stowage pocket
panel
4.Remove interior lamp from stowage pocket
panel
5.Remove alarm ultrasonic unit.
6.Unscrew ten fixings and remove stowage pocket
from headlining.
7.Disconnect motor wiring multiplug.
8.Remove three screws and motor.
Refit
9.Reverse removal procedure.
CAUTION: Ensure the motor is aligned
with fixing holes and the sunroof is in the
normally closed position. DO NOT rotate
the motor drive spindle in the rack - this may
result in incorrect operation of the sunroof.REAR MOTOR
Remove
1.Disconnect battery negative lead.
2.Ensure sunroof is in normally closed position
NOTE: If the electric motor has failed the
sunroof can be closed manually using an
allen key to turn motor spindle.
3.Remove headlining.
See headlining.
4.Disconnect motor wiring multiplug.
5.Remove three screws and motor.
Refit
6.Reverse removal procedure.
CAUTION: Ensure the motor is aligned
with fixing holes and the sunroof is in the
normally closed position. DO NOT rotate
the motor drive spindle in the rack - this may
result in incorrect operation of the sunroof.
Page 707 of 873
76CHASSIS AND BODY
40
REPAIR SUNROOF ELECTRIC CONTROL UNIT
Service repair no - 76.82.73
The control unit serves both front and rear sunroofs
and is sited above the front switches behind
headlining.
Remove
1.Disconnect battery negative lead.
2.Ensure sunroof is in normally closed position.
NOTE: If the electric motor has failed the
sunroof can be closed manually using an
allen key to turn motor spindle.
3.Remove switch panel from stowage pocket
panel
4.Remove interior lamp from stowage pocket
panel
5.Remove alarm ultrasonic unit.
6.Unscrew ten fixings and remove stowage pocket
from headlining.
7.Disconnect electric plugs from control unit.
8.Remove two retaining screws and control unit.
Refit
9.Reverse removal procedure.
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REPAIR SUNROOF REGULATOR MANUAL
Service repair no - 76.83.03/04
FRONT
Remove
1.Ensure sunroof is in normally closed position.
2.Remove retaining screw and regulator handle.
3.Remove switch panel from stowage pocket
panel
4.Remove interior lamp from stowage pocket
panel
5.Remove alarm ultra sonic unit.
6.Unscrew ten fixings and remove stowage pocket
from headlining.
7.Remove two retaining screws and regulator from
clamping frame.
Refit
8.Reverse removal procedure.
CAUTION: Ensure the regulator is aligned
with fixing holes and the sunroof is in the
normally closed position. DO NOT rotate
the regulator spindle in the rack - this may result
in incorrect operation of the sunroof.REAR
Remove
1.Ensure sunroof is in normally closed position.
2.Remove retaining screw and regulator handle.
3.Remove headlining.
See headlining.
4.Remove two retaining screws and regulator from
clamping frame.
Refit
5.Reverse removal procedure.
CAUTION: Ensure the regulator is aligned
with fixing holes and the sunroof is in the
normally closed position. DO NOT rotate
the regulator spindle in the rack - this may result
in incorrect operation of the sunroof.
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REPAIR GRAB HANDLE - TAIL DOOR - WITH REAR AIR
CONDITIONING FITTED
Service repair no - 76.58.35/20
Remove
1.Remove 'E' post trim casing.
See 'E' post trim
casing - lh - with rear air conditioning fitted.
2.Release foam strip from around grab handle
retaining bolts.
3.Remove 4 bolts securing grab handle to body.
4.Remove grab handle.Refit
5.Position grab handle, fit bolts and tighten to
10
Nm (7 lbf ft)
.
6.Secure foam strip to body.
7.Fit 'E' post trim casing.
See 'E' post trim
casing - lh - with rear air conditioning fitted.
HEADLINING - WITH SUN ROOF AND REAR AIR
CONDITIONING FITTED - 5 DOOR
Service repair no - 76.64.14/20
Remove
1.Remove both sun visors.
See sun visor.
2.Remove 4 grab handles.See grab handle.
3.Remove front headlining stowage panel.See
headlining stowage panel - front - with sun
roof fitted.
4.Remove LH alpine light trim casing.See alpine
light trim casing - lh - with rear air
conditioning fitted.
5.Remove RH alpine light trim casing.See alpine
light trim casing.
6.Release LH and RH sun visor clip retaining
screw covers.
7.Remove LH and RH sun visor clip retaining
screws.
8.Remove LH and RH clips.
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REPAIR
15.Release LH and RH, 'A' post trim finishers from
uppermost retaining clips.
16.With assistance, release headlining from LH and
RH, 'A', 'B' and 'D' post finishers.
17.Remove headlining assembly.Dismantle
18.Remove 22 nuts securing headlining stowage
nets and rear headlining panel.
19.Remove stowage nets and headlining panel.
20.Collect 7 mounting plates.
Rebuild
21.Position stowage nets and headlining panel, fit
mounting plates to studs and secure with nuts.
Refit
22.With assistance, fit headlining and position to LH
and RH, 'A', 'B' and 'D' post finishers.
23.Secure LH and RH, 'A' post trim finisher
retaining clips.
24.Fit rear sun roof aperture seal.
25.Fit and tighten screw securing rear headlining
panel to body.
26.Position vents to headlining, attach clips to vents
and secure to headlining.
27.Position rear sun roof switch, connect multiplug
and secure to headlining panel.
28.Position rear passenger interior lamp, connect
multiplug and secure to headlining panel.
29.Fit front sun roof aperture seal.
30.Fit LH and RH sun visor retaining clips to body.
31.Fit and tighten screws securing sun visor
retaining clips and secure screw covers.
32.Fit RH alpine light trim casing.
See alpine light
trim casing.
33.Fit LH alpine light trim casing.See alpine light
trim casing - lh - with rear air conditioning
fitted.
34.Fit front headlining stowage panel.See
headlining stowage panel - front - with sun
roof fitted.
35.Fit grab handles.See grab handle.
36.Fit sun visors.See sun visor.
Page 734 of 873
CHASSIS AND BODY
67
REPAIR ASH TRAY - DASH PANEL CENTRAL LOUVRE
PANEL
Service repair no - 76.67.26
Remove
1.Open ash tray.
2.Press release catch and remove ash tray.
Refit
3.Fit ash tray.HEADLINING STOWAGE PANEL - FRONT - WITH
SUN ROOF FITTED
Service repair no - 76.67.27
Remove
1.Remove 10 screws securing stowage panel to
body.
2.Release panel and disconnect Lucar and 4
multiplugs.
3.Remove stowage panel assembly.
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REPAIR Dismantle
4.Remove interior lamp lens.
5.Remove 2 nuts securing lamp to stowage panel.
6.Remove lamp.
7.Remove alarm volumetric sensor/blanking plate.
8.Remove electric sun roof switch pack.
9.Remove electric sun roof manual opening plug.
Rebuild
10.Fit electric sun roof manual opening plug to
panel.
11.Fit alarm volumetric sensor.
12.Fit electric sun roof switch pack to panel.
13.Fit interior lamp to panel and secure with nuts.
14.Fit interior lamp lens.
Refit
15.Position stowage panel assembly and connect
Lucar and multiplugs.
16.Align panel to headlining and secure with
screws.REAR FOLD DOWN SEAT BELTS - LH WITH REAR
AIR CONDITIONING FITTED
Service repair no - 76.73.28/20
Remove
1.Locate the seat in the down position, remove the
seat belt strap and buckle from their stowed
positions.
2.Remove seat belt strap and buckle retaining bolt
covers.
3.Remove bolts securing strap and buckle.
4.Remove seat belts and collect spacers.
Refit
5.Fit spacers to seat belt retaining bolts, position to
fixings and tighten to
32 Nm (24 lbf ft).
6.Fit seat belt retaining bolt covers.
7.Secure seat belt strap and buckle to their stowed
positions and position seat in the up position.