CHASSIS AND BODY
3
REPAIR 8.Disengage the lifting arm stud from the upper
lifting channel, manoeuvre the window regulator
and remove it from the lower centre opening in
the inner door panel.
9.Remove the exterior driving mirror.See
ELECTRICAL, Repair, exterior driving
mirrors.
10.Remove the waist rail seal from the top of the
door panel.
11.Remove the 'Torx' bolt from the hinge face of the
door which secures the front of the door frame.
12.Remove the bolt and plain washer from the
opening edge of the door which secures the rear
of the door frame.
13.Remove the bolt and plain washer from the
recessed hole in the front of the inner door panel
under the exterior driving mirror mounting plate.
14.Remove the screws and plain washers, from
inside the door, securing the bottom of the front
and rear glass channels.
15.Lift the door glass frame complete with glass out
of the door panel and remove to a suitable
bench.
16.Remove the adhesive tape securing the glass to
the door frame.
17.Slide the glass out of the door frame channel.
Refit
NOTE: When refitting the door glass
frame, ensure it is repositioned to suit the
door opening before fully tightening the
door frame securing bolts.
18.Reverse removal procedure.
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.
76CHASSIS AND BODY
50
REPAIR
NOTE: If heated front screen: 2 electrical
multiplug connectors are located under
the decker [cowl] panel. To access release
decker panel.
Remove
1.Remove windscreen wiper arms.
See WIPERS
AND WASHERS, Repair, wiper arms -
windscreen.
2.Remove rear view mirror and stickers from
glass.
3.Remove'A'post finishers.
4.Fit protective cover over dash panel and apply
masking tape to protect'A'posts.
5.Ease one end of bottom finisher away from
glass, pull to disengage finisher flange and
remove.
6.Lift lip of LH'A'post finisher and release sealing
strip along its length, pull to disengage finisher
flange from glass and remove.7.Remove RH'A'post finisher.
8.Remove header finisher.
9.Apply masking tape to protect paint finish around
glass.
10.Prepare cutting wire in handle'A'.Bend end of
wire to handle and tape over end.
11.Force cutting wire through sealer from inside and
100mm (3 7/8 in) from a top corner. Use a
needle if necessary to make a pilot hole.
12.Attach handle'B'.Allow 200mm (7 7/8 in) of wire
between handles, tape over end of wire.
13. With an assistant on the inside:Wedge the
tube of the handle'A'between glass and body
flange 100mm (3 7/8 in) ahead of hole in sealer.
14. From the outside:Carefully cut sealer from
flange using a straight pull away from the glass.
Continue in 100mm (3 7/8 in) steps around the
glass, use a sawing action at the corners.
CAUTION: Along the bottom edge, great
care must be taken to cut up to the 2
supports, positions indicated on the
obscuration band (See item 18).
15.Remove handle'B', withdraw the cutting wire
and insert it through the sealer between the
supports. Refit handle'B'.
CHASSIS AND BODY
53
REPAIR
31. With assistance:Attach suction cups to glass
and lift into position, carefully align the indicators
on the obscuration band with the supports.
Lower screen onto body flange, check alignment
and firmly press to seat glass in the aperture.
NOTE: The finisher on later vehicles will
not have cutouts, or supports fitted, as
shown.
32.Align cut outs with the supports and push
finisher fully onto the glass. Use a wooden block
to ensure fit.
33.Refit 'A' post finishers and interior mirror.
34.Refit wiper arms.FRONT SEAT - ELECTRIC
Service repair no - 76.77.01
Remove
1.Operate controls to adjust seat fully backwards
and remove 2 bolts securing seat slides.
2.Operate controls to adjust seat fully forwards.
3.Remove 3 studs securing seat side valance.
4.Remove side valance.
CHASSIS AND BODY
55
REPAIR Refit
7.Reverse removal procedure.
8.Tighten Torx screws securing seat to
29 Nm (21
lbf ft)
.
9.Tighten bolts securing seat slides to
22 Nm (16
lbf ft)
.
10.Tighten Torx screw securing seat belt to
32 Nm
(24 lbf ft)
.INTERIOR MIRROR (96 MODELS)
Service repair no - 76.10.51 - Manual
Service repair no - 76.10.54 - Auto dimming
Remove
NOTE: To remove manual mirror, follow
step 8 only.
1.Remove headlining front pocket.
2.Release left hand sun visor from clip and move
aside.
3.Release sun visor clip screw cover.
4.Remove clip securing screw and remove clip.
5.Remove 2 screws securing sunroof ECU and
move ECU aside.
6.Locate mirror multiplug, remove clip and
disconnect multiplug.
7.Remove tape securing harness (behind
headlining).
8.Release mirror from screen by applying sharp
downward pressure to the base.
CAUTION: Do not use tools to assist
removal. Mirror base should be moved in
direction of arrow, parallel to windscreen.
9.Release harness from behind headlining and
remove mirror.
76CHASSIS AND BODY
56
REPAIR Refit
10.Reverse removal procedure. Ensure harness is
correctly routed in mirror base so it does not
become trapped.
ELECTRICAL
1
REPAIR FUSE BOX - INTERIOR
Right Hand Drive shown
The interior fusebox is fitted below the steering column, behind the trim panel. It comprises of three integral units.
'A'Main fusebox,'B'Satellite 2,'C'Satellite 1.
A label in the fusebox cover shows the circuits protected, the fuse rating and their locations. Access is by
releasing the fixing screws and lowering the panel.
'A' Main fusebox
1. Stop lights, direction indicators
2. LH side light
3. Radio/cassette/CD player
4. RH headlight main beam
5. LH headlight main beam
6. Cigar lighter
7. Airbag SRS
8. RH side lights
9. Rear fog guard lights
10. RH headlight dipped beam
11. LH headlight dipped beam
12. Multi-function unit
13. Ignition feed for Multi-function unit
14. Instruments, reversing lights
15. Air conditioning, windows
16. Washers & wipers - front
17. Starter, glow plug
18. Wash/wipe - rear, mirrors, cruise control
'B' Satellite 2
1. Electric windows - front
2. Electric windows - rear
3. Anti-lock braking
4. Central door locking
5. Electric sun roof
6. Trailer lights
'C' Satellite 1
1. Anti-theft alarm
2. Headlight washers
3. Engine management
4. Anti-lock brakes
5. Anti-theft alarm
6. Rear air conditioning, heater
'D' Spare fuses (5 off)
ELECTRICAL
13
REPAIR EXTERIOR DRIVING MIRRORS
Service repair no - 76.11.10
Replacing the mirror glass
1.Press the outer end of the glass inwards to its
full extent.
2.Insert the fingers under the inner end of the
glass and pull outwards until the glass is
released from its two retaining clips.
3.Disconnect the two demister leads attached to
the back of the glass unit.
4.To replace the glass, locate the inner end of the
glass in the retaining clip of the housing first.
5.Carefully press the outer end of the glass
inwards until it securely locates in the front
retaining clip.
6.Reset the fine adjustment as required.Complete assembly
Service repair no - 76.11.10
Remove
1.Disconnect battery negative lead.
2.Carefully prise off interior finisher to reveal
retaining plate and securing screws.
3.Disconnect electrical plug.
4.Supporting the mirror assembly remove three
securing screws and retaining plate.
5.Detach mirror assembly from outer door frame.
Refit
6.Reverse removal procedure.
NOTE: To prevent damage to the electrical
lead ensure that it is not pushed down
inside the door casing.