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Body Closures - Door
Removal and Installation
Removal
Installation
WARNING: FOLLOWING REPAIR OR RENEWAL OF A FRONT DOOR, IT MUST BE ENSURED THAT A SIDE AIRBAG
WARNING LABEL IS AFFIXED TO THE REAR FACE OF THE DOOR.
• NOTE: The hinges are set during manufacture to achieve correct door fitment. This setting should on ly require adjustment
in the event of damage at the body or door hinge locations. 1.
Remove battery cover, and di sconnect ground cable from
battery terminal. Refer to 86.15.19.
2. Apply protective masking tape to overlap front edge of door.
3. Fully open door, withdraw harness gaiter from 'A' post,
disconnect multiplugs and posi tion them clear of 'A' post
aperture.
4. Remove door.
1. Slacken and remove the two screws securing check
arm to 'A' post and fully retract check arm into
door.
2. Slacken, remove and di scard hinge locking screws.
3. With assistance, lift d oor to clear hinge pins and
remove door from vehicle exercising care to avoid
damaging paintwork.
1. Using a thread chaser or gr ooved slave bolt, remove any
residual thread locking compound from locking screw locations.
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2.
Ensure that multiplugs are clea r of door front edge, and check
arm is fully retracted, then with assistance, lift door into
position and locate hinge pins.
3. Fit and fully tighten new hinge locking screws.
4. Position check arm bracket on 'A' post and fit and tighten
securing screws.
5. Fully open door and apply a thin co at of grease to both sides of
check arm.
6. Connect door harness multiplugs and fit and fully seat harness
gaiter in 'A' post.
7. Remove masking tape from front edge of door.
8. Check that door shuts correctly.
9. Wipe any excess grease from check arm.
10. Connect ground cable to batt ery terminal and fit battery
cover. Refer to 86.15.15.
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Body Closures - Front Door Opening Weatherstrip
Removal and Installation
Removal
• NOTE: Door seals should only be remove d when absolutely necessary, as removal may result in damage and the necessity for renewal.
Installation
1. Remove seal from door.
1. Using a trim removal tool, carefully pull seal complete
with securing pegs away from lower section of door.
2. Pull seal from chan nelling at top of door.
2. Clean door uppe r channelling.
1. Apply a suitable lubricant to upper section of seal.
2. Slide upper section of seal into channelling at top of door.
3. Check that seal is correctly positioned, then press and fully
seat the eight securing pegs into door locations.
4. Clean any excess lubricant from external surfaces and check
that door shuts correctly.
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Body Closures - Fuel Filler Door Removal and Installation
Removal
Installation
1.
Remove battery cover and disconnect ground cable from battery
terminal. Refer to Section 86.15.19.
2. Remove fuel filler flap and hinge assembly.
1. Open filler flap
2. Remove fuel filler cap but do not stow on lid.
3. Slacken and remove the two filler flap hinge securing nuts and remove flap assembly from vehicle.
3. Using a flat-bladed screwdriver, carefully ease magnet snap-fit
mounting from filler flap.
4. Depress the filler flap striker retaining tang and remove the striker
assembly.
5. Remove and discard rubber buffer from filler flap.
1. Fit new rubber buffer to filler flap.
2. Fit striker to filler flap.
3. Ensure that magnet location is clean and snap-fit magnet to filler
flap.
4. Locate filler flap studs in hinge plate and fit and tighten securing
nuts.
5. Connect ground cable to battery terminal and fit battery cover.
Refer to Section 86.15.15.
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Body Closures - Rear Door Opening Weatherstrip
Removal and Installation
Removal
• NOTE: Door seals should only be removed when absolutely necessary, as removal may result in damage and the necessity for renewal.
Installation
1. Remove seal from door.
1. Using a trim removal tool, carefully pull seal complete with securing pegs away from lower
section of door.
2. Pull seal from chan nelling at top of door.
2. Clean door uppe r channelling.
1. Apply a suitable lubricant to upper section of seal.
2. Slide upper section of seal into channelling at top of door.
3. Check that seal is correctly positioned, then press and fully
seat the eight securing pegs into door locations.
4. Clean any excess lubricant from external surfaces and check
that door shuts correctly.
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Interior Trim and Ornamentation - A-Pillar Trim Panel
Removal and Installation
Removal
Installation
1.
Remove the passenger assist handle.
For additional information, refer to: Passenger Assist Handle
(501-05 Interior Trim and Ornamentation, Removal and
Installation).
2. Detach the door aperture weatherstrip.
3. Remove the A-pillar trim panel.
Remove and discard the A-pi llar trim panel fir tree
fasteners.
1. To install, reverse the removal procedure.
Install new fir tree fasteners to the A-pillar trim panel.
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Interior Trim and Ornamentation - B-Pillar Trim Panel
Removal and Installation
Removal
1. Position front seat and squab fully forward.
2. Remove front seat belt upper and lower anchorages. Refer to
76.73.10.
3. Remove escutcheon from trim pad aperture and seat belt.
4. Remove draught welts from adjace nt door aperture flanges.
5. Using a trim removal tool and exercising care to avoid
damage, remove and discard th e two fir tree fasteners from
bottom of trim.
6. Carefully ease centre of trim pad inwards to release four
spring clips.
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Installation
7. Pass seat belt and fittings through trim pad aperture.
8. Remove trim pad from vehicle.
1. Position trim pad at B/C post an d pass seat belt and fittings
through aperture.
2. Firmly press centre of trim pad to fully seat spring clips.
3. Ensuring that adjacent dowels are correctly located in B/C
post, fit and full y seat new fir tree fasten ers to secure bottom
of trim pad
4. Fit draught welts to adjacent door aperture flanges.
5. Fit seat belt upper and lower anchorag es. Refer to 76.73.10.
6. Return seat to original position.