Page 2277 of 2490
Handles, Locks, Latches and Entry Systems - Exterior Driver Door Handle
Removal and Installation
Removal
1. Motor door glass to fully up position.
2. Remove battery cover and disconnect ground cable from
battery terminal. Refer to 86.15.19.
3. Remove door casing veneer panel. Refer to 76.47.11.
4. Remove door casing for access. Refer to 76.34.01.
5. Feeding electrical harness thro ugh water shedder, carefully
peel shedder from door and pl ace adhesive face down on a
clean dry polythene sheet.
6. Position PVC inner sheet for access.
7. Disconnect outer handle link rod from lock assembly.
8. Slacken and remove outer handle rear securing bolt.
9. Slacken and remove security gu ard lower securing bolt and
remove guard from door.
Page 2279 of 2490

Installation
14. Slacken and remove lock barre l securing screw and remove
lock barrel from handle.
1. Align and fit lock barrel to door handle and fit and tighten
securing screw.
2. Fit link rods to door handle assembly.
3. Align and fit handle assembly to door
4. Position clamping plate inside door, and holding handle in
position, fit and tighten securing bolts.
5. Position barrel link rod on lock assembly and secure with
locking collar.
6. Check for satisfactory door handle operation.
7. Slacken and remove door handle rear securing bolt.
8. Position door lock security guard and fit and hand tighten lower
securing bolt.
9. Fit and tighten door handle rear /security guard upper securing
bolt.
10. Fully tighten security guard lower securing bolt.
11. Connect lock link rod to door handle.
12. Reposition PVC inner sheet.
13. Connect ground cable to battery terminal. Refer to 86.15.15.
14. Check for satisfactory operation of locking system
15. Disconnect ground cable from battery terminal. Refer to
86.15.15.
16. Ensure that shedder contact area of door is clean and dry.
17. Position water shedder at door and carefully pass harness
through.
18. Fit and firmly seat water shedder on door ensuring
satisfactory adhesion.
Page 2283 of 2490

Installation
1. Position lock assembly in door, connect remote cable and fit
and fully seat securing clip.
2. Align lock assembly in door and fit and tighten the three
securing bolts.
3. Connect barrel to lock link rod and secure with locking sleeve.
4. Position security guard in door and fit but do not tighten lower
securing bolt.
5. Fit and tighten outer handle/security guard upper securing
bolt.
6. Finally tighten security guard lower securing bolt.
7. Position inner lock operating ro d in door and connect rod to
lock assembly.
8. Connect door outer handle operating rod to lock assembly.
9. Check for satisfactory door handle operation.
10. Reposition plastic inner sheet.
11. Connect lock actuator harness multiplug and fit multiplug to
mounting bracket.
12. Connect ground cable to battery terminal. Refer to 86.15.15.
13. Check for satisfactory door locking operation.
14. Disconnect ground cable from battery terminal. Refer to
86.15.15.
15. Ensure that water shedder contact area of door is clean and
dry.
16. Pass door harness through water shedder.
17. Fit and firmly seat water shedder on door ensuring
satisfactory adhesion.
18. Fit door casing. Refer to 76.34.01
19. Connect ground cable to battery terminal and fit cover to
batery. Refer to 86.15.15.
Page 2306 of 2490

Wipers and Washers - Wipers and Washers
Description and Operation
Windshield Wiper
The single wiper system is driven via a sh ort linkage, by an electric motor installed in (external on later models) a moulded
plastic weatherproof housing o ff the plenum wet area. The motor and housing are secured to the BIW bulkhead by three
bolts at the top and three screws (two on later models) with locking clips at the bottom. The complete assembly is handed
for left or right hand drive installation.
The windshield wiper is operated via the RH control column stalk switch. Operating modes are normal, high speed, flick wipe
and six settings of intermittent operation with delays ranging from 2 to 20 seconds.
Windshield Washer
The windshield washer is of wiper arm mounted running jet configuration. The je t assembly comprises two conventional
nozzles plus four nozzles of silicone rubbe r 'duckbill' design. If the system is initially operated at low ambient temperatures ,
the 'duckbill' nozzles permit an y frozen residual washer fluid to be ejected un der pump pressure. The washer jet feed tube
supplied assembled to the wiper ar m, fits at its lower end onto a central connector on the pl enum cover. Washer fluid is
conveyed by a rubber tube, from the washer pump to the jet assembly via a manifold on the underside of the plenum cover.
The windshield washer pump is installed on the rear face of the washer fluid reservoir. The 6.3 liter washer reservoir is
installed on the RH side of th e vehicle in a cavity formed by the front bu mper, the front wheel arch liner and the brake
Page 2310 of 2490
Wipers and Washers - Headlamp Washer Jet Removal and Installation
Removal
Installation
1.
Raise front of vehicle and support on stands.
2. Remove RH front wheel.
3. Remove RH front wheelarch liner. Refer to Section 501-02.
4. Remove and discard plastic clip from washer fluid hose and
disconnect hose from rear of jet assembly.
5. Slacken and remove screw securing cover to jet assembly and
remove cover.
6. Remove jet assembly from bumper.
1. Slacken and remove screws securing jet assembly to bumper.
2. Slide jet assembly forward and remove from bumper.
1. Position jet assembly in bumper an d fit and tighten securing screws.
2. Fit cover over jet assembly and fit and tighten securing screw.
3. Connect hose onto rear of jet asse mbly and secure with new plastic
clip.
4. Fit wheelarch liner. Refer to Section 501-02.
5. Fit road wheel.
6. Remove stands and lower vehicle onto wheels.
Page 2315 of 2490

Wipers and Washers - Windshield Washer Reservoir
Removal and Installation
Removal
Installation
1.
Open hood and fit fender cover.
2. Raise front of vehicle and support on stands.
3. Remove RH front wheel.
4. Remove RH front wheel arch li ner. Refer to Section 501-02.
5. Remove front undertray. Refer to Section 501-02.
6. Remove windshield washer and headlamp powerwash pumps
from reservoir. Refer to op erations in this section.
7. Disconnect Low Level indicator mu ltiplug. Refer to operations
in this section.
8. Carefully remove filler cap from reservoir filler neck.
9. Slacken and remove the four re servoir to BIW securing bolts
remove reservoir from vehicle, guiding filler neck through BIW
aperture
1. Position reservoir aligning with BIW holes and fit and tighten
the four securing bolts.
2. Clean pump seal locations.
3. Fit and fully seat new windshie ld washer and powerwash pump
sealing washers to reservoir apertures.
4. Apply suitable lubricant to sealing washers.
5. Fit windshield washer and powerwash pumps to reservoir.
Refer to operations in this section.
6. Fill reservoir with correct fluid mixture.
7. Check that all seals are free from leakage.
8. Fit and fully seat filler cap on reservoir filler neck.
9. Fit RH front wheel arch liner. Refer to Section 501-02.
10. Fit front undertray. Refer to Section 501-02.
11. Fit front RH road wheel.
12. Raise front of vehicle, remove stands and lower vehicle onto
wheels.
13. Remove fender cover and close hood.
Page 2318 of 2490

Installation
1.
Position motor in housing and fi t and tighten securing nuts and
bolts.
2. Apply suitable lubricant to bore of new spindle inner seal and
fit seal over motor spindle.
3. Holding the capillary and purge valve clear, position
motor/housing assembly on bulkhead.
4. Seat motor spindle seal correctly in upper plenum aperture and
ensure that housing lo cates on lower studs.
5. Fit and tighten the housin g upper securing bolts.
6. Fit and tighten the housing lower securing screws and slide
locking clips inwards.
7. Position throttle cable adjustment bracket on throttle body and
fit and tighten securing bolts.
8. Position purge valve bracket at bulkhead and fit and tighten
securing bolt and nuts.
9. Position engine harness multiplu g on mounting bracket and fit
and tighten securing nut.
10. Connect motor harness multiplug and locate in retaining clip.
11. Apply suitable lubricant to bore of new outer seal and fit with
washer to motor spindle.
12. Fit and fully tighten collar nut on motor spindle.
13. Fit plenum cover. Refer to 76.10.01.
14. Fit wiper arm and blade. Refer to 84.15.44.90.
15. Fit top covers to LH and RH bulkheads and rear of engine
compartment. refer to 76.11.33 and 76.11.35.
16. Fit ground cable to battery te rminal and cover to battery.
Refer to 86.15.15.
Page 2320 of 2490

Installation
9. Slacken and remove two bolts securing throttle cable
adjustment bracket to throttle body.
10. Release lower clips and slacken and remove the screws and
upper bolts securing plenum closure panel/wiper motor
assembly to BIW.
11. Guiding wiper spindle through BIW aperture, remove closure
panel/wiper motor assembly from vehicle.
E357931. Ensure that closure panel rubbe r gasket is correctly seated.
E357942. Guiding wiper spindle through BI W aperture, position closure
panel on plenum wall, swivelling motor/linkage assembly on
rubber seat to achieve optimu m spindle to BIW alignment.
3. Fit and tighten securing bolts and screws and slide retaining
clips inwards to lock screws.
4. Position throttle cable adjustment bracket on throttle body and
fit and tighten securing bolts.
5. Position purge valve bracket at bulkhead and fit and tighten
securing bolt and nuts.
6. Position engine harness multiplu g on mounting bracket and fit
and tighten securing nut.
7. Connect motor harness multiplug and locate in retaining clip.
8. Apply suitable lubricant to bore of new outer seal and fit with
washer to motor spindle.