Page 631 of 1007

DOORS
76-1-26 REPAIRS
Latch - front door - 3 door
$% 76.37.12
Remove
1.Remove upper plastic sheet.
+ DOORS, REPAIRS, Plastic sheet -
front door - upper - 3 door.
2.Release sill button lock rod from door latch.
3.Remove control rod from exterior handle.
4.Disconnect multiplug from latch.
5.Remove 3 Torx screws securing latch to door.
6.On drivers door, release door lock barrel
paddle from latch.
7.Remove latch from aperture.8.Open security flap on latch.
9.Release interior release cable clamp from
latch.
10.Disengage interior release cable from latch.
Refit
1.Secure interior release cable to latch and close
latch security flap.
2.Fit interior release cable clamp to latch.
3.Position latch to door. On drivers door, align
lock barrel paddle to latch.
4.Fit and tighten Torx screws securing latch to
door.
5.Connect multiplug to latch.
6.Connect exterior handle control rod to latch.
7.Fit sill button lock rod to latch.
8.Check operation of latch.
9.Fit plastic sheet to door.
+ DOORS, REPAIRS, Plastic sheet -
front door - upper - 3 door.
Page 632 of 1007

DOORS
REPAIRS 76-1-27
Latch - front door - 5 door
$% 76.37.12
Remove
1.Remove front door plastic sheet.
+ DOORS, REPAIRS, Plastic sheet -
front door - 5 door.
2.Release sill button lock rod from door latch.
3.Release control rod from exterior handle.
4.Disconnect multiplug from latch.
5.Remove 2 screws securing RH glass cable
guide and position guide aside.
6.Remove 3 Torx screws securing latch to door.
7.On drivers door, release door lock barrel
paddle from latch.8.Remove latch from aperture.
9.Open security flap on latch.
10.Release interior release cable clamp from
latch.
11.Disengage interior release cable from latch.
Refit
1.Secure interior release cable to latch and close
latch security flap.
2.Fit interior release cable clamp to latch.
3.Position latch to door. On drivers door, align
lock barrel paddle to latch.
4.Fit and tighten Torx screws securing latch to
door.
5.Position RH glass cable guide and tighten
screws.
6.Connect multiplug to door latch.
7.Connect exterior handle control rod to latch.
8.Fit sill button lock rod to latch.
9.Check operation of door latch.
10.Fit front door plastic sheet.
+ DOORS, REPAIRS, Plastic sheet -
front door - 5 door.
Page 633 of 1007
DOORS
76-1-28 REPAIRS
Latch - rear door
$% 76.37.13
Remove
1.Remove rear door plastic sheet.
+ DOORS, REPAIRS, Plastic sheet -
rear door.
2.Release exterior handle control rod from latch.
3.Release sill button lock rod from door latch.
4.Disconnect multiplug from latch.
5.Remove 3 Torx screws securing latch to door.
6.Remove latch from aperture.7.Open security flap on latch.
8.Release interior release cable clamp from
latch.
9.Disengage interior release cable from latch.
Refit
1.Secure interior release cable to latch and close
latch security flap.
2.Position latch to door, fit and tighten Torx
screws.
3.Connect multiplug to latch.
4.Connect exterior handle control rod to latch.
5.Fit sill button lock rod to latch.
6.Check operation of latch.
7.Fit rear door plastic sheet.
+ DOORS, REPAIRS, Plastic sheet -
rear door.
Page 636 of 1007
DOORS
REPAIRS 76-1-31
Operating cable - lock remote control - 5
door
$% 76.37.60
Remove
1.Remove door latch.
+ DOORS, REPAIRS, Latch - front
door - 5 door.
+ DOORS, REPAIRS, Latch - rear door.
2.Release cable from interior door release and
remove cable.
Refit
1.Connect cable to interior door release.
2.Fit door latch.
+ DOORS, REPAIRS, Latch - front
door - 5 door.
+ DOORS, REPAIRS, Latch - rear door.
Finisher - rear screen - side - 5 door
$% 76.43.81
Remove
1.Open tail door.
2.Release tail door glass seal from aperture for
access to side finisher fixings.
3.Using a suitable trim stud removal tool, release
3 side finisher fixings from studs on body.
4.Remove side finisher from upper fixing.
5.Remove and discard fixings from finisher.
Refit
1.Fit NEW fixings to finisher.
2.Fit door glass seal to flange.
3.Fit finisher and secure fixings.
Page 638 of 1007
DOORS
REPAIRS 76-1-33
Handle - exterior - tail door
$% 76.58.05
Remove
1.Remove tail door plastic sheet.
+ DOORS, REPAIRS, Plastic sheet -
tail door.
2.Raise glass by clicking latch.
3.Remove 3 nuts securing tail door handle to tail
door.
4.Release handle from tail door.
5.Disconnect 2 Lucars from number plate lamp.
6.Disconnect multiplug and remove handle from
door.7.Collect gasket.
8.Remove nut from lock barrel.
9.Remove lock barrel from handle.
Refit
1.Fit lock barrel to handle.
2.Fit gasket to handle.
3.Position handle and connect Lucars and
multiplug.
4.Fit handle to door and tighten nuts to 5 Nm (3.5
lbf.ft).
5.Fit tail door plastic sheet.
+ DOORS, REPAIRS, Plastic sheet -
tail door.
6.Reset latch to lower glass.
7.Close door.
Page 639 of 1007
DOORS
76-1-34 REPAIRS
Handle - exterior - front door
$% 76.58.07
Remove
1.Remove front door plastic sheet.
+ DOORS, REPAIRS, Plastic sheet -
front door - 5 door.
2.Release clip securing latch control rod to door
latch and release rod.
3.Remove 3 Torx screws securing door latch,
lower latch and release door lock paddle.
4.Remove grommet to access screw.
5.Remove 2 door handle screw fixings.6.Remove door handle.
7.Remove door latch control rod.
Refit
1.Fit door latch control rod to handle.
2.Position handle to door and tighten securing
screws.
3.Fit grommet to door.
4.Position latch, locate door lock paddle, fit and
tighten Torx screws.
5.Connect control rod to door latch.
6.Fit front door plastic sheet.
+ DOORS, REPAIRS, Plastic sheet -
front door - 5 door.
Page 693 of 1007

SCREENS
76-4-2 REPAIRS
Refit
1.Carefully remove excess sealer from body
leaving a smooth surface.
2.Use a vacuum cleaner to clear away any waste.
3.Original glass: Carefully cut back old sealer to
obtain a smooth surface without damaging
obscuration band on glass.
4.Fit spacer blocks to body.
5.With assistance, locate screen to body.
6.Apply masking tape reference marks to aid
fitment.
7.With assistance, remove screen and place
aside.
8.Clean frame and edge of screen with solvent.
Do not touch cleaned or primed surfaces
with fingers.
9.Apply etch primer to any bare metal on frame.
10.Apply bonding agent to screen and allow to
cure.
11.Apply primer over etch primer on frame.
12.Apply activator over old sealer on frame.
13.Allow activator to cure.
14.Fit pre-cut nozzle to sealer cartridge, remove lid
and shake out crystals, and install in applicator
gun.
Nozzle will need modification to achieve
required bead section.15.Apply a continuous bead of sealer around edge
of frame as shown.
16.Check for breaks and air bubbles in sealer.
17.With assistance, lift screen into place and align
to screen supports and tape. Raise screen up
to roof on ratchet support blocks. Lightly press
glass to fully seat sealer.
18.Remove protective covers and tape.
19.Test sealer for leaks, apply additional sealer if
necessary. If water is used, allow sealer to dry
before testing. Spray water around glass and
check for leaks. Mark any area that leaks. Dry
glass and sealer then apply additional sealer.
20.Fit 'A' post upper trim casings.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim finisher - 'A' post - upper -
renew.
21.Fit headlining retaining stud.
22.Fit sun visor retaining clips and sun visors.
23.Fit interior mirror.
24.Fit air intake panel.
+ HEATING AND VENTILATION,
REPAIRS, Plenum - air intake.
A curing time of 6 hours is desirable, during
this time leave a window open and do not
slam the doors. If the car must be used,
drive slowly.
Page 694 of 1007

SCREENS
REPAIRS 76-4-3
Glass - body side - rear
$% 76.81.18
The following equipment is required: Cutting wire
and handles Windscreen repair kit, Sealer applicator
gun, Suction cups.
Wear protective gloves when handling glass,
solvents and primers.
Wear suitable eye protection when removing and
refitting glass.
Remove
1.Remove rear quarter upper casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - upper
- 5 door.
2.Cover interior of vehicle with protective sheet.
3.Make knife cut in sealant at bottom of 'D' post.
4.Insert cutting wire through previously made
knife cut and fit handles as shown, with
approximately 200 mm of wire between
handles. 5.With assistance, wedge tube of handle B
between glass and body, ahead of cutting
position, and carefully cut sealer using a
continuous pull on handle A from the outside.
Ensure that glass is retained as last sealant is
cut.
If multi-strand cutting wire is used, a sawing
action can be used to cut through heavy
sealant deposits around corners.
Use of a sawing action may overheat and
break single strand wire.
6.Attach suction cup and remove glass body.
Lay glass on felt covered supports. Do not
stand on edge. Any chipping of glass edge
may develop into cracks.
7.Collect 4 spacer blocks.