Page 662 of 1007
INTERIOR TRIM COMPONENTS
REPAIRS 76-3-1
INTERIOR TRIM COMPONENTS REPAIRS
Sun visor
$% 76.10.47
Remove
1.Release sun visor from retaining clip.
2.Remove 2 screws securing sun visor to roof.
3.Disconnect multiplug from sun visor.
4.Remove sun visor.
5.Remove screw securing sun visor clip to roof
and remove clip.
Refit
1.Fit sun visor clip to roof and secure with screw.
2.Fit sun visor to roof and secure with screws.
3.Fit sun visor to clip.
4.Position sun visor and connect multiplug.
Trim casing - rear quarter - lower - 3 door
$% 76.13.12
Remove
1. 03MYRemove body side rear trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - body side - rear - 3
door.
2.Release rear seat squab and fold seat forward.
3.Release load space lamp from trim casing.
4.Disconnect 2 Lucars and remove load space
lamp.
5.Remove 6 Torx screws securing luggage
compartment carpet retainer.
6.Remove carpet retainer.
7.Release 4 turn buckles securing trim casing.
8.Release and remove trim casing from luggage
compartment.
Refit
1.Fit trim casing to luggage compartment and
secure with turn buckles.
2.Fit luggage compartment carpet retainer and
secure with Torx screws.
3.Position load space lamp to casing, connect
Lucars and secure lamp to casing.
4.Reposition rear seat.
Page 686 of 1007
INTERIOR TRIM COMPONENTS
REPAIRS 76-3-25
Glove box
$% 76.52.03
Remove
1.Open glove box and remove glove box mat.
2.Release illumination lamp from glove box.
3.Remove 4 screws from glove box and remove
glove box.
Refit
1.Fit glove box and secure with screws.
2.Fit illumination lamp.
3.Fit glove box mat.
4.Close glove box.
Headlining - 3 door
$% 76.64.15
Remove
1.Fold front seat squabs forward.
2.Remove both sun visors.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Sun visor.
3.Remove both 'A' post upper trim finishers.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim finisher - 'A' post - upper -
renew.
4.Remove 2 screws securing headlining to front
end of roof panel.
Page 687 of 1007
INTERIOR TRIM COMPONENTS
76-3-26 REPAIRS
5.Remove roof lamp lens.
6.Remove 2 screws securing roof lamp to body.
7.Disconnect multiplug from roof lamp and
remove lamp.
8.Release clips securing headlining rear finisher
to body and remove finisher.
9.Release 3 studs securing rear edge of
headlining to roof panel.
10.Remove 4 screws securing headlining to 'B'
posts.
11.Release 2 studs securing sides of headlining to
body.
12.Lower front edge of headlining.13.Release headlining from sun roof seal and
remove headlining.
14.Remove studs from headlining.
15.Remove 3 screws and remove pocket from
headlining.
Refit
1.Fit pocket to headlining and secure with
screws.
2.Fit studs to headlining.
3.Position headlining and secure studs to roof
panel.
4.Position headlining to 'B' posts and secure with
screws.
5.Secure headlining behind rear vent rubbers.
6.Fit headlining rear finisher and secure clips.
7.Fit headlining to sun roof seal.
8.Position roof lamp and connect multiplug.
9.Fit roof lamp and secure with screws.
10.Fit lens to roof lamp.
11.Fit both sun visors.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Sun visor.
12.Fit 'A' post upper finishers.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim finisher - 'A' post - upper -
renew.
13.Reposition front seat squabs.
Page 689 of 1007
INTERIOR TRIM COMPONENTS
76-3-28 REPAIRS
11.Release headlining from front and rear door
aperture seals.
12. Models with sun roof: Release and remove
sun roof surround finisher from sun roof
aperture.
13.Remove 5 retaining studs from headlining.
14.With assistance remove headlining through tail
door.
NOTE: Do not carry out further dismantling if
component is removed for access only.15.Release 8 tags securing front roof lamp support
and remove support.
16.Remove 14 nuts from stowage pockets, collect
backing plates and remove stowage pockets.
Page 690 of 1007
INTERIOR TRIM COMPONENTS
REPAIRS 76-3-29
Refit
1.Position stowage pockets, and backing plates
to headlining and secure with nuts.
2.Position roof lamp support and secure retaining
tags.
3.With assistance position headlining and secure
with retaining studs.
4. Models with sun roof: Position sun roof
surround finisher and secure in position.
5.Locate headlining to front and rear door
aperture seals.
6.Fit and secure 'B/C' post upper finishers.
7.Position rear interior lamp and connect
multiplug.
8.Fit rear interior lamp to headlining.
9.Position front interior lamp and connect
multiplug.
10.Fit front interior lamp to headlining and secure
with bolts.
11.Fit grab handle blanking plugs.
12.Fit grab handles, tighten screws and fit screw
covers.
13.Fit both sun visors.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Sun visor.
14.Fit 'A' post upper trim finishers.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim finisher - 'A' post - upper -
renew.
15.Fit rear quarter upper trim casings.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - upper
- 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 714 of 1007
SUNROOF
REPAIRS 76-6-1
SUNROOF REPAIRS
Sun/sliding roof - complete - front - 3
door
$% 76.83.01
Remove
1.Remove headlining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 3 door.
WARNING: Wear protective gloves when
handling glass, solvents and primers.
2.Remove and discard cable ties from drain
tubes.
3.Disconnect drain tubes from sun roof.
4.Remove 4 Torx screws securing clamping
plates and remove plates.5.Remove glass panels and 'T' bar.
6.Remove 8 screws securing wind deflectors and
remove wind deflectors.
7.Remove sun roof tray seal.
+ SUNROOF, REPAIRS, Seal - tray -
sun /sliding roof - front.
8.Mask up roof and sun roof aperture.
9.Cover interior of vehicle with protective sheet.
10.Make a cut through the sealer at the back of the
sun roof, a 90° bend in the cutting tool will help.
WARNING: Wear suitable eye protection
when removing and refitting glass.
Page 715 of 1007
SUNROOF
76-6-2 REPAIRS
11.Using suitable cutting wire, cut through PU
sealer securing sun roof to roof.
NOTE: If multi-strand cutting wire is used, a
sawing action can be used to cut through heavy
sealant deposits around corners.
12.Remove sun roof.
Refit
1.Clean surrounding area with solvent.
WARNING: Wear protective gloves when
handling glass, solvents and primers.
2.Use a vacuum cleaner to clear away any waste.
3.Cut sealer on roof flange down to a smooth
even finish.
4.Etch prime and paint any damaged areas.
5.Apply primer over etch primer on flange.
6.Apply activator over old sealer on flange.
7.Allow activator to cure.
8.Fit pre-cut nozzle to sealer cartridge, remove
lid, shake out crystals and fit cartridge to
applicator gun. If necessary modify the nozzle
to achieve required bead section.
9.Apply a continuous bead of sealer around roof
flange. Make bead slightly thicker at the
corners.
10.Check for breaks and air bubbles in sealer.
11.With assistance position sunroof and align to
roof aperture.
12.Fit sunroof tray seal.
+ SUNROOF, REPAIRS, Seal - tray -
sun /sliding roof - front.
13.Position sunroof clamping plates, fit and tighten
screws.
14.Connect drain tubes and secure with new cable
ties.
15.Remove body and trim protection.
16.Position wind deflectors, fit and tighten screws.
17.Fit 'T' bar and glass panels.
18.Fit headlining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining - 3 door.
Wind deflector - sun/sliding roof - 3 door
$% 76.83.28
Remove
1.Release and remove sun roof glass panel.
2.Remove 4 screws securing hinges, remove
wind deflector and collect hinges.
Refit
1.Locate hinges to wind deflector, position wind
deflector, fit and tighten screws.
2.Position glass panel and secure catch.
