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 691 of 1007
Page 692 of 1007

SCREENS
REPAIRS 76-4-1
SCREENS REPAIRS
Windscreen
$% 76.81.01
The following equipment is required: Cutting wire
and handles, Windscreen repair kit, Sealer applicator
gun and Suction cups
Wear protective gloves when handling glass,
solvents and primers.
Wear suitable eye protection when removing and
refitting glass.
Remove
1.Remove air intake panel.
+ HEATING AND VENTILATION,
REPAIRS, Plenum - air intake.
2.Remove sun visors and sun visor retaining
clips.
3.Remove 'A' post upper trim casings.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim finisher - 'A' post - upper -
renew.
4.Remove retaining stud from front of headlining.
5.Remove interior mirror.
6.Fit protection to bonnet and areas around
screen.
7.Cover heater ducts with masking tape.
8.Cover interior of vehicle with protective sheet.
9.Make knife cut in sealant at bottom of 'A' post.
10.Insert cutting wire through previously made
knife cut and fit handles as shown, with
approximately 200 mm of wire between
handles.
11.Using suitable cutting wire, with assistance if
required, carefully cut sealer. 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.
12.Attach suction cups and use assistance to
remove glass from body.
Lay glass on felt covered supports. Do not
stand on edge. Any chipping of glass edge
may develop into cracks.
13.Collect screen support blocks.
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.
Page 695 of 1007

SCREENS
76-4-4 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 rubber spacer blocks to body.
5.With assistance, locate screen to body.
6.Apply masking tape reference marks to aid
fitment.
7.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. Install cartridge 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. Make bead slightly thicker
at each corner.
16.Check for breaks and air bubbles in sealer.
17.Position glass to body and align to reference
tape.
18.Lightly press glass to fully seat sealer.
19.Secure glass with tape until sealer has cured.
20.Remove protective covers and tape.
21.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 leakage points and apply
additional sealer as necessary when area is
completely dry.
22.Fit rear quarter upper casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - upper
- 5 door.
Page 696 of 1007

SEATS
REPAIRS 76-5-1
SEATS REPAIRS
Front seat
$% 78.10.44.99
Remove
1.Make the SRS system safe.
+ GENERAL INFORMATION,
Supplementary restraint system
precautions.
2.Remove seat base finisher.
+ SEATS, REPAIRS, Finisher - seat
base - front - each.
3.Release pretensioner multiplug from seat
frame and disconnect.
4.Remove cover from rear securing bolt.
5.Remove 4 Torx screws securing seat.
6.Remove front seat.
Refit
1.Position front seat and secure with Torx
screws.Tighten screws to 45 Nm (33 lbf.ft).
2.Fit cover to rear bolt.
3.Connect pretensioner multiplug and secure to
seat frame.
4.Fit seat base finisher.
+ SEATS, REPAIRS, Finisher - seat
base - front - each.
Rear seat - LH
$% 78.10.48.99
Remove
1.Remove 2 Torx bolts from seat hinges.
2.Fold seat forward and remove 2 Torx bolts from
hinges.
3.Remove seat.
Refit
1.Position seat in vehicle and align hinges.
2.Fit Torx bolts to seat hinges and tighten to 25
Nm (18 lbf.ft).
3.Lower seat.
4.Fit Torx bolts to heel board and tighten to 25
Nm (18 lbf.ft).