CONTENTS
CONTENTS 13
Remote control - front door ............................................................................................................. 76-1-30
Remote control - rear door .............................................................................................................. 76-1-30
Operating cable - lock remote control - 5 door ............................................................................... 76-1-31
Finisher - rear screen - side - 5 door .............................................................................................. 76-1-31
Handle - exterior - rear door ........................................................................................................... 76-1-32
Handle - exterior - tail door ............................................................................................................. 76-1-33
Handle - exterior - front door ........................................................................................................... 76-1-34
Door pull - 5 door - up to 04MY ....................................................................................................... 76-1-35
EXTERIOR FITTINGS ............................................................................... 76-2-1
REPAIRS
Wing - front ..................................................................................................................................... 76-2-1
Liner - front wheel arch ................................................................................................................... 76-2-2
Liner - rear wheel arch .................................................................................................................... 76-2-3
Panel - underbelly ........................................................................................................................... 76-2-4
Mirror - exterior - electric ................................................................................................................. 76-2-4
Mud flap - front ................................................................................................................................ 76-2-5
Mud flap - rear ................................................................................................................................. 76-2-5
Bracket - spare wheel mounting ..................................................................................................... 76-2-6
Side rail - integral roof rack - 5 door ................................................................................................ 76-2-7
Bonnet............................................................................................................................................. 76-2-7
Cable/rod - bonnet lock control ....................................................................................................... 76-2-8
Bumper - assembly - front - up to 04MY ......................................................................................... 76-2-10
Bumper - assembly - front - from 04MY .......................................................................................... 76-2-11
Bumper valance - rear - up to 04MY ............................................................................................... 76-2-13
Bumper valance - rear - from 04MY ................................................................................................ 76-2-13
Finisher - sill - lower ....................................................................................................................... 76-2-16
Moulding - roof - 5 door ................................................................................................................... 76-2-17
Wheelarch extension - rear wing part ............................................................................................. 76-2-18
Body quarter vent assembly - 3 door .............................................................................................. 76-2-19
GENERAL DATA
04-35
Dimensions
* At EEC kerb weight
Overall length (inc. 195/80 spare wheel/tyre):
⇒ K1.8 4368 mm (14 ft 4 in)
⇒ KV6 4433 mm (14 ft 7 in)
⇒ Td4 4368 mm (14 ft 4 in)
Overall width (including mirrors 2.068 m (6 ft 9.4 in)
Overall height (including roof bars and cross rails)* 1.708 m (5 ft 7.2 in)
Overall height (including roof bars and cross rails)*
⇒ 3 door 1.808 m (5 ft 11.2 in)
⇒ 5 door 1.828 m (5 ft 11.9 in)
Ground clearance (minimum)*: 186 mm (7.3 in)
Wading depth (maximum) 400 mm (15.7 in)
Wheelbase 2.557 m (8 ft 4.7 in)
Maximum approach angle
*30.5°
Maximum departure angle (with towbar)
*24°
Maximum departure angle (without towbar)
*33.9°
Maximum breakover angle 24°
Track:
⇒ Front
⇒ Rear1534 mm (60.4 in)
1545 mm (60.8 in)
TORQUE WRENCH SETTINGS
06-30
Body
TORQUE DESCRIPTION METRIC IMPERIAL
Doors
Door lock striker to body screws 10 Nm 7 lbf.ft
Door stiffener Torx screws 9 Nm 7 lbf.ft
Front door control unit to glass clamp bolts 9 Nm 7 lbf.ft
Front door hinge bolts 30 Nm 22 lbf.ft
Rear door glass clamp bolts 8 Nm 6 lbf.ft
Tail door exterior handle nuts 5 Nm 3.7 lbf.ft
Tail door glass clamp bolts 8 Nm 6 lbf.ft
Tail door glass regulator lock nuts 14 Nm 10 lbf.ft
Tail door hinge bolts 30 Nm 22 lbf.ft
Exterior Fittings
Bonnet hinge, bolts 9 Nm 6.5 lbf.ft
Bonnet release lever to 'A' post bolt 9 Nm 6.5 lbf.ft
Exterior mirror to door Torx screws 6 Nm 4.4 lbf.ft
Front wing bolts5 Nm 3.7 lbf.ft
Spare wheel mounting bracket:
⇒ Bolts13 Nm 10 lbf.ft
⇒ Nuts25 Nm 18 lbf.ft
Spare wheel to bracket retention nuts 45 Nm 33 lbf.ft
Splash shield bolts 10 Nm 7 lbf.ft
Underbelly panel to body bolts 45 Nm 33 lbf.ft
Underbelly panel to body rear screws 8 Nm 6 lbf.ft
3 door vehicles
Hard back catch Torx screws 10 Nm 7.5 lbf.ft
Hard back retainer Torx screws 10 Nm 7.5 lbf.ft
Soft back support bracket bolts 25 Nm 18 lbf.ft
5 door vehicles
Roof rack side rail bolts 22 Nm 16 lbf.ft
Interior Trim Components
Engine compartment fusebox bolts 8 Nm 6 lbf.ft
Passenger compartment fusebox mounting plate to body and steering column
bracket bolts8 Nm 6 lbf.ft
Passenger compartment fusebox to mounting plate bolts 8 Nm 6 lbf.ft
Seats
Front seat runner to body bolts 45 Nm 33 lbf.ft
Front seat squab frame to cushion frame Torx bolts 45 Nm 33 lbf.ft
Rear bench seat to body bolts 25 Nm 18 lbf.ft
Rear seat cushion to squab Torx bolts 28 Nm 21 lbf.ft
Rear seat catch assembly Torx bolts 32 Nm 24 lbf.ft
Rear seat squab lock Torx screws 20 Nm 15 lbf.ft
Rear seat squab to cushion Torx bolts 28 Nm 21 lbf.ft
Rear seat hinge Torx bolts 25 Nm 18 lbf.ft
DOORS
REPAIRS 76-1-5
Door - tail assembly - remove for access
& refit
$% 76.28.19.99
Remove
1.Remove spare wheel from taildoor.
2.Remove RH rear quarter lower trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
3.Release and disconnect 3 multiplugs and rear
washer tube from lower 'E' post.
4.Remove 2 bolts from tail door check strap,
release strap and position aside.5.Release door harness sheath from 'E' post and
pull harness through 'E' post.
6.Mark position of hinges.
7.Support weight of tail door.
8.Remove 6 bolts securing tail door hinges to
body and with assistance, remove tail door.
Refit
1.With assistance position door. Fit securing
bolts but do not tighten at this stage.
2.Position check strap and secure with bolts.
3.Align hinges and tighten bolts to 30 Nm (22
lbf.ft).
4.Feed door harness through 'E' post and secure
harness sheath.
5.Connect and secure multiplugs and rear
washer tube at 'E' post.
6.Fit rear quarter lower casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
7.Fit spare wheel to tail door.
EXTERIOR FITTINGS
76-2-6 REPAIRS
Bracket - spare wheel mounting
$% 76.11.18
Remove
1.Lower tail door glass.
2.Remove 3 screws securing high mounted stop
lamp bracket to spare wheel carrier.
3.Disconnect multiplug and remove lamp.
4.Remove 3 nuts securing spare wheel to
mounting bracket.
5.Remove spare wheel from mounting bracket.6.Remove 6 Torx bolts and 2 nuts securing spare
wheel mounting bracket to tail door.
7.Remove mounting bracket.
Refit
1.Position spare wheel mounting bracket to tail
door and tighten bolts to 13 Nm (10 lbf.ft).
2.Tighten mounting bracket nuts to 25 Nm (18
lbf.ft).
3.Position stop lamp and connect multiplug.
4.Fit stop lamp and secure with screws.
5.Fit spare wheel and tighten nuts to 45 Nm (33
lbf.ft).
6.Raise tail door glass.
WIPERS AND WASHERS
REPAIRS 84-5
Pump - washer
$% 84.30.21
Remove
1.Remove front bumper.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
2.Position container to catch windscreen washer
fluid.
3.Disconnect multiplug from washer pump.
4.Release hose from pump.
5.Remove washer pump from reservoir and
remove and discard pump seal.
Refit
1.Fit new pump sealing grommet to reservoir.
2.Fit pump to reservoir.
3.Connect hose and multiplug to pump.
4.Fit front bumper.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
Arm - wiper
$% 84.35.01
Remove
1.Remove wiper blade.
+ WIPERS AND WASHERS, REPAIRS,
Blade - wiper.
2.Remove spare wheel mounting bracket.
+ EXTERIOR FITTINGS, REPAIRS,
Bracket - spare wheel mounting.
3.Raise nut cover on wiper arm and remove nut.
4.Release washer jet tube and remove wiper
arm.
NOTE: Do not carry out further dismantling if
component is removed for access only.
5.Release washer jet and washer jet tube from
wiper arm.
Refit
1.Position and secure washer tube and jet to
wiper arm.
2.Position wiper arm to tail door and connect
washer tube.
3.Set wiper arm with tip contacting joint line
between waist seal and rear door. Fit and
tighten wiper arm nut to 13 Nm (10 lbf.ft).
4.Fit wiper blade.
+ WIPERS AND WASHERS, REPAIRS,
Blade - wiper.
5.Fit spare wheel mounting bracket.
+ EXTERIOR FITTINGS, REPAIRS,
Bracket - spare wheel mounting.
LIGHTING
REPAIRS 86-2-7
Lamp assembly - rear
$% 86.41.15
Remove
1.Remove 3 Torx screws securing lamp to body.
2.Release lamp, disconnect 2 bulb holders and
remove lamp.
3.Remove lamp sealing rubber.
Refit
1.Fit sealing rubber and bulb holders to lamp.
2.Position lamp, fit and tighten Torx screws.
Lamp assembly - centre high mounted
stop (CHMSL)
$% 86.41.32
Remove
1.Remove 3 screws securing CHMSL bracket to
spare wheel carrier.
2.Release lamp bracket and disconnect
multiplug.
3.Remove lamp and bracket.
4.Remove 2 nuts and remove lamp from bracket.
Refit
1.Position lamp to bracket and tighten nuts.
2.Position lamp bracket and connect multiplug to
lamp.
3.Position lamp bracket to spare wheel carrier
and secure with screws.
HARNESSES
86-7-12 REPAIRS
Harness - tailgate
$% 86.70.19
Remove
1.Remove RH rear quarter lower trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
2.Remove tail door plastic sheet.
+ DOORS, REPAIRS, Plastic sheet -
tail door.
3.Remove 3 nuts and remove spare wheel.
4.Remove 3 screws securing CHMSL,
disconnect multiplug and remove CHMSL.
5.Release 2 harness clips.6.Disconnect rear washer tube from behind the
spare wheel carrier.
7.Remove 3 nuts from number plate lamp
housing and release housing.
8.Disconnect 2 Lucars and multiplug from
housing.
9.Collect 2 spacers and housing seal.
10.Remove housing.