Handles and Lock Mechanisms (01.14)
Body System (01.00)1-10-2 Workshop Manual May 2007
Specifications
Maintenance
Ignition Cylinder Lock - Renew
Removal
1. Remove steering column shroud (see Workshop Manual procedure 11.04.DB Shroud Assembly - Upper and
Lower - Steering Column - Renew).
2. Insert ignition key into steering lock and turn to position 2 (see Figure 1).
3. Push release button down (through hole). 4. Retract barrel by pulling outwards (gently rotate from
side to side) with key (see Figure 2).
5. Remove key from barrel.
Installation
1. Install key to barrel.
2. Install barrel into steering lock housing until button locates properly.
3. Install steering column shroud (see Workshop Manual procedure 11.04.DB Shroud Assembly - Upper and
Lower - Steering Column - Renew).
RH/LH Front Door Latch Assembly -
Renew
Removal
1. Remove glass regulator (see Workshop Manual procedure 01.11.DA/01.11.1DB Regulator - Door Glass
- LH/RH - Renew).
2. Remove aperture seal from inside door.
3. Remove rear rubber cheater panel, fir tree trim pins (x3), and inner glass seal.
4. Disconnect latch mechanism multiplug.
5. Disconnect exterior door handle inner and outer cable.
6. Remove nuts (x3) securing exterior door handle, remove
handle.
7. Loosen upper nut and remo ve lower nut securing key
lock mechanism.
Torque Figures
DescriptionNm
Door handle 5
Latch 9
Repair Operation Time
ItemCode
Ignition Cylinder Lock-Renew 01.14.AD
Figure 1
A0114311
Figure 2
Repair Operation Time (ROT)
ItemCode
Front Door Latch Assembly RH01.14.CE
Front Door Latch Assembly LH01.14.CF
A0114312
Handles and Lock Mechanisms (01.14)
Body System (01.00)
May 2007 Workshop Manual 1-10-3
8. Remove bolts (x3) securing door latch (see Figure 1).
9. Feed interior latch handle cable through inner skin into door interior.
10. Remove latch and keylock mechanisms carefully through aperture.
Installation
1. Install latch and key lock mechanisms through door aperture and feed interior door latch handle cable
through aperture.
2. Align door latch, install and torque tighten bolts (x3).
3. Align key lock mechanism, install lower nut, torque tighten nuts (x2).
4. Install exterior door handle, install and torque tighten nuts (x3).
5. Connect latch inner and outer cable to exterior door handle.
6. Connect latch mechanism multiplug.
7. Refit inner glass seal and rubber rear cheater panel, secure with tree trim pins (x3).
8. Refit door aperture seal.
9. Install glass regulator (see Workshop Manual procedure 01.11.DA/01.11.1DB Regulato r - Door Glass - /LHRH -
Renew).
Bonnet Latch Assembly - Renew
Removal
1. Remove grille (see Workshop Manual procedure 01.08.AA Grille - Radiator - Renew
2. Remove slam panel (bolts x12).
3. Remove bolts (x4) securing PAS oil cooler.
4. Remove bolts securing crossmember to inner wing (x4).
5. Remove bolts and spacers securing crossmember to wing (x2).
6. Move crossmember to one side and lift up clear of location (protect paintwork). 7. Disconnect bonnet latch multiplug.
8. Remove switch from latch body (to access cable).
9. Disconnect bonnet latch cable.
10. Remove bonnet latch from
crossmember (screws x2).
Installation
1. Install bonnet latch to crossmember (screws x2).
2. Connect bonnet latch cable.
3. Install switch to latch body.
4. Connect bonnet latch multiplug.
5. Install crossmember (as removed).
6. Install bolts and spacers securing crossmember to wing
(x2).
7. Install bolts securing cros smember to inner wing (x4).
8. Install bolts (x4) securing PAS oil cooler.
9. Install slam panel (bolts x12).
10. Install grille (see Workshop Manual procedure 01.08.AA
Grille - Radiator - Renew).
Hood Release Cable Assembly - Renew
(Roadster Only)
Removal
1. Remove hood latch (see Wo rkshop Manual procedure
01.14.BD Latch Assembly - Hood - Renew).
2. Remove Torx screw securi ng hood release handle to
body.
3. Disconnect hood releas e cable from handle.
4. Release cable tie fir tree fr om body, remove cable tie
from release cable.
5. Tie a length of string to the handle end of release cable for assembly purposes.
6. Remove bolts (x4) securing corner cross brace, remove
cross brace.
7. Move expansion tank aside for access (bolt x1, nut x1. hose clips x2, multiplug x1.
8. Remove LH front wheel arch liner (see Workshop Manual procedure 01.02.FB Wheel Arch Liner - Front -
LH - Renew).
9. Release clips (x2), release cable to under wing bracket and body.
10. Pull hood release cable th rough bulkhead, releasing
grommet from bulkhead.
11. Remove string from hood release cable, remove cable.
12. Remove grommet from release cable.
Installation
1. Install grommet on hood release cable.
2. Position hood release cable, tie string to cable.
3. Pull release cable through bulkhead, install grommet, remove string from cable.
Figure 1
Repair Operation Time
ItemCode
Bonnet Latch Assembly-Renew 01.14.BD
A0114142
Repair Operation Time
ItemCode
Hood Release Cable Assembly-Renew LHD01.14.BE
Handles and Lock Mechanisms (01.14)
Body System (01.00)1-10-4 Workshop Manual May 2007
4. Connect release cable to hand le, position handle, install
and tighten Torx screw.
5. Install and secure hood release cable with fir tree clip.
6. Install hood latch assembly (see Workshop Manual procedure 01.14.BD Latch Assembly - Hood - Renew).
7. Install and secure hood release cable with fir tree clips to under wing bracket and body.
8. Install expansion tank (bolt x1, nut x1, hose clips x2, multiplug x1.
9. Install corner cross brace, install bolts (x4)(torque tighten bolts with vehicle on level floor).
10. Install LH front wheel arch liner (see Workshop Manual
procedure 01.02.FB Wheel Arch Liner - Front - LH -
Renew).
11. Top-up cooling system.
Bonnet Secondary Latch Assembly -
Renew
Removal
1. Open bonnet.
2. Remove Torx screws (x2), securing secondary latch to bonnet (see Figure 1).
3. Remove secondary latch.
4. Remove sleeve from release lever.
Installation
1. Install sleeve on release lever.
2. Install secondary latch, install and torque tighten Torx screws (x2).
3. Close and re-open bonnet, check secondary latch for correct operation.
4. Close hood.
Tailgate Latch and Cable Assembly -
Renew
Removal
1. Remove trim - tailgate lid assembly (see Workshop Manual procedure 01.05.EF Trim - Tailgate Lid Assembly
- Renew).
2. Remove Torx screws (x2) securing latch assembly to
tailgate.
3. Manoeuvre latch from tailgate, disconnect multiplug, remove latch.
4. Release clips (x2), remove bezel from latch.
Installation
1. Install bezel on latch.
2. Install latch in tailgate, align manual release cable.
3. Install and torque tighten Torx screws (x2).
4. Connect multiplug to latch.
5. Install trim - tailgate lid assembly (see Workshop Manual procedure 01.05.EF Trim - Tailgate Lid Assembly -
Renew).
6. Check operation of tailgate opening and closing.
Fuel Filler Actuator Assembly - Renew
(Roadster Only)
Removal
1. Remove luggage compartment lid striker assembly (see Workshop Manual procedure 01.03.GE Striker
Assembly - Trunk Lid - Renew).
2. Remove front luggage compartment carpet (screws x4, trim clip x1).
Repair Operation Time
ItemCode
Bonnet Secondary Latch Assembly-
Renew 01.14.BF
Figure 1
A0114172
Repair Operation Time (ROT)
ItemCode
Tailgate Latch and Cable Assembly-
Renew 01.14.DC
Repair Operation Time (ROT)
ItemCode
Fuel Filler Actuator Assembly-Renew 01.14.FA
Handles and Lock Mechanisms (01.14)
Body System (01.00)
May 2007 Workshop Manual 1-10-5
3. Release left hand luggage compartment lamp, release multiplug and remove lamp (see Figure 1).
4. Remove lower left-hand luggage compartment carpet.
5. Remove upper left-hand luggage compartment carpet.
6. Release left-hand front luggage compartment carpet from studs and remove.
7. Remove 2 bolts securing fuel filler actuator assembly to body (see Figure 2).
8. Release multiplug from fuel filler actuator.
9. Release cable from fuel filler actuator assembly and remove actuator.
Installation
1. Attach cable to fuel filler actuator assembly.
2. Connect multiplug to fuel filler actuator.
3. Secure fuel filler actuator a ssembly to body with bolts.
4. Install left-hand front luggage compartment carpet over studs. 5. Install upper left-hand luggage compartment carpet.
6. Install lower left-hand luggage compartment carpet.
7. Connect left-hand luggage compartment lamp and
install.
8. Install front luggage compartment carpet.
9. Install luggage compartment lid striker assembly (see Workshop Manual procedure 01.03.GE Striker
Assembly - Trunk Lid - Renew).
Fuel Filler Release Cable - Renew
(Roadster Only)
Removal
1. Remove luggage compartmen t lid striker assembly (see
Workshop Manual procedure 01.03.GE Striker
Assembly - Trunk Lid - Renew).
2. Remove front luggage comp artment carpet (screws x4,
trim clip x1).
3. Release left-hand luggage compartment lamp, release multiplug and remove lamp (see Figure 1).
4. Remove lower left-hand luggage compartment carpet.
5. Remove upper left-hand luggage compartment carpet.
6. Release left-hand front luggage compartment carpet from studs and remove.
7. Release cable from fuel filler actuator assembly.
Figure 1
Figure 2
Repair Operation Time (ROT)
Handles and Lock Mechanisms (01.14)
Body System (01.00)1-10-6 Workshop Manual May 2007
8. Release bayonet fitting on release catch and remove cable (see Figure 2).
Installation
1. Install fuel filler release cable and secure release catch.
2. Attach cable to fuel filler actuator assembly.
3. Install left-hand front luggage compartment carpet over studs.
4. Install upper left-hand luggage compartment carpet.
5. Install lower left-hand luggage compartment carpet.
6. Connect left-hand luggage compartment lamp and install.
7. Install front luggage compartment carpet.
8. Install luggage compartment lid striker assembly (see Workshop Manual procedu re 01.03.GE Striker
Assembly - Trunk Lid - Renew).
Fuel Flap Release Switch - Renew
Removal
1. Remove Trim - upper panel - front pillar - LH (see Workshop Manual procedure 01.05.BE Trim - Upper
Panel - Front Pillar - LH - Renew).
2. Remove LH front sill plate (see Workshop Manual procedure 01.05.AK Plate - Front Sill - LH - Renew). 3. Remove trim studs (x2) securing lower A-post trim panel
to body (see Figure 1).
4. Disconnect multiplug from fuel flap release switch, remove trim panel (see Figure 2).
5. Depress clips, remove fuel fl ap release switch from trim
panel.
Installation
1. Install switch in trim panel.
2. Position trim panel, connect multiplug.
3. Position A-post trim panel, install trim studs (x2).
4. Install LH front sill plat e (see Workshop Manual
procedure 01.05.AK Plate - Front Sill - LH - Renew).
5. Install Trim - upper panel - front pillar - LH (see Workshop Manual procedure 01.05.BE Trim - Upper
Panel - Front Pillar - LH - Renew).
Figure 2
Repair Operation Time (ROT)
Figure 1
Figure 2
A0114168
A0114169
Handles and Lock Mechanisms (01.14)
Body System (01.00)
May 2007 Workshop Manual 1-10-7
RH/LH Tonneau Latch Motor - Renew
(Roadster Only)
Removal
1. Remove wind deflector (see Workshop Manual procedure 01.17.DA Wind Deflector - Renew).
2. Release 2 clips securing harness to latch motor bracket.
3. Remove 4 bolts securing latch motor bracket to body (see Figure 1).
4. Disconnect latch motor multiplug.
5. Release cable from latch motor.
6. Remove 2 screws securing latch motor to bracket and remove.
Installation
1. Install latch motor and secure to bracket with screws.
2. Secure cable to latch motor.
3. Connect latch motor multiplug.
4. Secure latch motor bracket to body with screws.
5. Secure harness to latch motor bracket.
6. Install wind deflector (see Workshop Manual procedure 01.17.DA Wind Deflector - Renew).
RH/LH Tonneau Latch - Renew (Roadster
Only)
Removal
1. Remove wind deflector (see Workshop Manual procedure 01.17.DA Wind Deflector - Renew).
2. Release tonneau latch multiplug from body and disconnect.
3. Unclip emergency pull string from tonneau latch (see Figure 1).
4. Mark position of tonneau latch.
5. Remove 2 bolts securing tonneau latch to bracket.
6. Unclip inner release cable from tonneau latch.
7. Unclip outer release cable from tonneau latch, remove latch.
Installation
1. Install tonneau latch and secure outer release cable.
2. Secure inner release cable to tonneau latch.
3. Align tonneau latch and secure with bolts
4. Secure pull string to tonneau latch.
5. Connect tonneau latch mult iplug and secure to body.
6. Install wind deflector (see Workshop Manual procedure
01.17.DA Wind Deflector - Renew).
Repair Operation Time (ROT)
Repair Operation Time (ROT)
Figure 1
Handles and Lock Mechanisms (01.14)
Body System (01.00)1-10-8 Workshop Manual May 2007
RH/LH Tonneau Cover Striker Assembly -
Renew (Roadster Only)
Removal
1. Operate roof to halfway position with tonneau open.
2. Support roof when hydraulic pressure drops with suitable straps and support tonneau cover with suitable
prop (see Figure 1).
3. Mark mounting position of right-hand tonneau striker.4. Remove 2 bolts securing right-hand tonneau striker and
remove (see Figure 2).
Installation
1. Align and install right-hand tonneau striker, secure with bolts.
2. Restore roof and tonneau to original position.
Tailgate Latch Assembly-Renew
(Roadster Only)
Removal
1. Open trunk lid.
2. Remove bolt securing strap to trunk lid and remove strap (see Figure 1).
Repair Operation Time (ROT)
Figure 2
Repair Operation Time (ROT)
ItemCode
Tailgate Latch Assembly-Renew 01.14.HA
Figure 1
Handles and Lock Mechanisms (01.14)
Body System (01.00)
May 2007 Workshop Manual 1-10-9
3. Remove clip securing cable to release lever and remove cable.
4. Release clips (x8) and remove trunk lid trim panel.
5. Disconnect multiplugs from latch and release solenoid.
6. Remove cable tie, remove bo lts (x3) securing latch to
trunk lid and remove latch.
Installation
1. Connect multiplugs to trunk lid latch and release solenoid.
2. Install trunk lid trim panel and secure with clips.
3. Connect cable to release le ver and secure with clip.
4. Install latch and secure with bolts and cable tie.
5. Install strap and secure with bolt.
6. Close trunk lid.