Interior Trim (01.05)
Body System (01.00)
Issue 5, January 2010 Workshop Manual 1-4-9
5. Remove sun visor allen screws (x2) (see Figure 2).
6. Remove sunvisor.
Installation
1. Position sun visor and install screws (x2).
2. Install courtesy light console.
3. Install grille.
4. Install rear view mirror (see Workshop Manual procedure 01.08.FA Mirror Assembly - Rear Dipping -
Renew).
Door Trimboard Assembly - Renew
Removal
1. Remove trimboard (see Workshop Manual procedure 01.05.CB Trimboard Assembly - Door - Remove for
Access and Refit).
2. Remove switch pack (screws x4).
3. Remove puddle lamp.
4. Remove door pocket (nuts x10).
5. Remove centre trim (velcro x6).
6. Remove top trim and speaker grille (screws x12).
7. Remove demist duct (screws x3).
Installation
1. Install demist duct.
2. Install top trim and speaker grille.
3. Install centre trim (velcro x6).
4. Install door pocket.
5. Install puddle lamp.
6. Install switch pack.
7. Install trimboard (see Workshop Manual procedure 01.05.CB Trimboard Assembly - Door - Remove for
Access and Refit).
Door Trimboard Assembly - Remove for
Access/Refit
Removal
1. Lower door glass fully.
2. Battery isolation switch ‘OFF’.
3. Remove Allen bolts (x2) securing door handle assembly to door panel.
4. Remove trim insert, discon nect door catch inner and
outer cable from handle and retaining plate. Remove
handle assembly.
5. Remove screw securing trimboard to upper front of door frame.
6. Remove screws (x4) securing trimboard to door frame.
7. Raise trimboard out and up to release from door frame clips, disconnect multiplugs (x2).
Installation
1. Position door trim panel, connect multiplugs (x2). Place
trimboard over top of retaining clips and pull out and
down to install trimboard.
2. Install and tighten trimboard screws (x4).
3. Install and tighten screw, trimboard to upper front of door frame.
4. Position handle assembly, connect release cable, install
handle trim insert.
5. Install and tighten Allen bolts (x2), handle assembly to door frame.
6. Battery isolation switch ‘ON’.
Lower Quarter Trim Panel Assembly -
Renew
(Roadster Only)
Removal
1. Remove Wind deflector (see Workshop Manual procedure 01.17.DA Wind Deflector - Renew).
2. Remove Panel centre (see Workshop Manual procedure
01.05.FS/01.05.FR Panel Assembly - Centre - Rear
Bulkhead - RH/LH - Renew).
3. Remove Speaker grille (see Workshop Manual procedure 01.05.CN/01.05.CP Grille - Speaker Rear
Quarter - RH/LH - Renew).
Figure 2
Repair Operation Time (ROT)
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Repair Operation Time (ROT)
Interior Trim (01.05)
Body System (01.00)1-4-10 Workshop Manual Issue 5, January 2010
4. Remove screw (x1) securing quarter trim to body (under speaker grille) (see Figure 1)
.
5. Remove screw (x1) securing bottom centre of quarter
trim (see Figure 2). 6. Remove bolt securing body side trim to quarter panel
via B-post roof aperture (see Figure 3).
7. Remove nuts (x2) securing panel quarter trim to body side trim (see Figure 4).
Figure 1
Figure 2
Figure 3
Figure 4
Interior Trim (01.05)
Body System (01.00)
Issue 5, January 2010 Workshop Manual 1-4-11
8. Release fir tree clip securing quarter trim to body (see
Figure 5).
9. Release quarter trim from heal board and remove quarter trim (see Figure 6).
10. Remove nut (x2) securing lower panel to quarter panel.
Removal
1. Install nut (x2) securing lower panel to quarter panel.
2. Install quarter trim and secure under heal board.
3. Install fir tree clip securing quarter trim to body.
4. Install nuts (x2) securing panel quarter trim to body side
trim.
5. Install bolt securing body si de trim to quarter panel via
B-post roof aperture.
6. Install screw (x1) securing bottom centre of quarter trim.
7. Install screw (x1) securing quarter trim to body (under
speaker grille) 8. Remove Speaker grille (see Workshop Manual
procedure 01.05.CN/01.05.CP Grille - Speaker Rear
Quarter - RH/LH - Renew).
9. Remove Panel centre (see Workshop Manual procedure
01.05.FS/01.05.FR Panel Assembly - Centre - Rear
Bulkhead - RH/LH - Renew).
10. Install Wind deflector (see Workshop Manual procedure 01.17.DA Wind Deflector - Renew).
Side Carpet Kit (RHD) - Renew
Removal
1. Remove handbrake gaiter (see Workshop Manual procedure 01.05.DK Gaiter - Handbrake - Renew).
2. Remove passenger seat (see Workshop Manual procedure 01.10.AA Seat Assembly - Front - RH -
Remove for Access and Refit
3. Remove drivers seat (see Workshop Manual procedure 01.10.AB Seat Assembly - Front - LH - Remove for
Access and Refit).
4. Remove LH quarter panel assembly (see Workshop Manual procedure 01.05.CM Panel Assembly - Quarter
- LH - Remove for Access and Refit).
5. Remove RH quarter panel assembly (see Workshop Manual procedure 01.05.CL Panel Assembly - Quarter -
RH - Remove for Access and Refit).
6. Pull back RH front centre carpet for access (press stud x1).
7. Remove LH rear centre (pre ss stud x2) and seat runner
carpets for access.
8. Remove RH sill carpet, pull from around, handbrake
lever and A-post trim.
9. Remove LH tunnel carpet, pull from under centre console and footrest.
10. Pull back LH front centre carpet for access.
11. Remove RH rear centre (pre ss stud x2) and seat runner
carpets for access.
12. Remove LH sill carpet, pull from around A-post trim.
13. Remove RH tunnel carpet, pull from under centre console.
Installation
1. Install RH sill carpet around handbrake lever and A-post trim.
2. Install LH tunnel carpet, push under centre console and footrest.
3. Install RH front centre carp et (ensure good fit around
pedals).
4. Install LH rear centre (ensure end tucked into sub woofer) and seat runner carpets.
5. Install LH sill carpet, ensure fit around A-post trim.
6. Install RH tunnel carpet, push under centre console.
Figure 5
Figure 6
Repair Operation Time (ROT)
Interior Trim (01.05)
Body System (01.00)1-4-14 Workshop Manual Issue 5, January 2010
Top Rear Console Finisher Panel
Assembly - Renew (Roadster Only)
Removal
1. Remove Wind deflector (see Workshop Manual procedure 01.17.DA Wind Deflector - Renew).
2. Remove Console panel assembly rear LH (see Workshop Manual procedure 01.12.DE Console Panel Assembly -
Rear - Roadster - LH - Renew).
3. Remove Console panel assembly rear RH (see
Workshop Manual procedure 01.12.DF Console Panel
Assembly - Rear Roadster - RH - Renew).
4. Remove screws (x2), collect washers and remove trim.
Installation
1. Install trim, washers and screws.
2. Install Console panel assemb ly rear RH (see Workshop
Manual procedure 01.12.DF Console Panel Assembly -
Rear Roadster - RH - Renew).
3. Install Console panel assemb ly rear LH (see Workshop
Manual procedure 01.12.DE Console Panel Assembly -
Rear - Roadster - LH - Renew).
4. Install Wind deflector (see Workshop Manual procedure 01.17.DA Wind Deflector - Renew).
RH/LH Bodyside Rear Trim Panel
Assembly - Renew
(Roadster Only)
Removal
1. Remove Quarter panel trim (see Workshop Manual procedure 01.05.CR/01.05.CS Panel Assembly -
Quarter Trim Lower - RH/LH - Renew).
2. Remove Wind stop hook (see Workshop Manual procedure 01.05.CZ Hook - Windstop - Renew). 3. Remove nut securing body
side trim to console panel
(see Figure 1).
4. Remove nuts securing trim to ROPS bracket (see Figure 2).
Repair Operation Time (ROT)
Repair Operation Time (ROT)
Figure 1
Figure 2
Interior Trim (01.05)
Body System (01.00)
Issue 5, January 2010 Workshop Manual 1-4-15
5. Remove bolt securing trim to B-post (see Figure 3).
6. Release fir tree clip and remove trim.
Installation
1. Install trim and secure fir tree clip.
2. Install bolt securing trim to B-post.
3. Install nut securing trim to Roll Over Protection System
(ROPS) bracket.
4. Install nut securing body side trim to console panel.
5. Install Wind stop hook (see Workshop Manual procedure 01.05.CZ Hook - Windstop - Renew).
6. Install Quarter panel trim (see Workshop Manual procedure 01.05.CR/01.05.CS Panel Assembly -
Quarter Trim Lowe r - RH/LH - Renew).
Tonneau to Body Weatherstrip Assembly
- Renew (Roadster Only)
Removal
1. Remove panel assembly body side LH (see Workshop
Manual procedure 01.05.DY Panel Assembly - Bodyside
Trim - Rear - LH - Renew).
2. Remove panel assembly body side RH (see Workshop Manual procedure 01.05.DX Panel Assembly - Bodyside
Trim - Rear - RH - Renew).
3. Mark fitted position of se al on B-post (both sides). 4. Remove nuts (x2) from seal retaining bar and remove
bar (both sides) (see Figure 1).
5. Remove retaining clip from B-post (both sides) (see Figure 2).
6. Remove margin seal retaining clip from B-post (both sides).
Figure 3
Repair Operation Time (ROT)
Figure 1
Figure 2
Interior Trim (01.05)
Body System (01.00)
Issue 5, January 2010 Workshop Manual 1-4-17
8. Release locating section from above A-post chrome trims (both sides) (see Figure 2).
9. Release seal from under A-post chrome trims (both sides) (see Figure 3).
10. Release seal from header rail and remove.
Installation
1. Clean adhesive from header rail.
2. Apply suitable adhesive to header rail and secure seal to header rail.
3. Secure seal under chrome trims (both sides).
4. Secure locating section from over chrome trims (both sides). 5. Secure seal from top of A-posts to under tonneau seal
(both sides) (see Figure 4).
6. Install screw and retaining stud seal retainer to A-post (both sides).
7. Install RH front sill plate (see Workshop Manual procedure 01.05.AJ Plate - Front Sill - RH - Renew).
8. Install LH front sill plate (see Workshop Manual procedure 01.05.AK Plate - Front Sill - LH - Renew).
9. Install RH door assembly (see Workshop Manual procedure 01.03.EA Door Assembly - RH - Remove for
Access & Refit).
10. Install LH door assembly (see Workshop Manual
procedure 01.03.FA Door Assembly - LH - Remove for
Access & Refit).
11. Install header rail finisher (see Workshop Manual procedure01.08.JA Finisher - Header - Windshield -
Renew).
12. Perform water leak test (see Workshop Manual
procedure 01.17.XX Water Test).
Figure 2
Figure 3
Figure 4
Exterior Trim (01.08)
Body System (01.00)1-5-2 Workshop Manual May 2007
RH Wing Side Strake - Renew
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove mesh - RH side strake (see Workshop Manual procedure 01.08.CE Mesh - Side Strake - RH - Renew).
4. Remove Torx screw, (inside A-post) securing side strake to body.
5. Remove nut securing side strake to RH inner fender.
6. Remove side strake.
Installation
1. Install side strake, install and tighten nut and Torx screw.
2. Install mesh - RH side strake (see Workshop Manual procedure 01.08.CE Mesh - Side Strake - RH - Renew).
3. Lower vehicle on ramp.
4. Connect vehicle battery.
LH Wing Side Strake - Renew
Removal
1. Raise vehicle on ramp.
2. Remove mesh - LH side strake (see Workshop Manual procedure 01.08.CF Mesh - Side Strake - LH - Renew).
3. Remove nuts (x3) mesh to side strake.
4. Remove mesh.
5. Remove screw inside A-post side strake to body.
6. Remove nut side strake to wheel arch.
7. Remove side strake.
Installation
1. Install side strake, nut and screw.
2. Position mesh to side strake and install nuts (x3).
3. Install mesh - LH side strake (see Workshop Manual procedure 01.08.CF Mesh - Side Strake - LH - Renew).
4. Lower vehicle on ramp.
Channel Assembly Divider Bar - Renew
Removal
1. Remove window regulator (see Workshop Manual procedure 01.11.DA Regulator - Door Glass - RH -
Renew). 2. Remove fixed glass (see Workshop Manual procedure
01.11.BG Glass - Front Door - Fixed RH - Renew).
3. Remove seal.
4. Remove screw, divider bar to mirror (see Figure 1).
5. Remove nut (hold stud with Allen key) divider bar to door and remove (see Figure 2).
Installation
1. Install bar and nut (hold stud with Allen key).
2. Install screw, divider bar to mirror (Do not tighten at this point).
3. Install seal.
4. Adjust bar. Rotate Allen stud in centre in/out until desired alignment of bar is achieved, then torque fixings.
5. Install fixed glass (see Workshop Manual procedure 01.11.BG Glass - Front Door - Fixed RH - Renew).
6. Install window regulator (see Workshop Manual procedure 01.11.DA Regulator - Door Glass - RH -
Renew).
Repair Operation Time (ROT)
Repair Operation Time (ROT)
Repair Operation Time (ROT)
Figure 1
Figure 2
A0108170
A0108171
Exterior Trim (01.08)
Body System (01.00)
May 2007 Workshop Manual 1-5-3
Windshield Header Finisher - Renew
(Roadster Only)
Removal
1. Operate roof to halfway position and support roof when hydraulic pressure drops using suitable straps (see Figure
1). 2. Release header seal from tr
im buttons (x2) to access
retaining screw and remove screws (both sides) (see
Figure 2).
3. Remove screws (x2) securi ng finisher to windscreen
frame and remove finisher (see Figure 3).
Installation
1. Position finisher and install screws (x2).
2. Install screws under header seal (both sides).
3. Clean trim buttons, apply suitable adhesive and affix seal (both sides).
4. Restore roof to original position.
Repair Operation Time (ROT)
Figure 2
Figure 3