Page 57 of 947

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
Page 58 of 947

Interior Trim (01.05)
Body System (01.00)1-4-16 Workshop Manual Issue 5, January 2010
7. Release seal from B-post adhesive (see Figure 3).
8. Release inner part of seal from tonneau (see Figure 4).
9. Release outer seals from body (both sides) and remove seal.
10. Remove chrome trims and clips from seal.
Installation
1. Clean adhesive from B-posts.
2. Install chrome trims and clips to seal.
3. Apply suitable adhesive to B-post part of seal.
4. Align and install seal to fitted position on B-posts (both sides).
5. Position retaining bar and install nuts (both sides).
6. Install outer seals to body (both sides).
7. Install inner part of seal to tonneau.
8. Install margin seal retaining clip from B-post (both sides).
9. Install retaining clip to B-post (both sides). 10. Install panel assembly body side RH (see Workshop
Manual procedure 01.05.DX Panel Assembly - Bodyside
Trim - Rear - RH - Renew).
11. Install panel assembly body side LH (see Workshop Manual procedure 01.05.DY Panel Assembly - Bodyside
Trim - Rear - LH - Renew).
Door Trim Weather Strip Assembly -
Renew (Roadster Only)
Removal
1. Remove LH door assembly (see Workshop Manual procedure 01.03.FA Door Assembly - LH - Remove for
Access & Refit).
2. Remove RH door assembly (see Workshop Manual procedure 01.03.EA Door Assembly - RH - Remove for
Access & Refit).
3. Remove LH front sill plate (see Workshop Manual procedure 01.05.AK Plate - Front Sill - LH - Renew).
4. Remove RH front sill pl ate (see Workshop Manual
procedure 01.05.AJ Plate - Front Sill - RH - Renew).
5. Remove header rail finisher (see Workshop Manual procedure 01.08.JA Finisher - Header - Windshield -
Renew).
6. Remove screw and retaining stud seal retainer to A-post (both sides).
7. Release seal from under tonneau seal and to top of A- posts (both sides) (see Figure 1).
Figure 3
Figure 4
Repair Operation Time (ROT)
ItemCode
Door Trim Weather Strip Assembly-
Renew 01.07.AX
Figure 1
Page 59 of 947

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
Page 60 of 947
Interior Trim (01.05)
Body System (01.00)1-4-18 Workshop Manual Issue 5, January 2010
Page 61 of 947

Exterior Trim (01.08)
Body System (01.00)
May 2007 Workshop Manual 1-5-1
Body System (01.00)
Exterior Trim (01.08)
Maintenance
RH/LH Applique Sill - Renew
Removal
1. Raise vehicle on ramp.
2. Remove road wheel/s.
3. Release rear of front wheel arch liner (screws x7) for access.
4. Remove nut and bolt, sill to front fender (see Figure 1).
5. Release front of rear wheel arch liner (screws x5) for access.
6. Remove nut and bolts (x2), sill to rear body (see Figure 2). 7. Remove screws (x5) sill to body (see Figure 3).
8. Remove margin seal (see Workshop Manual procedure
01.07.AM Seal - Front Door Margin - Lower - RH -
Renew).
9. Remove screws (x4) from sill top (see Figure 4).
10. Refit wheels with 3 nuts and lower vehicle to floor.
11. Release clips (x2) wing to sill and remove sill.
Installation
1. Install sill.
2. Install screws (x4) to sill top.
3. Install margin seal (see Workshop Manual procedure 01.07.AM Seal - Front Door Margin - Lower - RH -
Renew).
4. Remove wheels and raise vehicle.
5. Install screws (x5) sill to body.
6. Install nut and bolt, sill to front wing.
7. Position front of rear wheel arch liner (screws x5).
8. Install nut and bolts (x2), sill to rear body.
9. Position rear of front wheel arch liner (screws x7).
10. Install road wheel/s.
11. Lower vehicle on ramp.
Repair Operation Time (ROT)
A0108151
A0108152
Figure 3
Figure 4
A0108153
A0107150
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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
Page 63 of 947
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
Page 64 of 947
Exterior Trim (01.08)
Body System (01.00)1-5-4 Workshop Manual May 2007