FORD CAPRI 1974 Workshop Manual

.80 Chapter 11 B odywork and fitting
10 Windscreen -re rnavnl and re titting
II you ;lIe unlo,'unnlO enough 10 h:1\IO .1 wind$CICCIl shallC., 01 should you wIsh 10 . enew yOu. present windSClccn. humg J rel)lncemcnt is ono 0 1 the few Johs wluch lhe nvC'alJC owner IS advIsed 10 leave 10 n profeS SIon<l1. but lor lhe owner who wIshes to a ucmpllhc lob h irnscll. Ihe followlnU m SlfuClions ,ue uivcn 2 Cover Ihe bonno WI,h n bl:1I1kot or cloth 10 prevent a CCidental (t,llllagC "nd ,emOIlO lho wInd screen Willer hl;ldlls find (\1,115 IlS dmadcd in 011lp10' 12. 3 PIll on a pili, o f hUluwciUh shoes nll(1 \Jet "'10 ono o f thl) front SCiIiS . W,th a PU.lCC 01 ~oll Cl01h tJl~lwccn th(l sa le 0 1 you. shoes illld IIie w,nd~crccn IJlilss. pl<lcC bOlh fe 01 It1 one 101) comer 0 1 the wmdscreen
;'lIld Ilush r"lIlly (Sr.e Fill 11 5) 4 Whr.n Ihe wemhcrslIIp hns f,ecd Ilse l! fromlhe hody U<ln\)e III Ih<ll
'lrfl<l. rc pem IhC piOCtl5S .1l flCqllenl Ull(HV,ll$ <lIon\) Ihe lOP tlri!l'l 0 1 Ihn wuutseleCIl uII lIl. from o!llsidc Ihe G;lr. Ihe Ul",.;s <Inri WOOllhe(l,lnp Coan htl removed louclher. 5 It you <Ire "<lv.no 10 .cne w your wlll(lS(:rI)cn due 10 a shnllercd scrcen. lomov(! nil unecs 01 senhnU compound and hloken \)I"ss from Ihe we,lltlerstrip nnd harly U"ngll. Gcm ly p'lse OUI the ch p which cove.s Ihe 101111 of Ihe chromlullI fmlshcr SIIlP nnd I)ull Ihe tUlIshnr StliP out of Ihe wealhelSllljl Then remove Ihe weathcrSlllp from the Ulilss 0'. II 01 IS on Ihe c;n (as 111 Ihe ense 01 ,1 shattcre d scr/Nn) remove 01 from Ihe hody lIanoo 7 To 111 ,1 new wOlld Sf.I/Nn Slarl liy flllnl\) Ihe wC;'lllw,slrop ,1lOUIHI Ih" ncw WllldscrllCIl !.I';I!>s. 8 Apply ,1 s",,;,hle S\:a lantlO Ih e wealhcrsllIlHn·hndy !Iroovc FI1 a IUle. hut SlrOIlO . 1)ICCe 01 COr(1 .iUhllhe way rOIlIlc1lhe !jIo()ve. ;1IJowII'!1 an ove.laj) 0 1 ,.bout 150 mm (6 111) althe 101nt. 9 F.om oulsid c Ihe car, placo Ihe windSCH!el1 III lI S cnlll'CI pOSIIoOI1. Illnking su re Ihallhe loose end o f Ihe cord is IIlslde Ihe C,l'
1 0 Wilh an assis tant I>ressin g firml y on Ihe ouls.(Je of Ihe windscreen. gOI 1010 Ihe ca. and slowly puU the co.d Ihus d.,lwlng Ihe weathe.SllIll over Ihe body ffnnge (See FiU. 11.6). 11 Apply a lurlher Inye . 01 se"lilllI 10 Ihe omlelslde 01 Ihe lubber·lo·glass groove. from oOlside Ihe car. 1 2 Rellllh(l chromiom flnis hCI suit) Into I1S !!Joove In Ihe weallu"slliP ;"lIld 111 Ih(l clip which covers Ihe ,0inl. 1 3 CmefuHy clc,1 n all ;Iily SUiplus seal;mt 111)'" Ihe wlO\d~;&#34;&#34;&#34;..!&#34; 1I';lss. ileJooe 1t ha s a Ch;'l"C!! to h;.,den ilild Ihell leflt the wtndscrecn WI",!r WillS ; IIId blades
11 T ailijato window g lnss -rem ov;,1 nnd rcfitting
Where applicnble. !elllove Ihe window ijl<1sS wipe. nrm and bln(l(l. and calefolly disconnCC I Ihe hunter elemenl conneCliOlls. 2 C,lr(lfully priso OUI Ih o myl;'l r Inser t from the rubber moullhng 3 If possIble. 01l1,1111 hell1110111 an nssist;1II1 nnd "nelolly usc a Illunt blnded scrcw(ffivcr 10 IlU sh the wenthc,slrop hi) "Ionu the u llpe. transverse sCGlion unde. th(l Inl lijnte aperl\lIe flange. When applOxl' Illately two Ihirds o f the wei'lherslllp hi) has been treated III Ihls manne •. pressu. e s holiid be apl>hed to the gl<ls$ from Inside Ihe C;'1I. The gt;'lss and wenthersl.il > can then Uc removed from the outside. 4 Clean Ihe !tp o f t he wmdow apc.lOre ilnd the ijlnss and weathe'Slrip i f they are to be used ngam. D o not usc solvents soch as pel.ol or white spirit on the weathe,s\lip. ilS Ihese may cause delerioration 0 1 the .u1J1Je •. 5 Wh(ln ' (lfotting. lit I he wenthe.str'p 10 Ihe glass. Ihen inser t a d.awcord in the .01J1Je.·to·body Oroove. so Ihatthe co.d ends eme.ge at the 1JOllom centre with npl>roximately 150 mm (6 in) 01 overlap. Doring this ope.ation it may help to relilm the w(latherstrip t o Ihe glass by using s horl lenUlhs o f ll1ilsking IiIP(l.
G Apply a $uililhle seill,IIl1 to I he hody flilnijo . Posilion Ihe glass and w(lather$llip ;'I5sembly 10 Ihe body i1perlUre nnd pus h up unlil thO wemherstrip Oroove (lngnues tho top tl<lnvcrse flang(l of the body i1pe rtull1 Ensule Ihalthe ends o f Iho drilWco.d ale inside the car. tholl getlhe assist;'lnt 10 pos h th(l window lirmly althe \.lase whdsl one end of Ihe drawcord is pullod from Ihe weiltherstrip groove. Ensur(llhallhe cord is pulle d al rioht·;'Ingles 10 the flango (ie towards Ihe C(lntre 01 the Jlass) alld Ih;'ll IlreSSUre IS always being appllcd on the oOlside 01 Ihe glass in the vlcinil y o f the poinl where th(l drawcold is being pulled. 7 When th(l Ulass is in posilion. HlmOV(l the masking Iilp(l which may Mile been uS(ld. then seal Ihe w(lalh(lrsttip 10 Ihe glass.
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FiU . 11.5 Win dscreen removal (Sec 10)
FiO . 11.6 Windscree" filting using a drawcor d (Sec 10)
8 LubflCillO the mylnr insert wilh a rubbel lobricanl and re lit il. 9 Refit Iho wi,>or arm and blado (whele applicable) and leconne<:t the heale. elemenl connections.
1 2 D
oor rClliote control handle -removal and .elitting
I Flcmovc Ihe door uim panel. as descflhed in SeCI;on 13.
2 Posh Iho rem OIO COnlrol h,lndl(l ilssembly low;"uds the lronl of 1110 C1ll and poll il oot o l lh e opening in Ih(l dool inner pan(ll (photo).
3 L ilt Ihe protec tive cap o ff the rea, and Iwis t Ih(l assembly 10 dis(lngago itlrom Iho operating .od {phOIO).
4 Removo t h(l prO leClivo cap hom Iho operating .od 5 Flel illing is Ihe reV(ltSe of the removal procedu.e.
----------------------------~~ 灲潣慲浡湵慬献捯m

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FiIJ . 11.7 Door handle ;lssemiJly (Sees 12 .. nd 16)
5' RIK(R PU\I£
-
122 Rt'!m ovlnU the remall! con"ol h~ndle l.oIIl [he door 123 Olsengauc [he remote control handle from Ihe ope.allng 10(1
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82 Chapter 11 Bodywork and fitting
3 , n,~(lIOVlr&#39;!J
13 Door trim
Ih" w in, low winder mson ( ' , ,lIC, models)
panel re'noval ,,,,(1 refit" III!]
1 Carefully loll (photo) "p alU l "'II" 2 ' I"e {I", w Remove II", '''dow w"HI",
",,' ",,,,,,,,". ~&#34;&#39;d&#39;&#34; ',.",d'"'·" ,,,"",, .. """" 3 • Remov e Ih~\:hOIOS) u . ",wl\1 sc,ew ,,,,d pull
:0 ",,' po" mol ,,~.&#34;&#34;&#39;&#39;&#39;&#39;&#39;&#39; ,,'''''''''' ,," "" h"",," C~{cfllil (. lOp II .",. ( , !J SCtcws. luon II Y !<""OVc Ill" J Ii lo toS) ,e ",m,est I t. ,,,.note cont , I HOUIJh 10 ilelclt 'Y shduUJ 11 10 . rWiuds ilnd
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13 2A R ",nove 11 h -'" ~clew
lJl1sere I 5 W wile!,,,,,,,,,,, -, h"I() _') I . 01_ InltlO.1 I knob ( I • I P U:<lI1I1,. """ ' 1'11"IOS) G T- P ,oto) ,.{,leW the nUl (
,.,,, .... '''''' """ ",," " """ "" , ..... ,,"' "'" '"'''' ",. " d,,,,",,,, '" ""''0' CO,,,,,,,
d'SCOIlIlCC.l II c ,"m p.mel r til() p,mel UI 7 n I 'U spc~kc&#39; lorn th o do I"""lwork ","""'"'' . w""'" (ph'" "' "."'"' W, """,, '" ,h,,, w,,..,, ,;, "'''"." ,,' ""'"',,' 7" "". "pp''''''''; pOSitIon . () wmduw IS (;1{1' ,u, I" the wm I sp<l. tl\(: WitH I", IS &#39;: &#39;OI~e~~I1(I(&#39;r ilo1n(lie wer VP',llCo1l
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13 3A R emove lile st,ews 133B lhen'turn l' remove 11 Ie m rmes! 90 ' 10
13 <1 B Door lock iJul10n 13" R :.:> emoving tl mmOi control kn~~ nul frOlll lhe t)xt eriOi
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Chapter 11 Bodywork and fitting 183
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13 6A Door Ir;I" rwool lewining chp 136(3 Oisconll(:CIIIlg spen kOl WiWl!J when ICIllOV;"U Ihe dool Ir"ll p;lnel 14.2 Removing Iho plastic sheel from tho inllcr (Ioor
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14.4A On l a tel models Ihe window IC9ullltor is I;ve ted 10 the doo.
14 Door window rcgul;otor (lsscf11b ly -r el1lov(l1 lmd refining
1 Remove Ihe dool II"n Ihlllei. liS dcscllb(~(1 III lhe preVIOUS Seclloll 2 Peel oH Ihe pl;1StiC shee t (phOto) 3 Teltll)Ol;111ly ICfl1 the wI"der h;1nd le and lowel the WII1(low 4 On emil' models lelllOve the screws SCC!ll"lU the reuul;rIOI ~<~ernbly to Ihe innel dool p;1l1el On l<lter 1l1odels the nl<l"l <lssembly is
t mlln pOSition <lnll lh(~ livels Inust he dlliled out. The rel;1y 1)r;1cket IS sec lued uy screws (photos). ~ )I<lW tho legulmo. ;r~selllhly tow<llds the leM of the door. to d&#39;~~l1gage If hom the .unnel <It the base of Ihe w;nduw.
G Push t he window g lilSS UI) ilnd use ildhcslve t.,pc on eilch Side of Ihe glilSS and over the Window ";rmc to rewin It If It IS to be lelt fO/ lilly
Fig.l1. S Door window regulator assembly (Sec 14)
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14.48 Window regulilto r relay b.acket
sc'ews
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nglh of '"lle. usc a wooden SUI>I>o.t ,,5 well 7 W,thdl<lw the legulmol hom Ihe d Oo r. 8 Rellttlll!J's the .eve,~e o f .he lelllov<ll I)lO\;odu .e, alr\]llrllell! beill\l uhw",,!d hy adillstll'\j Ihe piVOt pl.1le /lS Ileccss;1'y . A rivele. tool and lIew rivets Will he refllllled t o fll Ihe lilll.:r Hsscmhly.
15 Exterior door handlo -f(!1ll0vHt (rn(i refilling
1 R eillove Ihe door 11;111 pam:l. ;15 plevlously deSCfibed . 2 Pull aw"y horn the pl"sII c sh ee . 'he cxtello, handle then dlsconncc. 'he .wo corlll&''''iJ hnks from 'he door lock \0 the extello, handlc .
Fig. 11.9 Ex te rior door hlllldle (Sec 15)
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)84 Chapter 1 1 Bodywork and fitting
3 Remove Ihe lWO h,1ntllc mi.,,,,,,,\! 1I01.s illld Wllhd.llw Ih" hilOldle 4 Rclrlhng IS t he reve.s.: Ollhc ,cUloy;] 1 l"l)l:",h"c. hul ,In "01 lurgel 10 install the hushoS 10' Ihfl link .ods A 1o.lIfll>cl,olcum ]dly on the .od ends 10",11 nSS,Sl w'lh the" "lsWIlIll'/)1l
16 Door lock tlsSClllhly rClllovnl illld refitting
Remove Ihe ct()or HUll p:mel as l&#34;flVlou~IV ,h~5Cflhcd ,1nf! remove the pfilstic sh elHlng 2 Remove thl! Hl!l101(! conlrnl h;]llcth~ ,111(1 Iwn WII\(low ,.;1",e boilS 3 Using " St:rcw(hrv e., Pl15U tlw .;Io,'S tron, Ih" ".111"0' h;uufiu rort ,1,,<1 doweh the ,OIls '''1111 II", Iud il Remove Ill" \,to~s·I&#39;u,1(1 ~,:r&#34;ws ~i:(:&#34;&#39;&#34;\H II,,, I""k .0 Ih" ~h,,11 ;lIld the plnslJc clips SU(;UIIlljl 11,,~ ")""01,, cOlll",1 ",<I (n Ih'l 11,,10:1 I""'cl (phOIO). 5 Remove 11," I,,<:k f,l)m lilt) (Iuo, Ih,m'!II, Ih" lown, r,,;)[ ar:r:l,ss <lp~rlur~. 6 Wh~rl rHhll&#34;&#39;~1. "''''''I 110" rWII"I" .;r",I",1 rod II"ollUh II", door ap~fllHe. ""S"""!llh.oI II,,, ,,,,1 h"s ;ru&#34;&#34;&#39;~llh&#34; door "m,,, p.llu;1 l.u:.lle
Ih e lock o n IIUl .Ino. ~1&#34;:lI. pu~hll&#39;!llhe halllfl lowa.ds Ih.! oul,,, panfil. 10 ennllie Ill" I",:k 10 10" ,;orrm :lly po~&#39;I,or&#34;,d 01, II", W;rr sh,,11 , Sucu,,, 11\11 h,, :k w,lh Ihe lto",e S<:&#34;&#39;w~ ,11\11 S()CU'C Ih" ""nOle conllol 'od 10 II", "'''''' parl!:l. w'lh 11m two pl.l~hC clops 8 Rein II", ",xh,um han.llI; ""h '" Ih(", &#34;,~p •. ~:I&#39;v() luck 10";'1'0115 1'0511,on Ih" 1,1.".k I,u~h A IIIId wl"l() Iru~h,,~ IJ .IS ~hnwil III r'!1 11 10.
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16. 4 Door lock and reta'l1"IIi screws
Fig. 11 .11 Romoving I h o door bell moulding (Sec 17) 9
The ,emilUldcr 01 I
ho rChllll1!) procedure .s the levelse 01 lhe rcmov~1 prOCedure .
17 Door window glilSS -removal and refining
Remove the door trim pilOel. as previously described. Ihen peel the plas lic sh ee ling away 110m ' he dool panel apertures. 2 Remove Ihe doO! bel l mouldlnU/Wealhf]rsllip assembly (see Fig. 11.11 ). 3 Wind up Ihe w,ndow glass. Ihen lemove 'he pivot plate screws. Remove Ihe four rellulmor lIem plme securrog screws or rivels . Disengage Ihe stu(ls and rOllers of the regulntor mms hom the door glass channel an(1 cmefully hit oul the \jlnss Allow Ihe regulalor 10 fall ilwily. piVOI,ng on Ihe legulmor hnndle shilli.
" When refi llin\j. initially Insert a snlall hloc k 01 wood in Ihe hOllom 01 Ille door assembly. locate Ihl} \)1,155 on Ihl} door panel. so thm il is leSl ,nu on Ih e woodell blo ck 5 locale lh e sluds nnd rolle,s ollhc ICUUI,lIOI ann 11110 ttw door IIlilSS ch~,ulel. I hen ICmpornrlly inswlllhc w,ndow handle and turn ,110 alton
Ihe ueilf pl,lle w'lh Ihe panel flxin!JS . SecIHe Ihe fllal~ 10 Ihe ,nner pnrlel. 6 loosely assmnhle Ihl} p,vOI pia!!!. Ihen Wind up tim UI,lSS ,1m! al'lIn
, I ,n Ihe Irame T,uhlell Ihe p,vOI 111;r1l! SCICWS 7 The remain(l el 01 Ihe rellHmU procedure IS the rev ..... se 01 Ihe .emoval proc(.~lu,e
1
FiU. 11 .1 0 Tho hlack (A) lHld whi:e (0) door lock bushes (Sec16)
Fig . 11 .1 2 Removing Ihe door window g lass (Sec 17)
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) Chapter 11 Bodywork and fitting 185
18 Door window 'ramo -re moval and re litting
Remove the door !fUll pimo' as previously desclibed, Ihen paollho plas tic sheeting away from the lowe. door p;lnel apertures 2 RClllove Ihe door belt mouldinO/wCiJlherst,ip assembly. 3 lower Ihe window glllss, then peel back the lower front corne. of 1110 plastic shee tIng ilild remove Ihe felicclO' (where ilpplicablc) \0 g1\1n access 10 the I rOl1land rOil' lower fixing bolls. <I RcmOIlO the flvo boilS .. flU lrilnlC sC<Jls, \0 free the frilmc from lho shell. Push the glass oul of Ihe '.ame at Ihe ,eil' of the door. so Ihallhc 1r;1IlIC lies between lhe 011lS5 and Ihe outer [lilllOI , RCPCilClof the from of the (tOOl . 5 pun tllo .e;1I 01 the framo hom the shell, whils t guiding the fronl 01 Ih e frome .c,uw,u(is p!l St the fi.St door bolt 11l0uldlnIJ retOllninlJ clln TIlls ennbles the IrnrHo 10 1)0 lilted cle;)r. (l When reliu inU. inselt the Iron I 01 Ihe ft[lnlO $0 111M Ihe verticnl leu
hes t o the reilt of Iho fitSI Illouldm!l chp 7 S,)tinn Ihe real of the h;'lme 11110 the shell. so Ih.lt Ihe hame lies hdwcon Ihe 1.11.155 ,ltld Ihe outer p.l0,, 1. whIlst spml!J"'g the frame fr Ont eltlcal len pasl Ihe mouldln!! chi). so Ih,11 Ihls <llso Ires hetween lire !.I1&#34;s~ ,md Ihe "111(:' I)anol Sp"n!J l ire "ame n.numllhe nlolSS and secule.1 wilh the fIve holls. Pull Ill!! we"thws llll) frOIll lire door ilperlure fliln!Je. Ihen shul Ihe door <rlld iJdlUSI Ihe flilme 10 OIrt.1111 il \.I"P tmlwCfln Ihe frame <lnd 11.111\10 (In an(1 (111) of l O tI) 14 111I1I (04 100 G III). and belwoen th\!
framo and the l\,p,II,lr (fore and aft) 01 8 to 1 2 nUll (03 10 05 10)
TI\lhtrm Ihe holts 10 The .elnalnde. of t he fI:hlllllg plor-edur!.! IS II", IOVOIS" o f Iho removall)rocedure.
19 Window frame moulding ,md door weathers trips -removal and refitting
Where armlrc<lble. wind the WIndow dOWll 10 liS fullest eKtent Cme fully Wise the we,llhetstrip OUI 01 Ihe groove in the door outer might metal finish mouhJ inU .
2 When rehl1inu. corrCClly 1)OSltion Ihe weOlthCf StflJl over liS U.oov!.! . W,th Ihe thumhs. cOlrclutly I)IIse lire st"l) lully 11110 th!.! !JlOove J W",d Ihe WIndow up (wl""e ilpplrc<lhlo) lmll check Ihm th!.! w()iI\lre,slll!) IS l,lIel! r:OI'c.:lly
'1:0 Door _ r!.!llloval (lnd fl.lfitti"u
Wllh Ihe doo. Ol)!.!". remove Ihe dip IrOIll 'he bOliom ollh!.! check ... rn 1)lvot l)lfl Ihen relllove tho .)Ul \I}holoj 2 SUllIlOtI the door on blocks of \'1/00<1. 3 Where doo. speOlkers Olre fIlled relllove Ih!.! Irllll !)OInel (Sec' ion 1 J) Ihen remove Ihe WirlllU from tire frolll etlu!.! of Ihe doOt.
4 Where rull pin typo hlllUfis ,lie hlled (eOlrly models) use <l 1)<lIfOW drr t o drive oultlre .01l1)1I1~. thelllCllIove tlr!.! dool from Ihe CHI. Who.!.! solid hinge pillS are f,lled (photo) the pillS Ciumo. he removed <llld th\! hinues muSI therofore ho det.lched hom the body 11111011 ns follows·
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'A ,
FiU. 11.13 Window frame relaining bolts - arrowed (Sec 18)
Prisc out rcllec/or (or ,1CCCSS to A "fld Imlf bock pli/stic slleel over B
5 Remove Ihe scuff "Iilte Itont sCrow and locally Irftlhe wOilther stllp (j Remove Iho lowor I~cia p~nel. 7 On Ihe lI(jhl·hnnd side. rOlllove Ihe instrument p,mel ilS describ ed
III Chilpter 12. On Ihe lelt·hOlnd sid!.! remOve Ihe glove compartment a Remove the Inco lovel vont. 9 UnsCtew the nu's OInd remove the plmes hom Ihe inner sidos of tire
l unges. Ihen Irlt Iho dOOf from t he Cill. 10 Reflllin(j is n reversal of tcmovOlI. but check the <100' striker adJustllwnt [IS desc ,ibed in Section 7.
2 1
Door privDte lock -removnl ilnd refitting
I Remove the doo. 111m panel DS desCtl bed in Secllon I J. 2 P rise the clip hom the control rod ;md d,sconnect It from the m,llll dOOf lock (pho.o).
3 Slide Ihe . e .arninu chp down th!.!n Wllhd.,lW Ihe pllva.e lock frOlll lire outsid!.! of the door 4 Rehllinu IS ,1 .everS<l1 of remo"",!
22 Rear quarter trim p(lnel -relllovill OIml relining
Remove the screws rel'llnlrlU Ihe wrndow <Iuarte. tlllll ilnd hit HW<lY
thet""'. 2 Remove t he B 'Plllar vertlcOlI \I11 Olnd th!.! seatbelt screw (whe.e
OIpp
ciltJle) 3 Remove Ihe twO screws [Inti remove Ille r!.!Dt seat cush ion Whele Jpplrc<l I)le. feed Ih!.! se~tbell ,HId hvc kle OISSCIllI)IrCS thlOuyh the
opel\ln!J "I tire cuslHon.
4 Remove Ihe three 1Iim panel screws !llld the SIOI) 1)lilI!.! Wlre.e
, 20. 1 Door check Ollln (arrow!.!dj 20.4 Door hlnye on <I later model 21.2 Inner view 01 the p"vate door lOCk
, I
" :,
i
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Chapter 11 Bodywork and fitting
ilpphcolble. remove Ihe lugg,1ge COlllpillllllent book. Cilrefully prise ilwilY the trim pnneL 5 Ref,uing is the reverse of the rernovnl p,ocedure, but on cOll1pl elOoll, tighten Ihe semuelt bolt to the specif ied torque.
23 OPI)rlirlg reM qUMter glass ilssembly -removal and refittin g
flemove Ihe trim covers f,olll Ihe 8 -pilnel and the qUilrlCr willdow ~U&#34;O\rr10 (1,un) Where ilpplicilble first remove Ihe reM seillbelt inerl i.) r",,1 (S"r.lro" 36) 1 R(!lllove Ihe two toUUfe rewinrn\j screws ilnd ,emove Ihe tog\jle (,om Ihe le,lI C'p ,lI;u
:I Hemove Ihe WIIlO OW frillllC wemhe'Slrip then d,ive oul Ihe 1&#34;~t~Jlc-(() cill!:h relollnin" pill ilnd remove Ihe IOggle . <1 flr:fnllll!J IS Ihe reverse of the reillovill plOcedure, but luhricale the II p,t L" IUIl!I'! P'VOIS With il SOilP 50ltl1ion prior 10 hHrIlO Ihe Ulass :r~~&#34;&#34;&#39;&#39;&#39;ty AdJusl Ihe IO!JOlc. or w Cillhe rS H'l) lIan\je. to ilcl\leve 8 to 10 n (03100 <1 In) !Flp hetween Ihe glass olnd the WeillherSlr,p flan\je.
I 'Uhl"" Ihe to!I!Jh ! screws to th e speclfred lorque.
211 Load spa,-e Irim panel -r e 'noval nnd re fitting
H",,,,,v,, Ih" ,(!ar <iua,ter l"lll panel, as P,(!v,ously de5crr lwd :> f&#39;ulllll<~ S<:;H forwa,d and remnve Ihe wn secul l"O sr.rcws . II may .• I~;o I,,~ necessary 10 (/(!Iach Ihe ba ck 10m p,lrwl (f,ve screws) J Ren'ovo Ihe inleriof hUllt connection a"d Ihe se,lliJilck lock kn ob H"d Ihe" 'emove the panel. <1 fluf'lInlli is the reve rse of the removill procedure, EnSlUe 111,,1 Ihe ~ollnd deildenin\j nwterioll is correctly posilioned and tha i Ihe I,nn panel does nOI foul the sem releilse hinge mectwniSIll_
25 BOil net release c(lble -r e m ova l an d re fitting
I" It", <:v<:nl 01 Ih!) rdcn~e cilhle hreilking. it is posslhle 10 rerilOve Il,,, ,.Hir.llor !II ,lie to Otu""le Ihe lock spring hy hil"d. Grrllc rCrllov,,1 'S oI""tl With II, S,,,:tron 9. hul SUIC(! ii's nOI poss,hle to open Ihe bonnet. II WIlli", 1""11.1 a Iotlle d,lfl(;ull (lilou!lh nOlm,poss,bl(!) 10 WI in ilCCCSS 1011", 111'1>' " &#34;~1aU&#34;&#34;\I scrc ws. In &#34;&#34;&#34;()VI~ II,,! ,,,ICilSC cabl!) II, normal CllcomS I,l n ces . rcn,ov!) Illc ,;,11" "Pl'u, cowl plain :1 I,,,,,, "'s,de IIie ca r. !(!1Il0VC bOlh Ihe cl(!vrs pins and tire sprlllg and ."""cl lire II!h,a se cahle fro", Ihe control le vcr (photo) II Sl;&#34;:~,&#39;,, 11 1I~ caht(! adJustcr elll"'p and release the cil bl!) /rO'll Ih!) h",k lock ~P&#34;&#34;!I !-, n,,,,,,,ve It", c;,IJle "'''I,nn'!) clrps, th(!n plllllh(! cable th'oll!Jh the rI .... 1 1'"",,1 to re"'ove 11. I; n"frltrrl!1 01 Ihe cilhle IS essen li,lll y th(! 'eV(!rse of tir e r(!Ill oval PI(r<:,·rtUI". &#34;dJIJ~t,ng ;1$ "(!cess.l!y. t o rCrilOve any cable slac k. For
•
Fig. 11 .1 4 QUMter windo w fixing screws _ .. rrowed (Sec 23)
lurllH), ,,,fonnatlon ou thiS. [(:1", II) pn,a\jlaph 6 of Ihe follow,,!U Scctron
2 6
Bonn et -removill, refitting and ildjuslnlCnt
Open 11l(! honne t 10 ,ts fulieSI eXlflnl. USrrlU n suiwble nnplemen!.
scrrhn .1 Irne around t he hrn!Jes, Remove Ihe screw seCUflllg Ihe enrlh le.ld where ,1ppircnble (photo).
2
Rcmove Ihe Iwo holts ilnd wnshers secu"no ench SIde of Ihe
bon"el 10 ItS hrnoes (phOIO)_ W'I" ass,swnce, , t C,ln IlOW he lofted off. 3 flefm"'(J IS ,) reve,s.,1 of remov,, 1 jlrocedure Before lullV "ulHenulU Ihe seCllri ll!1 holts, ensule Ih<l the h"'IICS ,"e alrUllfal wilh the scrrlwd III;rrks Tills w,1I C "SlHe CorrC(:1 ahU'''"(!nl, 1 11 ,I IS found Ih;1 lhe honne l requi,es adlus lment. Ihis C;ln be cfl(!c tud rl) III(! vC'IICill plilllC hy sl,lcke'''ng the calch post locknut illld scre wrnU Ihe calch pOSI III Of oul F Ofe-and·nh adjustment Ciln he dfecICd by slac kenrn!) Ihe I"n\je boilS
5 AdJusl"ble hump ,uhbe,s .lIe also provIded ""d these should be pos'troned "s "eceSSilry 10 Slop vlhrailon, b U I JI Ihe Sal1le time muSI allow the bo""el 10 he closed eas,ly 6 Adlustmenl of the bonnel 10ckrnU sprrnU Ciln be Illa(fe hy sinckenlllg Ihe cable CI.11111> o n t he upper crOSSIll('mhcr and shdlnH Ihe outer c<lhle II"olllJh the clop <lS necessa,y When cOfl(!clly positioned. Ille hood lock spfI"ufcnbfe SetTing (hmcnsion should he as shown in F'g 11 15 T ighten Ihe clnll'p screw when the ildlllsl'nenl is
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26, 1 Removing bonnet enrth lead 26.2 Remov ing bonnel hinge boilS
procarmanuals.com

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) Chapter 11 Bodywork and fitting 187
16mm ~ 0.5 -1.0
( 0.63," t 0.0
19 ) -O.O~
Fin. 11 .1 5 [30l1 ,1f!1 lock;,, !) ~p&#34;iI1U ~(llling dimensi o n {Sec 26 }
OP"I) II", t."I!!,,!!, ;ond <1<:1;1(,11 Ih.: OIl hne COIHlCClOrs IWIll the d;;Jlllpcr(s)hlllll(S) (llh(l\OSj 2 SUppOI! the lilll!late. tIH!!l d&#39;~<;&#39;&#39;&#39;lI1&#39;&#39;cl the d;lIl1pc,S hy 11"5111(1 out the p11'l511(; w(!(IU',s w ith a sIu;,1I se:lcWdllVCI (photo). 3 With hulp foam an assI stan t. ~UPPOlt tile taIlgate and lumovu It I,y removlno the hmgc holls (photo) 4 When Ulstalilng. nh\jn the tnit~ID1C so thnt t he ed\jl.'s nrc flush wllh the ,ea, of the roof nnd the C 'p llla, s.des. nnd the \jnp hetween the l<Iilg~teiHld the root edge is 7109mm (03100.4 in) ··see FlO. 1110. 5 Align the lowe, e(ines of the wllg.1te. so that It is flush wIth the ,eal
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700mm( 275,n )
.200rnm( 078,n)
-OOOmm(OOO,n
Fig .l1.16 Ta ilgate-to-roof eduo illiglllllf! llt (Sec 27)
f-Ol,H)rs of tho body. with the Sillkm plaH, III th,! lippe, ec,H",1 pos'tlon G Pints C,111 he used hcnC<llh the C·plll;u h&#34;,,,pel~ 1m ahU'HlU)1l1 of the 1;,,1\1,110 sales with the C·pill<Jr slope (photo) Note Ih~1 the thic k end 01 11m humper l<lces lOwards the front of the vehicle Oil (!olr1y models 7 On completion, rcf 'llhc dampers ;lnd W""") c&#34;rHlf!ctOI~
28 Tailga!C privnte lock -relllov,,1 n n d refitting
Open the wilgate ilnd prise oft the trml. then ,,,Illove the Inleh (th,ee Loolts and wash&rs) (flhotoj. 2 Remove tl)() lock cylinder ,etninin\! nul. then tlUn thu lock spIder. to
" .' .'
27.1A Tnilg~te dampe, connl.'ctlon to body 27 .1 B Tailgate (fnmpe, con"cc\'orl to \ailgmc 272 Method of d,SCOllncC t."u the l<llignte dampers
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27.6 Tadgate bumper pad 28.1 Tailgate l<I1ch
• _____________________________ J~I
灲潣慲浡湵慬献捯m

I 188 Chapter 11 Bodywork <lnd fitting
(A j (8 ) (c ' 'D E F G r
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Fig_ 11 .17 T"il\J"w privnte lock components (Sec 28)
A Ollie. holly f' I.",:k ",,"':/
" S",II r NIII
C Wo,sl"."1 " S"IItI!) f) S"i!l,:1 " C UI;/i"
lIet<lch II Ir0ll11he lock cylinder illld ouler hody 3 Refill'''!) is lhc reverse 01 the femovili p ro<.:c(huc 4 If It is found IlCCCSS<Uy [0 remove the lock h,Hfct Ih,s C<111 he dono after II hil~ beon removed, hy rcmovin\J Jhe cifellI> from lhc I)""cl hOllSIll!J . The spring. h~rrcl ~nd spider C<ln thon be dewehed and <l new h;,,,,", Inl.!<1 by IfNc,sin(J tlus procedure
29 T" il\Jillc shiker plate·- rCIllOV1Il and refittin\!
01'0:11 Ihe lad\F,le th"ll cn",llIliy ~c!lIJe ,I Ill,!rk ,uouml the s["ke, 10 1.1I:II,l.,I" ,,,1'11"11) (photo). 2 n(:lllOVI! the ~11l\)lc hoi! ;lIul w~she&#39; null la k e off the striker plate_ He/,lllll!! 's tlw WV1"se of Ihe ,emoval p'ocedure. tolioWIl1!! which "lP'SI"',,"1 1';11) he "",dc, ,I fou"d neclJss,rry, [0 Ob[.1"l s.1lislaclUry -'''''''!) and elos'''!1 01 the I,HIU<1w
30 Fuel fiHer flnp -relllov,ll nlld refi\1il19
1 HCIllOV1! 2 Il{'m(jvc Il:rp
Ihe tir e lo"d space t'''l1 panel, as pwvlously descrIber!. two soews from Ills"je tire cm "nd hit ilw<ry the jlller
3 Bej,u,,,!! ,s [Ill) 'eve'se 01 the wmOV.11 p 'ocedure,
31 Fnc;fj panel -removal ,md refitting
1 DISCOllll()c t the l)~ttcry earth le<Jd_ 2 flcrnove IhD stee.iI1\) columll shroud ret<1illlllg screws. Remove the lowl'1 hall ,lll(! release the upper h<J1f re1<JinUlg lug 110m i[s spring clip hy plllhn!J sharply upwards. 3 Remove the inst""llell t cluster. as described in ChJpler 12. 4 DCI<rch the fh:xlble pipes from the dash p.1nel vents and de fIO Sters_ 5 Where npplicilble remove the ashtray <lnd centre vent and remove the conceJled screws (photos) G Hemove the lelt and rl\Jllt-hllnd A-pillar l"I11 S (2 screws eJch) -Jiso Ihe ural) handle. ,I f,"ed. 7 Remove the instrument panel PJd reW,n'nu screws and lilt the pad lay. If approprltltc. remove the dash panel vents and trJnsler them \0 _ole new inS trun1<:Jrlt panel. 8 Inswll.1t,on is essen ti,1l1y the reverse of the rernov JI procedure. but connect the IIcxlble p'pes 10 the vents Jnd defrosters before the cr~sh pad 's I ,tted
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31 5A r"su "ul 11,,· 1'I:1Il", v",nt
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31_5B
procarmanuals.com

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) Chapter 11 Bodywork and fitting 189
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32 8A I&#39;,,~c 0111 Ihe alp 32 an ali(I ,(,mo .. c the console screw 329 Removing the hnndbrake lever boot find be~el
Fig.n.la C lock ro:.,,"ov<ll tools (Sec 32)
1 () "'I!! (0 If; "') /J IOO",m (()/I() III)
32 Centre cOIl~ole·· fUIllUV,,1 ,,,,d refiUinu
IJasic tYlle '.111 Ihe caqll:l 110m ;!lolllni the r'OIlI of t im t:()Il~()lo, thun push the " .J <llld hel..,1 out of Ihe hUlls&#39;&#39;&#39;~J DlsCO""CCI the dock 1r~<](ls 2 Remove 11", two SCI(lWS il( Ill(.' reiH cnd ,inti two (I101e hom the clock emt. to 1!.,lu<lst: Ihe cOllsol", 3 rlell10vc the \lP;" l<:vcI ~&#34;(lh, or T·h""dln 1 Lilt 0/11110 consul" As dpphcilhlc. !(:r!'UVC the clock 11l0llrlll1l!) pl<lIC screws "ud/or UCilrstuft lever hoot 5 flchtl;nu 15 the reverse of the 'clllov,,1 1110<:odlllO.
Gfli,1 type (also Il((ed fa I(I/ef nVI)-Glli" modrds) 6 Lift the Cil'PCl hom ;"oulld the IrOll1 oj the console 7 F,.brIC<lte twO sm~11 h",cke!s f,om 1 5 ""n (0 06 ,n) sheet sleel (sce Fig . 11.18) ,1I)d ,nsel1 (hese hel"nd (he IJlilck hewl to ,emove the clock Disconnect the w,,,ng. 8 Remove the two console ,etammg 5c,ews. then prIse oul the Cflp in hOIl! 01 the gearshift lever ~n(f rcmove the screws heneilth (photOs). 9 Cilrefully p,,~e the h;Ul(llJrilkc lever hoot ilnd belel ;)ssembly from tlie conSOle ;)nd remove II (photo). 10 Cnwluily PrlSC out the Gellire pflilel cover hom behind lhe gear lever. 11 Lilt up the cenlle il&#34;llfe~1 and remove lhe screw hom the bottom of the comp,lrtmen1 12 Remove the ;)rrn(CSI h"'\Je screws and place the ;)"nrest in the comp;),tment 13 Remove thc lwo screws ,I[ the hont end 01 Ihe iI&#34;,&#34;e~t rUSC out the cap at the r"ar 01 the console and remove th e scre w • Ca(elully lilt Oli! the 'eilr seCllon. I,onl s(:ctlon and console COlllpilftmcnt 16 Remove the he,ll "'5ul"tll1g pad Irom bene,l1h the consola Cornpnrtment ilr..,a
17 As appliCill)le. remove lhe eleeuical connector from Ihe base 01 cilch senlhelt s(;llk and rcmove the stn lk ".lI1g boll th,ouOh the top of thc consolc. Rcmove the stnlk ilssell1hly thrOuoh tlHl II1SIdc console suppo,!. 18 Pull the cMpet awny hom the SIdes of the 5UPPO,1 assen,bly. then detilch the support hy removIng (he eluht S!)CUW1!J screws. 19 Hefil!lnU is bilS'C,1I1y Ihe reV«($e ollhe !«Illoval procedlHe. hUI Illst ensure lh,11 illl Ihe splle nuts ilre corrCClly loenled on Ihe brflCke(s. Tluhten tile sefllhelt SliIlks to the specilied IOlque.
33 Sunroof piln el -ndjustments
Gap adjustment 1 When closed. a Unp of 5 8 10 6.9 mm (0.2310 027 "') should eXI~t hetwecn thc slIn(oof and (h e CM rool. II;) vmyl roof cover IS lilted. Ih,s gap should he reduced by 1 .78 mm (0.07 Ill). If adlllst'!\(Jnl IS requued. pwceed ns detaIled below. 2 With the sunrool hall open. remove (he sunrool heildhlunll hnlne 3 Close the sUllfool. then pull Ihe hei!dhnll1H hOIll (he Ie." and remove ,I. 1 To ndlust the hOnl 01 the sumoo!. loosen the front Uu,de relillnu1U screws. then whIlst p,essu1!J (he Uuitles IIlwilrds. lighten thc screws. 5 To ;)d,ustthe rear. loosen (he twa h.II1!) screws nt eneh Side of the ,1dlustinU hnsc. thcn p,ess (he reilr shdes mw,uds ,1"d t'Uh!Cn . 6 F,t the hCildllmn(J and hemU",,,,U h,,,ne 7 lithe ild)lIsunenl is slill Incorrect. ,emove (he we,l\hel$I"p from Ille rool panel ;)11(1 hend ,IS mountll1g lIange as necessary
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FiU 11.19 Sunroof controllllechanism (Secs 33. 34 and 35)
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