door lock FORD CAPRI 1974 Workshop Manual

" ,
'6 Routine maintenance
)
Every 250 miles (400 lUll) or weekly -whichever comes first
Check the engine 011 level and lOp up " OCCCSSJry (Chapler 1) Check and adlus t lhe IYIC pressures (Chilplcr 10) Clean the windscreen and windows C lean the hcadlamps
Every 6000 miles (10000 km) o r six Illonlhs - whichever comes fir s t
£II[1ille (Clwpter 1) Change engllle 011 and IIher
Cleiln oil flilm c"p Chcck 10 1 ,IllY fluid leaka!)e ,n enUme CO'llp:lnUlCIl1
Cooling syslem (Clwptet 2) Check cool:'lnt level
Fuel syslem (Clmpler 3) Check idh"U mi~lUle (cmiJUiello1 IllUdels onlv) al I"SI se.v,ce ollIe, overhaul C heck idllllg sj)ee d
Ignition sys/Cm (C/I,Wler 4) Clean ,1nd re!)"p Sl)".k plu!)s (.:on!nC ' breilkCl Illudels olllv) Cle an and check d'Shibu\o. C"I). '010'. HT lealls mId co.1 (COllWct
bleaker modcls only) Check elwell angle (cOntact b.e"ke. mo Cllltch (e/Mllter 5) Check adjuSlmenl
Bri/king sys/Cm (Ch,1pter 9) Check selva
Che ck hydraulic flu id h,vel
Ch(: ck p"ds :'Illd sho(:s lor wear Check h.ake hllcs and hoses
Suspension .wel stvi'ring (Chi/pICr 10) Check tyres 10' w ear and dam:lge Check steering COmp{lIlCnlS l o r w e:l l "lid d.1nlilue
Bodywork. .111d fittings (Clwptef 11) C lu .. >ek se"t belts fa. we .... damage :lnd secwity
Elvc(ric.11 systcm (Ch,7jJ(ef 12 ) Check Ope.iltoon 01 "Uhts Check wilsher flUId levels Check b.1ltery eleclrolvle lev el
Every 12000 miles (20000 kill) or 12 mOll1hs - whichever comes first
III .1(/(lIlioll 10 Ihe 6000 m/le sciler/Ille
Engine (Ch.1f)ter 1) Check and adlUSI valve clearanc es
r"' .......... ~.~-.... ._ •• -.... __ .... . 3lii1&l •
Cooling system (Chapter 2) Check condition "net tension of 1111011)<1101 dflvehelt
Fllel sys tem (Chapter 3) Tighlcn inlel IIHlnl lold boits/nuts Check vacuum hoses Check e~hiluSI syst em Check ll1r ctonne. temperature cOllllol (,I applicable) Renew fuclllllC ' (fuel injec tion models only)
Ignilion system (Chapler 4) lubricate th e dis'flbulOf (conUlel br eake r models only) Renew the coninCt hu,akcr points (II nppllcJblc) Renew the spMk plugs
Transmission (Chapter 6) Check ool/th"d level Lulmc;ue automatIC 1.,'Insmlss,on IInk:'lue
Rcar axle (C/MplCt 8) Check 011 level
Bli/king system (Chaplet 9) Check v,lcuun' hose
llliJllc:'l1C Ihe handhlake Imk,loe
Suspensioll {//j(J swelill!J (C".1plt~( 10) Check condItIon and hlllSlon o f POWI.II ~I!'tllllli dllvthtl1 (II .1l1pllcal,
Check MlspenSlon 101 we;" ;111(1 d;1Il1.1!)e
Bodywork ,1I)d fillings (Clwpler 11) Check opera lion of all locks Check secu.ity 01 dOOf check sl.aps
LlIl)fIcalC locks. door c heck S\','P5 :'Ind fuel fdler cap flap
Check underbody pr olCctive coalm!)
Electrical system (Chapter 12) Check Opcra1l0n of all eleC111!:al IIcm5
Evcry 2<1 000 llIiles (40000 kill) or 2 yc;u s -\Nhichever comes firsl
III ,1(/111/'011 10 the 12000 111"'1 $d'~'f/u/e
[nyino (CIWpICf 1) f!ell'!W crankC:l $e e""5510l1 v;llve
Cooling syslofll (Clwptor 2) Renew COO!:1II1
Fllel SYS(CIII (Ch, '/pliJr 3) Renew"" II Ih!r elemenl
TrallsmissiOIl (ClwjJWr 6) AdjUSI aulom;1\IC trall5nll5SIOll h,ake b;'IIld
Every 36000 miles (60000 kill) o r 3 yenrs - whichever comes first
III .1(/{/I('01l 10 Illc JJIl'VlOUS schc(/ulcs (",lIc" JJJIJ"ci,bfc)
Brakillg system (Clwpter 9) Renew hyd,auhc flUId
procarmanuals.com

Chapter 10 Suspensio n and ste e ring 165
he IllJhlCned when Ihe em IS on Ihe '1IOUI1(1. \0 Ihe speclhe(1 100quO Lock Iho cnSlC\lnlCd I1UI wllh n new spill pin.
9 Renr shock nbsorbcr -rClllovnl nlld rofitting
Early models 1 Remove Ihe bnck sent. th~ lIoor ns~ombly crossmemher. 2 Remove Iho screws secIIIlllg Ihe SO,1 !Jell 10 Ihe lap o f Jl1() B ·pllI"r 3 Dowcll Ihe B·pllf Liller //lor/cis Remove Ihe cover hom tl,,~ :l,:c,,~s hole III Ih e rea r srdl! H un
.pholo)
. models ~, CIlr:ck the front wheds Ihun F":k up th,) rca r olthc (:;" and SUPI"lI l on "xle swnds. tCmovH Ihe ,o.ldwlwel 10 Unsc,ew Ihe nu(S Iron' tim lOp 01 III" ~hock ilhsnrhe, ilnd ,,:move the wa~her and ,nsul"l!)r rllhh,,,. 11 Unscrew nllll ,emove Ihe hollom IIH)l1ll1l"~1 holl and wllhd,.lW Ih(, shock nhsOliJer trom the cnr. Now tlw 100:"t,on of Ihe Sllacr:, '" II",
1110ul1lll1g lubber. 12 If nocessmy (he moun(lng lUhbers IIlay be relwwed sepal;l1cly 13 Relittinu is il reversal of refllovlIt l 10 ReM leaf spring -rell1ovnl. bush rellewnl "nd refiltin g
C
hock I hl) hOI1l whl)l)ls then Inck up Ihe rl);11 of Ihe cm nntl SliPPOlt
98 Renr shock ilhSOlbel upper mOIJnlln\j
nccess hol e
"
-----------_.-
II 2 Re~, stabi llser b ar mountinu on Ihe rear a xle
on fully eXlClld"d 3 Undo till: "';11 sh;,ekle nUIS ilnd remove the combined shackle boll lind plill0 asse,"l>lrus. Ihon removo the rubber Ilushes. 4 Undo lh" InJl Iron , Ihe honl mounlln\) and tilke oultho bolt runnltlg Ihrough 1111, ""'"lllmn (l'hO(o) 5 Undo Ih" lIul<; on Iho ends of Ilw fOIll U·bolts ilnd remove the
U ·lJol ls. 10'1",1"., WIth Ihe all.lchment pl,110 ilnd fubber splinf)
Insulatols (1,1",11') U The I(lhll'" Ilu~h"s C;\l1 be p,es'>vd 01 dl1ven oul. lind new bushes fllted ns {I",.( ·"l,,·d 11)1 Ih" hushes OIl Ihl! s!ahd ,se r bnr lind end pieces in
SectIon 11 1I1r1l1t~ !lIY CI;"nc. or I,,"kr, flUId . WIll 11
R eM st"hiliscr har -rcmovnl ,,"d refitting
Chock tlr" from WIH't:I~ Ihen Jack up (h o ron, 01 the cal ~nd ~Hpport 011 nxle stands il"I1love Iho rear whet:ls fo, holtcr ilCCeS$ 2 USlnO :1 11111111 !J"P wlCnch. 0' sll1>llnr tool. to hold the swoiliser b,'r IOwa,ds 11r" 3 D'SCOJ111"ctlhc l1ul and uolt ilt ench end of Ihe stabiliser bar. whefe It IS allached to Ihe floor ilssembly. lind WIthdraw tho bnr (photo). " To fenow a stablilser bill mounting bush. ,emove lhe locknut 1 the stnhillse r bar
5 0'$1 Ih(~ new ruhber bushes III olycelll1e. 01 hrake lIuld. ensure that tho stabIlise, b.H ~(JIlnce is clc 10 5 ReM sprinU U ·bolts 11.3 Re i:
procarmanuals.com

Chapter 11 Bodywork and fittings
Contents
i'ldIUS\Oy,ll and luhlllnq 25 ~ 'PCIS ,,:~mO\l.11 and reassembly.... .... ........ ..... ..... 45 HCillcr controls ~ ildluSlmenl . 40
Specifications
Torque w rench settings Se.llbel ls :
) pillar .\ lIoor .............. ............. .......... _ ._ ..... .. . Openlnu rcar qUilrter glass tougle 10 C pIllar.
Heal"r cOlllrols removill im(1 rchUrn!! lIemcr Willer villve (heilvy dull' he;II'~r) rcrnoval and rel,ttrng I"tc"or m ,,,or -remov,,1 and refrtllng . LOild spnce I"", pifflel -refl1ov~1 and refillmu M,l,nten;mcc bodywork ,1nd underfr;lflle M;r,nICnnnce • upholstery imd C;Hpets Millo r body dilm SeillS -remov,,1 ilnd refilling Sunroof -rcmoval an(1 ref ininu. Sunroof bracket an(1 dnve ilssernbly _. removal and refitting SUrlrool PJnel - T;rilgJte -removal "nd refilting Tailgnte p"vale lock -removal "nd refillinu Tailgate striker plate -removal "nd refilling Tailgate window glass -removnl and relittin(1 Window frame moulding "nd door weatherstrips -rcmov,,1 refitting Wrndscreen -removal ilnd rellllltlg
NIH
2010 30 35 10 42 4.5
Ib l It
15 to 22 26 1 0 31 33
41
" 38
" 3 4 G 5 23 ,
22 2 3G 39
" 35
33
27 28
" 11
"nd 19 10
----------------------------
.. !i
procarmanuals.com

)76 Chapter 11 Bodywork and fitting
General description
The body is of all-s teel welded construction with impact ilbsorbing hont Dnd rear sections . Anli-burSllocks nrc lilted 10 the doors, ilnd the
t ailgDte is supponcd by \J 2 Routine nwintenancc
AI the in1erVills speCIfIed in the Routine M"IIl\cnilnCe section in the front 0 1 the nl Check seal bellS 1 ThorouUh1y check nil sent hellS 101 frayu10 . cu\s, iheck and lubricafe bonnet and door locks 2 011 the bonnet lock ilnd sillety c~tch ilnt! check thilt they oper~lle correctly. 3 011 illl the (Ioor check strilps ilrld lock hilrwls 4 011 the luel 1IIIer CilP hlnw:! ilnd lock
Check underbody protective coatiog 5 W,th the CM supponed on i1xle stilnds. check the cond,tlon 01 the un(lelbody protcctivc coating. i1nd wherc neceSSilry clean w 3
M,,;ntcll The gorH)! ose solids which lIl.1y have stllt:k to the vehIcle. It is i",portant 10 Ilush these oU in such a way ilS 10 prevent \}lIt 110m scratching Ih(l Irni sh . T11e wheel arches o1I1(f unded'nrne need w~lshln9 in the s;rrne
Wily to remove any aCCUIllUI,lted mud whIch WIll retillll mOlslu re f or inspection. Periodically, except on vehicles w'lh iI wax· bnsed underbody protec tive cO After w 4 Mnintenllnce -upholstery MId eMpets
Mats and C 5 Minor body dnnl rhe phOlo{Jr.1phic SCl/rICIICCS 011 P,IflcS 174 ilfld 175111051'.11" Ihe OIWfil/iofl$ d"lo1Ifcd ill Ih" 101i0willY suh·SCC(IOII$. Note: Fo, mon' (il-1,1iIL'd ili/OlilialiOIl 01/)01/1 I}odywork fCfwir. Ihe U"ylll:s P"hlislllilY Group pu/)/ish II book by Lilli/say POller c!llIed The C,If lJodywork H"II,11f Mill",al flII:~ lIIeorpor"ll!s ;lIlo,,,,,l(ioll on sllcli Repair of minor scratches it) bodywork II the scratch is very superllclill, MId docs not penetrilte 10 the Illelill 01 the hodywork, repnir is very simple. LIghtly rub the area 01 the scratch with a pilintwork renoviltor, or il vcry line CUtlll'\} p pa il11work by rubbing Ihe sC/Dtch men w ith iI pilintwork renovator or a
very line culling pils te. Finally, opply wax polish. WhNe the scrotch has penctrDt(ld right through to the metill of the bodywork. causing the mowl \0 rust. iI d ifferent repa ir lechnique is
required. Remove any loosc rus t fronl the bottom 01 the scra tch with a penknile. then apply rUSI inhibiting paint 10 prevent the lormation 01 rust in Ihe future. Using n rubber or nylon appliCiltor fill the scratch with bodystopper paste. II requ ired. this paste Ciln be mixed with cellulose thinners to provide a very thin paste which is ideal for filling narrow scratches. Before t he stopper·paSI(l in the scratch hardens. wrilp il piece 01 smooth COllon rJg i1round the lOp 01 J linger. Dip the finger in cellulose thinners and then quickly sweep it i1CIOSS the surlace of the 5topper-pJste in the scratCh: this will ensure tha t the surfilce 01 the stopper,pilste is slightly hollowed. The scratch can now be p Repair o f dents ill bodywork When deep denting 01 the vehicle's bodywork hilS taken plilce. the
first wsk is to pull the dent out, untrl t he affected bodywork almost
procarmanuals.com

) Chapter 11 Bodywork and fittin g 17 7
~!t~InS its oriOin,11 sh~flC. There is lillie point in trying to restore the original s hllpe complClC ly, as the me1011 on the darnllged arca will have stretched on impact ilnd cannOl be reshaped fully !O its original contou r, II is belter to bring the level of the dellt up to 11 poin t which is aboul ~ in (3 111111) below the level 01 the surrounding bodywork . In cases whe.e the dent is very shallow anywi'lY. i, is nOI worth trying \0 pull 1 ou t 111 all, II the ull{lersidc 01 the dent is accessible. il can be hammercd oul gently from behind, using a malleI with a wooden or plastic head. WhilSt doing Ihis. hold a suitable block of wood l'flllly a{),111151 the outside 01 the panel 10 absorb the impact from the hammer blowS and thuS Il,event 11 Imge area of the bodywo.k hom being 'belled,ouf, Should tho dem be in a section of tho bodywo.k which has iI double skin or SOI1IIl other filclOr mokil1g It inaccesslhle from behind, a
dllferent technique is cillied lor, Drill severill sm;1U holes through the
mewl II1slde the i1reil (Jilrtlcul,ldy in tho deeper section, Then screw long sel1·tap~ing screws into the holes IllSt suffIcien tly for Ihem to gilln iI good purchase In the mewl. Now the Ilen t C"n he 1)lJlled out by pulllllg on the protruding headS of the screws wllh iI pnll of pliers. The no.t stilgo of the rep,lir is the .emOllill of the PilUlt from the 113Ued meil, and hom nn Inch or so of tho SurroundlilU 'SOUfl(r
Jdywork , Tills is accomplished most oilslly by usil1U a wire brush or ab'~sllle pild on " ,)owe< dflll, ~,lthou9h It Clln he done Just i1S e ively hy hnmf usmg shoots 01 1I1)'i151110 P.l,)C •. To COlll,llete the p Repair of fIIst holes or gashes ill bodYWOlk Romovo i111 point f rom the affected ;lIen i1nd from ifn IIlch or so 01 the surrounding 'sound' bodywork. using ;1Il nll.a$llIe pnd or 11 wire brush on 0 power drill. If these iIIe not i111",lahle a few sheets 01 abrasive pilper will do the job JUSt as offoctivilly Wrth the paint removed you will be able to gauge the sovori ty of the corrosion alld
thorelore decide whether to renew the whole polllel (II this IS possihle) or to .ep[lir the affoctod illoa. New body Po1nols arc not ,1S expensive as mos t flCOple think and it is often (Iuicker and mo.e satislacto • .,. to fit" new t)anelthan to auempt to rellair larue n.e,1S 01 corrosion.
RenlOlifl all f,llln\Js hom the .. lIeeted a.o" cxcoptthose which Will
act ~s ,1 uu,(ie t o the oliUllwl shape 01 the (i,lIlla\je(i bodywork (ell hn,1(1lnll1l) ~h.~lIs etc). ThOll, USlnu tin snIps or ~ h"cks all 100SI) met,,1 ,,,,d allY other IIwtill b;I(I'Y 1IIIo.:t..,d hy cOffosion H"lIllller tIro cdIJlls 01 lire hole Il\wartfs In Older to CW1Ite a shulrt
d epreSSion fo r Ih c frllcr pas\(!
'll/lle hrush the aHected Me[l to 'CIilOlle tiro powdery rust from the ,ICO 01 the lelllilllllll!l lIlet,,1 P;lInl thc "flected arc" wllh lUst
IIII"I)ltll1l) p""'t. If the hilck 01 the ,usle.1 me,1 's accesSlhle treolt tillS
" delo.o frlhflU cml t some w".,. . Th,s COil be [lchl(~ved by tho use 0 1 aluminium o. Illastlc
me sh. or altlflll1l1um t",Joe. AlulIll"'um 0' pl;1strc mesh IS Il.oh"bl.,. lile hest m lar\Je holo. Cut a I>.eeo to tho "pprOXlfll"te Srte ;1n(1 sh[lpe 01 the hole to he frlled. then pOSit lOll It in tho 11010 so th;rlltS ed!leS arc below the lovel 01 the sUffoundrng bodywork. It c"n he ret"mcd in position by sevcral blobs of hiler paste [lround Its per'l)lIelY,
Aluminium wpe should be us ed lor slll ;rll 0' vCly narrow holes. Pull a picce oil tho .011 ond tri'" It to tho apIl r equired, Ihe n pull off the backrng p,1por (If used) and stick th e tape
ove . the hole, rt C[ln be overlapped II tho thickness of one piece is
i nsufficient. Burnish down the 00ges of tho tapO With the handle 01 "
screwdrillC ' or srmllOf, to ensure that the ",po.s securely auached to the
metal undomeath .
Bodywork rCIJ<1irs -filling a"d re-sprayi"g BefOte uSlIlg thiS Seetion, soe the Sections on denl. doep scratc h.
rust holes "nd gash repai.s . M~ny types of hodyfllfer Me ~val'ahlo, but Uonerally spe~k.ng those nrOpnelOry kits which conlain 0 till of f illor paste and a tube of resin h~fdener Me best for this type of rcp,llf A wide, !ieKilJle plured fUlish 10 thc surface 01 Ih c filler , h up a hulc fille. 011 a cle,,,, piece 01 card or boo.d -measure tho
hardener carefully (follow the m"kCI's instructions on the pack) othe.wrse thO folic. Will !>tt too rill)luly or tOO Slowly . Using the
"pplicator apply the filler paste to Ihe prcpared area: draw the
applicalOr across the surfaco 01 tho IllIer to achieve the correct contour and to lovel the fillef surface. As soon /1S it contour that approxim"tes 10 thO corrOCt one is achielled, SlOp wo.kinU the pas le - il you carryon too long the pasto will becomc sticky and begin to 'pick up' on tho
app lic"tol. Continue to add thin layels of Iiller paste at twenty· minute intervals until the level of the filler is just pfoud of the surrounding bodywork Once the IllIer has hardened, excess can be removed using a met;!1 plane or IiIe. F.om then on. progressively finer grades of abrasive paper should be used. starling with a 40 grade p.oduction paper and l.nishing With 400 o."de wet·and·dry paper . Always wrap the abrasille p"pcr IIrOUlld a flat rubber, cork. or wooden block -otherwise the surfaco 01 the frller Will nOI be completely flat. DUling the smoothing of the fIller SUI face the wel·and·dry paper shoufd be periodically rinsod in walCr. ThiS will ensure thaI alle.y smooth linish is imparted 10 the frller (It th O flllni SHIIJO. At t!\l S st1lge the 'dont ' shoul(! be surrounded by a ring of bme
mowl, whIch in IUfn Should he encirclod !.Iy the finely 'feathered' edge
0 1 th e good paintwork . Rinse tho repair nrea wilh clean water, until all 01 the dust I>roduced by the rubblllu·down operation has gone. Sp."y the whole .ep.1ir a.oa with" light coat of primer -this will show UI> any ,mpcrfOChons in lhe su.face of the fll1e •. Repai. theso Iml)CdectlOIlS with frosh 1,110' paste or bodySlOpper, and onco mOte
smoOth the sUflaper, If bodystopper is used, it c"n he mixed wllh cellulose thinnors to lorm a really thi n p.1Ste which is Idt(lllo, "'''ng smilll holes. Repeat this spray and repair procedure until you a.o satIs fied th"tthe sudaco of the filler, and the fe thl'.! pnintwork nrc perfect. Ctean thO rep"ir ;lfea with clean water and .1l1ow to d.y fully, The .ep,," arc" is now ready for 1",,,1 sprilying. Paint spraying muSI
he call1od out in a w".m, dry, wind loss and dus t free atmosphero. This condition can be created mtllicially II you have access to a large indoor working "reil. but rl you nre lorced to work in the open. you Will have to pick your day lIe.y ca.efully . II you a.e working indoors. dousin\J the
floor in the work mea with water will holp 10 SOllie the dust which would otherwise be in the iltmosphe.e . If the ,epai. mea is con fined to one bod.,. pilllOl, mask off tho SUffoundlflg panels; lhis Will hell) 10 minllllise tho effocts 01 a slight mis,match in lH,lint colou.s Bodywo.k hUUlUS (eU ch.omo strips. door handles Otc) Will "'SO noed to be
"';1sked ot! Use uenume fII thon s pray n tes t mea (0' I>enod,cally . insed III w"ter. Allow to dry befo.e sprayinu 011 mOl(l ,laln t
S ilray on t he t op CO"1. "\Jain bUlldmu ull the tluckness by usul9
sOllof1lllhlfl'"ye .s 01 p<111l!. S Ia .t spraying in theCllnlre 01 the .epair mOil and theil, USH\g a clfcular mOllon, work outwards untrlthe whole ropmr
"rea ond al>out 2 inches 01 tho surrounding origmal pallltwork IS COvered Remolle allm"sklng mnteflaf 1010 15 minutes alter spr paint Illto the OXlst lng paintwork . Frnally. apply wax polish
Plastic compOllc"ts Wllh the use 01 mo.o and more pl"stic l>ody components by the
vehrcle manufac turers (eg bumpers, spolle.s. and in some cases major
body panels). reCllilcation 01 damago to such items .hilS .t.>e<:0me a
mOller o f eHhor emruSling relhl'r wOtk to a specialist m thiS field, o. renewing complete components Rep"ir by the DIY owner is nOlleillly feaSible owing to Ihe cost of the equipmen t and materials reQui.ed for effecting such repairs. The baSIC technique inllolves making a grOOllo
atong th o hno of the crack in the plastic using a rotary hurr in a pow~r drill. The damnged pal! is then welded hack togeth er by uSing a hot "" gun to heat up nnd luse a pl plastiC is then remolled an(lthe Mea .ubbed down to a smooth l in ish. I t IS Ifnpo.t3nt that a IllIer rod 0 1 tho correc t plas tic IS used. as body components can b e made of a lIaliety 01 dlHerenl types (eu
polyca.bonate. ABS, poIYllropylene) .
procarmanuals.com

17 8 Chapter 11 B odywork and fitting
If the owner is renewing ~ complete component himself. he will be left with the problem of IlIldmg a sUI1 6
Major u o d y damage - repair
Where serious danHlge has or.cur",d or la,ue aWroperly and. secondly. nneven slresses w,1I be Impos".r nil tli,! S1o:"rmu. (!n\l'n(~ nnrt
Ir 7 Door r The most common C (,1)
Loose door or window winde, ",,,,dft,!; (Ii) Loose 0' lIIiS.lliUned d(Jo, lock c(lillj/olJC!lJl~ (c) Loose or worn relllOle con/iol ""."/."";",i$III
2 It IS quite possrule 10' r,rllies 10 he the ",suit of" [O,,,lrrllirl,Orl 01 111<.1 atrove laullS. so a c;,r(:/ul <.1xanrrrr;riron should he rn",h, 10 ilCIl'UllU1e III<, exact CillrSf:! 3 If cd\Jes A and B (FIIJ . 11 1) should I", p,Hirl l,,) ,md "an he d1ecked by slrrnm\J a torch tlrrou\jh Ihe dOllr \Jap lrom "iJovo 'Irld Irelow the strrker • Cheek the ..
)
7 .3 Door striker plate
f ,i
j
I
j
I
\:
it
1
(.'----+"<, --'-1 ------<0
00>-----1\.. -~--.
F i!J.1l.1 A lignin!J the s triker 10 lock support plnte (Sec 7)
Edyes A and lJ shoold be 1'.1(.lllel
A
'0- - -- . ,
,'---I.::i.I I ,
--/
F ig 11.2 Lock claw·to·striker cleiHance (Sec 7)
A -70,11111 (028111)
5 Wrlh t he lock in the open positron. check the lock cl milterral on Ihe siroker POSI ,lnd cheding Its hergllt n!tar gently closll1g the doo •. The striker plale call be reposnroned verlrC d lmensron. bw t~ke Colle 10 not to dislurb any prevrous milral se1\lI1gs 01 Ihe pl,lte.
8 Bumper s -removal nnd refitlin g
FrOIll bumpN 1 D,sconnect the u<.rttery earth lend. Also where necessary dis connect the IIldrC 3 Renlove the fOI" bumper rewining screws (pholo) nnd hit away the bumper. On Imer models drser1!lage the bumper corner sectiOns f,om the body side clips as the I)umper IS wnhdrJwn. <1 Refrl1ing r$ the reverse 01 the removal p.ocedure. but do nOI fully truhlCn Ihe uolts unlrl tire bumper is correclly aliUned .
Rear bUll/pel 5 Open the lJ.tgate. Ihen rernOve the mal ilnd the sub·floor. G Remove the Jack ilnd washer water reservOIr (where applrcable) . 7 Remove the two nuts. Sp",l(J wilsher and 11m wilshers. procarmanuals.com

82 Chapter 11 Bodywork and fitting
3 , n,~(lIOVlr'!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",
",,' ",,,,,,,,". ~"'d'" ',.",d'"'·" ,,,"",, .. """" 3 • Remov e Ih~\:hOIOS) u . ",wl\1 sc,ew ,,,,d pull
:0 ",,' po" mol ,,~.""'''''' ,,'''''''''' ,," "" 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
",'.
13 2A R ",nove 11 h -'" ~clew
lJl1sere I 5 W wile!,,,,,,,,,,, -, h"I() _') I . 01_ InltlO.1 I knob ( I • I P U: ,.,,, .... '''''' """ ",," " """ "" , ..... ,,"' "'" '"'''' ",. " d,,,,",,,, '" ""''0' CO,,,,,,,
d'SCOIlIlCC.l II c ,"m p.mel r til() p,mel UI 7 n I 'U spc~kc' lorn th o do I"""lwork ","""'"'' . w""'" (ph'" "' "."'"' W, """,, '" ,h,,, w,,..,, ,;, "'''"." ,,' ""'"',,' 7" "". "pp''''''''; pOSitIon . () wmduw IS (;1{1' ,u, I" the wm I sp ---
'"
,
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
procarmanuals.com

Chapter 11 Bodywork and fitting 183
.", .
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
•
:, .. '
•
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 t mlln pOSition 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)
...r,
14.48 Window regulilto r relay b.acket
sc'ews
l e
nglh of '"lle. usc a wooden SUI>I>o.t ,,5 well 7 W,thdl 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)
procarmanuals.com

)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"flVlou~IV ,h~5Cflhcd ,1nf! remove the pfilstic sh elHlng 2 Remove thl! Hl!l101(! conlrnl h;]llcth~ ,111(1 Iwn WII\(low ,.;1",e boilS 3 Using " St:rcw(hrv e., Pl15U tlw .;Io,'S tron, Ih" ".111"0' h;uufiu rort ,1,,<1 doweh the ,OIls '''1111 II", Iud il Remove Ill" \,to~s·I'u,1(1 ~,:r"ws ~i:(:"'"\H II,,, I""k .0 Ih" ~h,,11 ;lIld the plnslJc clips SU(;UIIlljl 11,,~ ")""01,, cOlll",1 ", Ih e lock o n IIUl .Ino. ~1":lI. pu~hll'!llhe halllfl lowa.ds Ih.! oul,,, panfil. 10 ennllie Ill" I",:k 10 10" ,;orrm :lly po~'I,or",d 01, II", W;rr sh,,11 , Sucu,,, 11\11 h,, :k w,lh Ihe lto",e S<:"'w~ ,11\11 S()CU'C Ih" ""nOle conllol 'od 10 II", "'''''' parl!:l. w'lh 11m two pl.l~hC clops 8 Rein II", ",xh,um han.llI; ""h '" Ih(", ",~p •. ~:I'v() luck 10";'1'0115 1'0511,on Ih" 1,1.".k I,u~h A IIIId wl"l() Iru~h,,~ IJ .IS ~hnwil III r'!1 11 10.
., ,
,
16. 4 Door lock and reta'l1"IIi screws
Fig. 11 .11 Romoving I h o door bell moulding (Sec 17) 9
The ,emilUldcr 01 I
ho rChllll1!) procedure .s the levelse 01 lhe rcmov~1 prOCedure .
17 Door window glilSS -removal and refining
Remove the door trim pilOel. as previously described. Ihen peel the plas lic sh ee ling away 110m ' he dool panel apertures. 2 Remove Ihe doO! bel l mouldlnU/Wealhf]rsllip assembly (see Fig. 11.11 ). 3 Wind up Ihe w,ndow glass. Ihen lemove 'he pivot plate screws. Remove Ihe four rellulmor lIem plme securrog screws or rivels . Disengage Ihe stu(ls and rOllers of the regulntor mms hom the door glass channel an(1 cmefully hit oul the \jlnss Allow Ihe regulalor 10 fall ilwily. piVOI,ng on Ihe legulmor hnndle shilli.
" When refi llin\j. initially Insert a snlall hloc k 01 wood in Ihe hOllom 01 Ille door assembly. locate Ihl} \)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)
procarmanuals.com