DOORS

Refit
REPAIRS
DOORS

Door - front 1. With assistance position door to hinges.

2. Fit 'C' clips to hinge pins.
$% 76.28.01.99 3. Position check strap to 'A' post and secure with
new roll pin.
Remove 4. Feed door harness through 'A' post.
1. Release 'A' post lower trim and position aside. 5. Connect and secure multiplugs at lower 'A'
post.
6. Connect harness sleeve to 'A' post and door.
7. Fit 'A' post finisher.
8. Check door for flush fit to adjacent panels and
door edges for equal gap. If adjustment is
necessary:
a Open door
b Place a wooden block on jack and position
jack to support door lower edge.
c Loosen 4 bolts securing hinges to door.
d Loosen 2 Torx bolts securing door latch
striker.
e Use jack to assist with door alignment.
f Tighten hinge bolts.
g Remove jack, close door and check for
correct alignment.
h When alignment is correct, tighten door
hinge bolts to 30 Nm (22 lbf.ft).
i Adjust door latch striker and tighten Torx
bolts to 26 Nm (19 lbf.ft).

2. Release and disconnect multiplugs from lower

'A' post.
3. Release harness sleeve and pull harness
through 'A' post.
4. Remove roll pin from door check strap.
5. Release check strap from 'A' post.
6. Discard roll pin.
7. Remove 2 'C' clips from door hinges.
8. With assistance raise and remove door.

REPAIRS 76-1-1
DOORS
Refit
Door - rear 1. With assistance position door to hinges.
2. Fit 'C' clips to hinge pins.
$% 76.28.02.99 3. Position check strap to 'B' post and secure with
new roll pin.
Remove 4. Feed door harness through 'B' post and
1. Release 'B' post lower trim casing and position connect multiplugs.
aside. 5. Connect harness sleeve to 'B' post and door.
+ INTERIOR TRIM COMPONENTS, 6. Fit 'B' post lower trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - lower - 'B' post.
REPAIRS, Trim casing - lower - 'B' post.
7. Check door for flush fit to adjacent panels and
door edges for equal gap. If adjustment is
necessary:
a Open door.
b Place a wooden block on jack and position
jack to support door lower edge.
c Loosen 4 bolts securing hinges to door.
d Loosen 2 Torx bolts securing door latch
striker.
e Use jack to assist with door alignment.
f Tighten hinge bolts.
g Remove jack, close door and check for
correct alignment.
h When alignment is correct, tighten door
hinge bolts to 30 Nm (22 lbf.ft).
i Adjust door latch striker and tighten Torx
bolts to 26 Nm (19 lbf.ft).

2. Release multiplugs from within 'B' post and

disconnect.
3. Release harness sleeve and pull through 'B'
post.
4. Remove roll pin from check strap and discard.
5. Release check strap from 'B' post.
6. Remove 2 'C' clips securing door to each hinge.
7. With assistance raise and remove door.

76-1-2 REPAIRS
 DOORS

Door - tail

$% 76.28.19.99

Remove
1. Remove spare wheel from tail door.
2. Remove tail door trim casing.
+ DOORS, REPAIRS, Trim casing - tail
door.
3. Carefully release water shedder from tail door.

14. Release 3 clips securing harness to tail door.

15. Release harness sleeve from door outer edge
and feed harness and washer tube through
door.
16. Remove spring clip securing check strap to tail
door aperture and collect washer.

4. Disconnect multiplug from door latch.

5. Disconnect multiplug from rear wiper motor.
6. Disconnect 2 Lucars from Heated Rear
Window (HRW).
7. Disconnect multiplug from number plate lamp.
8. Remove 2 screws securing Centre High
Mounted Stop Lamp (CHMSL) cover to tail door
glass.
9. Remove CHMSL cover.
10. Disconnect 2 Lucars from CHMSL.
11. Attach draw string to CHMSL wires and draw
wires through tail door. Disconnect draw string
from wires.
12. Tape draw string in tail door to retain its
position.
13. Release washer tube from rear of wiper arm.

17. Mark position of hinges.

18. Support the tail door on a jack, using a block of
wood to protect the door.

REPAIRS 76-1-3
DOORS
19. Remove 6 bolts securing tail door hinges to
body and, with assistance, remove tail door. Glass - front or rear door
Refit $% 76.31.01
1. Support the tail door on a jack, using a block of
wood to protect the door. Remove
2. With assistance position door. Fit securing 1. Remove door trim casing.
bolts but do not tighten at this stage.
3. Fit washer and spring clip securing check strap
+ DOORS, REPAIRS, Trim casing -
front door.
to aperture.
4. Adjust position of tail door in relation to
+ DOORS, REPAIRS, Trim casing -
rear door.
aperture, ensuring gaps around all 4 edges 2. Carefully release water shedder from door.
are consistent, and door closes cleanly onto 3. Front door glass only: Remove exterior door
dove tail. mirror.
5. When tail door is correctly adjusted, tighten tail
door hinge bolts to 34 Nm (25 lbf.ft).
+ EXTERIOR FITTINGS, REPAIRS,
Mirror - exterior - electric.
6. Feed harness and washer tube through outer 4. Remove inner waist seal.
edge of door and connect harness sleeve to
door.
7. Secure harness to tail door with clips.
8. Connect washer tube to rear of wiper arm.
9. Remove tape from draw string and secure to
CHMSL wires.
10. Draw wires through tail door and connect
Lucars to CHMSL.
11. Fit CHMSL cover and secure with screws.
12. Connect multiplug of number plate lamp.
13. Connect Lucars to HRW.
14. Connect multiplug to rear wiper motor.
15. Connect multiplug to door latch.
16. Fit water shedder to door.
17. Fit tail door trim casing.
+ DOORS, REPAIRS, Trim casing - tail
door.
18. Fit spare wheel to tail door.

Front door shown, rear door similar

5. Remove 2 clips securing ends of outer waist

seal.
6. Remove outer waist seal.
7. Remove 2 bolts securing glass to regulator. If
necessary, lower glass to access bolts.
8. Remove bolts securing frame to door.
9. Remove door frame complete with glass.
10. Slide out and remove glass from frame.

76-1-4 REPAIRS
 DOORS
Refit
1. Fit glass to frame. Quarter light
2. Position frame to door and tighten bolts
securing front door frame to 10 Nm (7 lbf.ft) and $% 76.31.31
bolts securing rear door frame to 22 Nm (16
lbf.ft). Remove
3. Secure regulator to glass with bolts and tighten 1. Remove rear door glass.
to 6 Nm (4.4 lbf.ft).
4. Fit inner and outer waist seal and secure with
+ DOORS, REPAIRS, Glass - front or
rear door.
clips.
5. Front door glass only: Fit exterior door mirror.
+ EXTERIOR FITTINGS, REPAIRS,
Mirror - exterior - electric.
6. Fit water shedder to door.
7. Fit door trim casing.
+ DOORS, REPAIRS, Trim casing -
front door.
+ DOORS, REPAIRS, Trim casing -
rear door.

2. Remove 2 bolts securing quarter light glass to

frame.
3. Remove quarter light glass from frame.

Refit
1. Fit quarter light glass to frame.
2. Fit bolts securing quarter light glass to frame
and tighten to 10 Nm (7 lbf.ft).
3. Fit rear door glass.
+ DOORS, REPAIRS, Glass - front or
rear door.

REPAIRS 76-1-5
DOORS

Regulator and motor - front and rear

door glass

$% 76.31.45

Remove
1. Remove door trim casing.
+ DOORS, REPAIRS, Trim casing -
front door.
+ DOORS, REPAIRS, Trim casing -
rear door.
2. Carefully release water shedder from door.

9. Remove 3 Torx screws securing glass lift

motor to regulator and remove motor.

Refit
1. Clean mating faces of regulator and motor.
2. Fit glass lift motor to regulator and tighten 3
Torx screws to 5 Nm (3.7 lbf.ft).
3. Position regulator in door. Fit bolts securing
regulator to door and tighten to 6 Nm (4.4
lbf.ft).
4. Connect multiplug to glass lift motor.
5. Remove wedge holding glass and position
glass to regulator.
6. Secure glass to regulator with bolts and tighten
to 6 Nm (4.4 lbf.ft).
7. Fit water shedder to door.
8. Fit door trim casing.
+ DOORS, REPAIRS, Trim casing -
front door.
+ DOORS, REPAIRS, Trim casing -
rear door.

3. Lower glass and remove 2 bolts securing door

glass to regulator.
4. Raise glass and secure with a suitable wedge.
5. Disconnect multiplug from glass lift motor.
6. Front door: Remove 6 bolts securing glass
regulator assembly to door.
7. Rear door: Remove 4 bolts securing glass
regulator assembly to door.
8. Manoeuvre regulator through access hole at
bottom of the door.

76-1-6 REPAIRS
 DOORS

Trim casing - front door

$% 76.34.01.99

Remove

1. Remove 2 screws securing hand rail to door.

2. Remove screw securing door handle
escutcheon to door. 6. If fitted, disconnect multiplug from upper door
3. Remove escutcheon. speaker.
4. Remove 4 screws securing pocket to door. 7. Disconnect multiplug from lower door speaker.
5. Carefully release 10 clips securing trim casing 8. Remove trim casing from door.
to door.
Refit
1. Position trim casing to door and connect door
speaker multiplug(s).
2. Secure trim casing to door with clips.
3. Fit escutcheon to door handle and secure with
screw.
4. Fit hand rail to door and secure with screws.
5. Fit pocket to door and secure with screws.

REPAIRS 76-1-7