Section 1A'

BODY 1A-1
SECTION 1A'
BODY
CONTENTS OF THIS SECTION
Subject Page
GENERAL INFORMATION ..................................... 1A-1
UNDERBODY ............................................................ 1A·7
FRONT END ............................................................. 1A-17
REAR COMPARTMENT LID & TAIL GATE ....... 1A-29
FRONT & REAR DOOR ASSEMBLIES ............... 1A-43
STATIONARY GLASS............................................. 1A-67
SEATS & SEAT BELT ASSEMBLIES .................. 1A-103
HEADLINING AND REAR END TRIM ................. 1A-121
EXTERIOR ORNAMENTATION............................. 1A-137
SPECIAL TOOLS ..................................................... 1A-154
GENERAL INFORMATION
INDEX
Ref. Subject Page Ref. Subject Page I
1 GENERAL DESCRIPTION .............................. 1A·1 2.5 METAL REPLACEMENT PARTS
2 SERVICE NOTES ............................................. 1A-2 FINISHING ......................................................... 1A 5
2.1 BODY SHELL PARTS REPLACEMENT....... 1A·2 2.6 BODY LUBRICATION ..................................... ·
1A-5
2.2 ANTI-CORROSIVE TREATMENT .................. 1A-3 Parts Readily Accessible .................... 1A-5 • :
2.3 WATER AND DUST LEAK DIAGNOSIS...... 1A·3 Parts Concealed Necessitating 11
I
2.4 LOCK CYLINDERS AND KEYS .................... 1A-4 Disassembly............................................ 1A-6 ·
1. GENERAL DESCRIPTION
This section contains descriptions and procedures for interior and exterior body service operations for 'SL', Berlina and
Calais 'VL' Series Models. The completely restyled front end consists of new sheetmetal bolt-on components attached to
an integral body frame construction.
The new front end panel houses homofocal headlamps on all models with remote controlled headlamp part covers
featured on Calais models.
A new bonded windshield using installation procedures similar to those employed on the 'J' Series Camira is introduced..
Exterior mouldings, badges and nameplates are new.
The Calais interior features new door and seat trim designs and materials. On all models the method for retaining the
front end of the headlining has been revised.
Also new are the instrument panel facia, pad, housing and switches, radio facia and graphics, and a modular designed
transmission console.
1A-2 BODY
2. SERVICE NOTES
CAUTION: As a sound deadening medium, a small SIDE OUTER
volume of polyurethane foam is installed into the upper ACCESS OPENING FOR. EXT. PANEL
section of the rear body pillars of VL Series sedans, as POLYURETHANE FOAM
illustrated in the shaded areas in Fig. 1A-1. During QUARTER INNER ]
normal service operations, there is no risk associated PP E R R E IN CE E
with its use. However, when polyurethane is subjected to : :
: ;
high temperatures such as during welding or naked flame �
cutting, this material can release black pungent fumes.
During repair of the body structure involving high heat '\::,;C·��,,
application, appropriate precautions against fume inhala SIDE INNER EXT. PANEL
tion such as the wearing of respirators, forced ventilation,
etc., are mandatory. Whenever possible, such repairs
should be carried out without the use of high temperature
producing equipment.
Figure 1A-1
IMPORTANT: Whenever items such as body side

mouldings, Dealer name plates, mud/splash guards, etc.,
which require piercing of sheet metal panels are added to
a vehicle after it has been manufactured, a possibility
exists for sheet metal corrosion to occur in areas where
the metal has been pierced, as well as other areas
affected by water entry at the point of piercing. Abrasion
of the painted or treated surfaces by the 'added-on'
material may contribute to corrosion and unsightly
appearances.
The reliability and performance of 'add-on' equipment
installations must become the responsibility of the maker
and the installer (Dealer or vehicle owner). For this
reason, you should evaluate the procedures used in your
)
Dealership (and outside sublet shops) to assure that
proper steps are taken to provide appropriate sheet metal
corrosion protection to offset any adverse effects of
'add-on' equipment.
2.1 BODY SHELL PARTS

REPLACEMENT
When replacing or repairing a part or sub-assembly, care
must be taken to ensure that correct alignment and
strength of unit as a whole is maintained. In some
instances, major damage to the body or frame can be
more effectively and economically repaired by replacing a
part or sub-assembly with a new one, rather than
repairing the damaged part.
Spot welding is used extensively for joining panels
together, particularly around the flanged edges of dash
panel, windshield and back window openings, along
edges of rocker panels and lower edge of the rear body.
When replacing a section that is normally attached by
this method and spot-welding equipment is not available,
or the location of the parts restricts access, the part or
assembly should be attached by the welding method
known as 'plug welding', which is as follows :
1. Remove the damaged part by cutting through the
spot welds between the panels with a thin-edged
chisel or by drilling the spot welds.
2. Drill 5 mm diameter holes in either the new or
mating part to correspond with the spacing and
location of the original spot welds. (Parts to be
drilled are determined by accessibility for the follow
ing operations).
3. Clamp the new part in position and gas or arc weld
the two parts together through each hole, finally
dressing off any high spots on exposed surfaces.
i r,
BODY 1A-3
When replacing parts such as roof panels, rear quarter or

rocker panels; where a butt or overlap weld is required,
the joint of the panels must be formed below the normal
contour. This allows for filling over the join and eliminates
/�-'\ the possible reduction of sheet steel thickness following
\ ,) the necessary buffing or grinding of a normal welding
operation.
IMPORTANT: Following replacement or repair of body
components, it is essential that effective rust proofing
techniques, as outlined in the following paragraphs, be
observed.
2.2 ANTI-CORROSIVE TREATMENT

Precoated and galvanised steel is used extensively for
various body panels for increased corrosion protection of
the body.
Body panels such as the door, tail gate and rear
compartment lid outer panels are precoated on the inner
surface of the metal to improve corrosion protection.
Other body structure members have complete double
sided galvanised protection.
In addition, a rust preventative material is sprayed after
paint application to areas such as interior surfaces of
doors, etc.
Any repair or replacement of panels, assemblies, etc.,
that disturb this anti-corrosive treatment must be resealed
and should be included as part of the repair or
replacement operation.
Anti-corrosive compounds used for repairs should be light
bodied materials designed to penetrate between metal
to-metal surfaces such as pinch weld flanges and integral
panel attaching points.
All bare metal surfaces must be treated with metal
(
\
\ conditioner and primed. These operations need to be
carried out prior to the application of sealers, waxes and
sound deadeners. Attaching points of new replacement
panels should be resealed. The hemming flanges of
replacement doors, tail gates and rear compartment lids
will require resealing.
Open joins which require bridging of sealer to close a
gap should be sealed with a heavy bodied caulking
material.
When colour application is required to restore repaired
areas to original appearance, conventional refinishing
preparation, undercoat build-up and colour application
techniques should be employed.
When deadeners are disturbed during damage repair, or
a panel has been replaced, the deadener material must
be replaced with an equivalent material. The location and
pattern for replacement material can be determined by
observing the original deadener application outlines.
IMPORTANT: Follow label directions for materials
selected.
2.3 WATER AND DUST LEAK

DIAGNOSIS
Diagnosis of body leaks are complicated by the fact that
the appearance of water at one point can be caused by
seepage through any one or more of many possible
locations. As an example of this indirect entry, the cause
of wet front floor coverings may be due ·to water entering
past the door weatherstrip, through the door inner panel,
between the windshield and its adhesive compound or
through any one of the joins in the floor panel, ventilator
or dash panels, therefore, point or points of water or dust
entry must be established before effective resealing can
be carried out.
1A-4 BODY
A comprehensive coverage for fixed glass water leak

diagnosis and testing is included in 'Stationary Glass' in
this Section.
2.4 LOCK CYLINDERS AND KEYS

The two key locking system on 'VL' Series includes a
plastic headed primary key which operates all locks on
the vehicle. An all metal service key only operates the
doors, and ignition.
The key identification number is stamped on the heads of
both keys (refer Fig. 1 A-2). On the service key, the
identification number is stamped on the knock-out section
of the key. This should be removed from the key by the
owner and secreted for safe keeping. MADE BY
LANE AMAL.
HARDWARE CO.
AUST.
BRIGGS & STRATTON
USA
1--
V
,)I
Figure 1A-2
If the key is lost and no record of the key number is

available, this number can be found on the white plastic
locking lever located on the end of the lock cylinder
( )
(refer Fig. 1 A-3) in the driver's door. ASSEMBLY
Figure 1A-3
To view this number necessitates removal of a door lock

security bracket (refer Front and Rear Door Assemblies,
in this Section). A lead light inside the rear upper part of
the door will reveal the number on the lock cylinder lever.
When the key number has been determined, GMH
Dealers will be able to provide the six bitting depth
numbers necessary to cut the new key.
Key blanks for the primary and service keys are available
from GM P&A.
BODY 1A-5
The Dominion Lock 'Exacta' key cutting machine fitted

with existing 'V' car key cutting attachments, are desig
ned to cut keys for the 'VL' Series.
/- -------\
\ ) 2.5 METAL REPLACEMENT PARTS
FINISHING
Metal service replacement parts (or assemblies) are
painted with a black, 'high-bake' factory primer. For
proper adhesion of colour coats in service, the following
refinish steps are necessary.
1. Clean part with a wax and grease removing solvent
such as Prepsol.
2. Scuff-sand panel lightly with wet or dry number 400
paper and water. Avoid cut-throughs. Reclean part,
then apply sealer to entire part.
3. If factory primer coat has been cut through, apply
metal conditioner to the exposed bare metal. Follow
directions on container label.
4. Apply primer-surfacer to entire part; allow to dry
thoroughly before sanding.
5. Sand primer-surfacer using wet or dry number 400
paper and water. Do not sand sealer.
6. Re-clean part.
7. Apply colour coats to parts.
8. Follow direction on container label for drying time
before compounding.
9. Compound part by hand or with power equipment.
10. Nonsealing polish may be applied after rub-out if
desired. Waxes, however, should NOT be applied
until the paint finish has aged for at least two
months.
)
2.6 BODY LUBRICATION
The moving mechanical parts of the body which have
metal to metal contact are lubricated at assembly.
Operating conditions, whether normal or otherwise, de
termine the effective life of the lubricant and for this
reason, lubrication in service is important.
Equally important is the type of lubricant to be used and
for your guidance we list locations and recommended
lubricants.
WARNING: CARELESS OR EXCESSIVE APPLICATION
OF BODY LUBRICANTS CAN RESULT IN STAINING
OF PAINT FINISH, INTERIOR TRIM OR DAMAGE TO
CLOTHING. USE LUBRICANTS SPARINGLY AND RE
MOVE ACCIDENTAL APPLICATION FROM PAINT FIN
ISH IMMEDIATELY.
PARTS READILY ACCESSIBLE

Where practicable, use lithium grease; otherwise use light
oil.
Engine Hood Catch
Engine Hood Lock
Engine Hood Hinge
Door Hinge Sleeves and Check Links
Rear Compartment Lid Hinge
Rear Compartment Lid Lock Mechanism
Rear Seat Hinges (Station Wagon)
Floor Filler Panel Hinge (Station Wagon)
Tail gate Hinge Assembly
Tail gate Locking Mechanism
1A-6 BODY
Lock Cylinders
Apply Powdered Graphite through Key Aperture (do not
oil)
Ignition Lock Cylinder
Rear Compartment Lid Lock Cylinder
Door Lock Cylinder
Instrument Panel Compartment Lock Cylinder
Tail gate Lock Cylinder
Locking Fuel Cap Lock Cylinder
Door Lock Striker Bolt/Fork Bolt

Use Solidoil or equivalent.
Door Lock Striker Bolt
Door Lock Fork Bolt
PARTS CONCEALED NECESSITATING

DISASSEMBLY
Where practicable, use lithium grease, otherwise use light
oil.
Door Window Regulator
Door Window Glass and Cams
Door Lock Mechanism
Door Lock Remote Control
Front Seat Adjuster
Driver's Seat Height Adjuster
Seat Back Locks (Station Wagon)
(
"--/'/
BODY 1A-7
UNDERBODY
INDEX
Ref. Subject Page Ref. Subject Page
1. GENERAL DESCRIPTION .............................. 1A·7 2.5 FLOOR COVERING ASSEMBLY · BODY ... 1A-12
2. SERVICE OPERATIONS................................. 1A·9 Remove.................................................... 1A-12
2.1 UNDERBODY ALIGNMENT ........................... 1A·9 Reinstall................................................... 1A-14
2.2 TRANSMISSION CONSOLE ASSEMBLY .... 1A·9 2.6 FLOOR COVERING ASSEMBLY • REAR
Remove.................................................... 1A·9 COMPARTMENT • SEDAN............................. 1A·14
Reinstall................................................... 1A·11 Description............................................. . 1A-14
2.3 SHROUD LOWER TRIM ASSEMBLY........... 1A·11 2.7 CARPET ASSEMBLY • LOAD
Remove.................................................... 1A·11 COMPARTMENT • STATION WAGON ........ 1A·15
Reinstall................................................... 1A·11 Description.............................................. 1A-15
2.4 ROCKER PANEL COVER · FRONT AND
REAR .................................................................. 1A·12
Remove.................................................... 1A-12
Reinstall................................................... 1A·12
The underbody of the VL Series has been modified to accomodate the catalytic converter, new power trains and the
revised brake and fuel lines and front seat mountings.
The revised underbody dimensions and hoist pad locations for the VL Series, are illustrated in Fig. 1 A-4.
The new modular designed VL transmission consoles feature various assemblies such as auto/manual transmission
controls and switch assemblies for electrically controlled door window regulators, depending on the particular model and
option application.
(
\_ __ j
.....
TRANSMISSION MOUNTING* UNDERBODY DIMENSIONS & HOIST LOCATIONS
800.5 TO TRANS. CENTRE MOUNTING HOLE RH
822.5 TO TRANS. CENTRE MOUNTING HOLE LH m
0
TRANSMISSION MOUNTING C
73 FROM CENTRE HOLE RH -<
130 FROM CENTRE HOLE LH
l188��,-��
t4------------2354.2---+--------11.&-4-
t 877 1
TRAILING ARM
UPPER MOUNTING
I
0 <(
N
r-- en�
- - --- -
·,1gc, --
,
en -�
-l r·-- (
0
)-��
1�1 : ,,.., ' . 'J.i!;.;;s 30'
HOIST PAD LOCATION
TRAILING ARM
ALL DIMENSIONS ARE METRIC LOWER MOUNTING
TOLERANCE ON ALL
DIMENSIONS± 1.0 mm
• PAINT DRAIN HOLES
Figure 1A-4
BODY 1A-9
2. SERVICE OPERATIONS
2.1 UNDERBODY ALIGNMENT
,,,,---� Correct underbody alignment is essential, as any mis-
( '. alignment of the underbody can adversely effect sus
pension, fitment of doors, engine hood, tail gate or rear
compartment lid. The underbody should therefore be
aligned to within 1.0 mm of dimensions specified in
Fig. 1 A-4. These dimensions should be accurately chec
ked with a tram gauge consisting of a parallel bar or rod,
fitted with two adjustable trammels, capable of gauging
all underbody dimensions specified.
In preparing for an underbody alignment check, place the
vehicle on a level surface with the weight of the body
supported at wheel locations.
2.2 TRANSMISSION CONSOLE

ASSEMBLY
REMOVE
1. Disconnect battery ground cable.
2. On manual transmissions, unscrew the gear shift
knob illustrated in Fig. 1 A-5, in an anti-clockwise KNOB�
direction. R
��; GEA SHIFT
R
�
/�/- l
. ":-,/ »
�/ : COVERTRANS.
/ � ./
CONTROL
I
RETAINER
��---GEARSHIFT
LEVER BOOT
Figure 1A-5
1A-10 BODY
3. For automatic transmissions, carefully prise the front
of the cap assembly, illustrated in Fig. 1A-6, Section CAP ASM CONSOLE
A-A, upwards, then forward to release. Disconnect
electrical connector. Turn assembly through 90 de
grees then remove the cap assembly off the selector -- "\
lever 'T' handle. }
SECTION A-A
Figure 1A-6
4. Remove the caps covering the console attaching

screws illustrated in Fig. 1A-7, then remove the
screws.
CAP ASM CONSOLE KNOB�

SWITCH ASM. ELECTRIC
WINDOW REGULATORS.
� BOOT GEARSHIFT
LEVER
)
SCREW - 3 PLACES
RETAINER
GEARSHIFT
CONSOLE ASM.
AUTOMATIC TRANSMISSION
rV.
SECTION C-C SECTION A-A
SECTION B-B
Figure 1A-7
5. Remove the park brake lever cover then, where

fitted, carefully prise out the window regulator switch
assembly. Turn the switch assembly on its side and
feed it through the aperture in the console, sim
ultaneously raising the rear end of the console.
BODY 1A-11
6. Disengage the electrical connectors attached to the

console, then ease the console rearwards, out of the
vehicle.
(- ) REINSTALL
Reverse removal operations.
2.3 SHROUD LOWER TRIM ASSEMBLY
REMOVE
1. Prise front end of rocker panel cover illustrated in
Fig. 1 A-8, Section B-B, from rocker panel, then ease
lower front end of finishing lace illustrated in Fig. 1 A-
8, Sections C-C and F-F, from door opening
pinchweld flange.
2. On the right hand shroud lower trim assembly, use a
fabricated trim clip removal tool (refer 'Special Tools'
in this Section) located between the shroud lower
trim and shroud panel, directly under the fastener
head illustrated in Fig. 1A-8, Section G-G, then
carefully prise fastener from the shroud panel,
removing trim.
3. On left hand shroud lower trim assembly, remove the
screw illustrated in Fig. 1 A-8, Section A-A, retaining
the shroud trim and E.C.C.S. module bracket, remov
ing the shroud lower trim assembly.
REINSTALL
SECTION F-F
SECTION 8-8
SECTION C-C
l)
SECTION 0-0 SECTION E-E
Figure 1A-8
1A-12 BODY
2.4 ROCKER PANEL COVER - FRONT

AND REAR
REMOVE
Using a wide bladed prising tool positioned between the
outer edge of the cover illustrated in Fig. 1A-9, Section
A-A and rocker panel, carefully prise the cover from the FRONT ROCKER
PANEL COVER
door opening lower pinchweld flange.
SECTION A-A
� ; .:::::::_J
SECTION B-B SECTION C-C
Figure 1A-9
REINSTALL
Locate the front cover over the door opening lower
pinchweld flange, ensuring that ends of cover overlap
ends of door opening finishing lace, then using the hand
or a rubber mallet, tap top of cover until it completely
engages retaining flange.
NOTE: On rear covers, locate the front end of the rear
cover so that it butts against the rear end of the front
seat belt retractor cover prior to tapping the cover into
position.
2.5 FLOOR COVERING ASSEMBLY -

BODY
REMOVE
2. Remove front and rear rocker panel covers (refer
2.4) and shroud lower trim assemblies (refer 2.3) in
this Section.
3. Remove transmission console (refer 2.2 in this
Section).
4. Remove the front seat assemblies and rear seat
cushion assembly (refer 'Seat and Seat Belt
Assemblies' in this Section).
5. Carefully prise out the front seat belt retractor
covers, then remove the front seat belt lower
attachment bolts illustrated in Fig. 1A-10.
BODY 1A-13
RETRACTOR
SEAT BELT HOUSING
RECTRACTOR COVER
MAIN WIRING HARNESS
DOOR HARNESS OVER

BRACKET AND UNDER
CARPET
w CAP
�� SEAL SEAT BELT RETRACTOR INNER CAP

SECTION E-E TO CENTRE PILLAR INNER PANEL R & LH
WITH NON HARDENING SEALER AROUND SEAL WITH NON-
HARDENING SEALER
&
ENTIRE PERIMETER.
35-50Nm SECTION C-C
Figure 1A-1O
6. Lift covers and remove bolts securing seat belt

buckle assemblies to transmission tunnel then re
move buckle assemblies.
7. Remove the footrest pad illustrated in Fig. 1A-11,
Section A-A. FOOTREST
RUBBER PAD
. .
.
I
1
\
;_-�-:s��.-- l
;1/J
1
A /
� ---..._____/ \V!j/jA ·,
ENSURE RUBBER PAD IS \ : --.:.______ \
INSTALLED FIRMLY ON (/! � :
BRACKET SECURING -. 0
; ---------- -
J, . .·
CARPET �:HO,WN
. · . )
. .
. /
SECTION
--...,__I-
�
A-A
�//If
Figure 1A-11
1A-14 BODY
8. Using a fabricated trim clip removal tool (refer 'Special

Tools', in this Section)located between the edge of
carpet and rocker panel and directly under the head of
carpet retainer, prise retainer from the rocker panel (refer
Fig. 1 A-12, Section B-8) then remove the floor covering.
rr==�"
lli .-- ·,
j CARPET /
RETAINER
(2 PLACES)
SECTION 8-8
Figure 1A-12
REINSTALL
Reverse removal operations noting the following:
Tighten front seat belt attaching bolts and seat belt
buckle assembly attaching bolts to 35-50 Nm.
NOTE: Separate front and rear floor coverings are
available from G M P&A Distributors as Service
Replacements.
\
2.6 FLOOR COVERING ASSEMBLY -
REAR COMPARTMENT - SEDAN
DESCRIPTION
On 'SL' and Berlina models, the right, rear side of the
carpet is retained in position with Velcro tape attached to
the underside of the carpet and to corresponding
locations on the compartment floor. The opposite side of
the carpet is held in position with the car jack.
On the Calais, Velcro tape retains the carpet at five
locations, refer Fig. 1 A-13.
FLOOR CARPET
Figure 1A-13
Removal and installation of the carpet assembly involves

the lifting of the front and rear of the carpet during
removal and the correct location of the carpe1--edges and
the firm pressing down on the carpet at the Velcro tape
locations during installation.
BODY 1A-15
2.7 CARPET ASSEMBL V • LOAD

COMPARTMENT • STATION WAGON
DESCRIPTION
The carpet assembly covering the load compartment on
station wagons is retained with Velcro tape attached to
the underside of the carpet and to corresponding
locations on the load compartment floor.
Fig. 1 A-14, Views 'A' and 'B' illustrate the three locations
at the front of the carpet and the four at the rear.
Removal and installation of the carpet assembly involves
the lifting of the front and rear of the carpet during
removal and the correct location of carpet edges and the
firm pressing down on the carpet at the Velcro tape
locations during installation.
ADHESIVE BACKED VELCRO TAPE.

TO BE PRESSED INTO PLACE DURING
INSTALLATION OF CARPET (3 PLACES).�
ADHESIVE BACKED VELCRO TAPE.
TO BE PRESSED INTO PLACE DURING
INSTALLATION OF CARPET (4 PLACES).
r., ... ) -
. -�
VIEW�
CARPET ASSEMBLY - LOAD COMPARTMENT
Figure 1A-14
\ ,
"-___ _/
1A-16 BODY
NOTES
,r, •
BODY 1A-17
FRONT END
INDEX
1. SERVICE OPERATIONS ................................. 1A-17 1.3 INSTRUMENT PANEL COMPARTMENT..... 1A-22
1.1 INSTRUMENT PANEL LOWER TRIM Remove.................................................... 1A-22
ASSEMBLY· RIGHT AND LEFT SIDE........ 1A-17 Reinstall................................................... 1A-22
Remove.................................................... 1A-17 1.4 INSTRUMENT PANEL LOWER· LEFT
Reinstall................................................... 1A-18 SIDE.................................................................... 1A-23
1.2 INSTRUMENT PANEL LOWER· RIGHT Remove.................................................... 1A-23
SIDE.................................................................... 1A-19 Reinstall................................................... 1A-26
Remove............................. ·...................... 1A-19 1.5 INSTRUMENT PANEL PAD ASSEMBLY ..... 1A-26
Reinstall................................................... 1A-22 Remove.................................................... 1A-26
Reinstall................................................... 1A-27
CAUTION: To avoid damage when servicing instrument
panels, frames, instrument clusters, etc., it is essential to
handle these components with the utmost care.
1.1 INSTRUMENT PANEL LOWER TRIM

ASSEMBLV - RIGHT AND LEFT SIDE
REMOVE
1 . From under the instrument panel and using a
pre-fabricated trim clip removal tool (refer Special
Tools in this Section), carefully prise out the faste
ners and on the right side, the clip securing the trim
assembly to the instrument panel lower (refer
Fig. 1 A-15, Sections A-A, B-B and E-E).
NOTE: Removal of the right side lower trim necessitates
disengagement of the adjustable strap partially securing
the trim to the steering column. (Refer Fig. 1 A-15,
Section D-D).
1A-18 BODY
FASTENER
- 3 PLACES R/SIDE
- 3 PLACES L/SIDE
LOWER PART OF
INSTRUMENT
PANEL
ACCELERATOR PEDAL
SUPPORT CAP
CLIP
TRIM - INSTRUMENT
ENSURE TRIM BOARD IS PANEL LOWER R/S
ASSEMBLED IN ACCELERATOR
PEDAL SUPPORT CAP AS SHOWN
TRIM ASM.
SIDE PART OF
LOWER RETAIN FRONT EDGE OF INSTRUMENT
EXCESS STRAP TO BE PANEL LOWER TRIM RIGHT SIDE TO
� TUCKED AWAY OR TRIMMED STEERING COLUMN DASH PANEL SEAL
SECTION D-D WITH ADJUSTABLE STRAP.
SECTION E-E
Figure 1A-15
REINSTALL
Reverse removal operations ensuring that:
1. The inner edges of both trim assemblies are located
above the side edges of the heater assembly, as
illustrated in Fig. 1A-15, Section C-C.
2. The leading edge of the left side trim assembly is
located beneath the dash panel bracket.
3. The leading edge of the right side trim assembly is
located in the accelerator pedal support cap, as
illustrated in Fig. 1A-15, Section B-B.
\ )
BODY 1A-19
1.2 INSTRUMENT PANEL LOWER -

RIGHT SIDE
REMOVE
2. Remove the right side instrument panel lower trim
(refer 1.1).
3. Remove the steering column upper and lower covers
illustrated in Fig. 1A-16, from the steering column.
ffi 3.6-4.6Nm
CJ Figure 1 A-16
4. If cruise control is fitted, use a small diameter pin

punch or drill bit inserted through the hole in the
inner wall of the instrument location cover, depress
the retaining tang and remove switch. Disengage the
electrical connector from switch.
If cruise control is not fitted, remove the two cover
plates from the instrument location cover using a fine
bladed screwdriver. Refer Fig. 1A-17 for details.
5. Remove the screws securing the touch control
satelite switches to the instrument location cover,
then disengage the switches from the instrument
location cover retaining lugs illustrated in Fig. 1A-17,
Section 8-8.
i
WINDSHIELD WIPER/WASHER
......
B OUCH CONTROL SWITCH ASM.
TAILGATE WINDOW WIPER/WASHER N
DEMIST AND POWER ANTENNA \
0
TOUCH CONTROL SWITCH ASM.
INSTRUMENT LOCATION m
COVER ASSEMB 0
� C
7
�-------
BEFORE INSTALLING SWITCHES FEED SWITCH

-----CONNECTORS THROUGH APPROPRIATE
OPENINGS IN COVER ASSEMBLY. FOR
CONTINUATION OF WIRING REFER SECTION 12.
INSERT PIN PUNCH IN HOLE

TO RELEASE SWITCH REMOVE
SECURELY FIT SWITCH TO LUG
COVER/$ BY HAND.
BEFORE INSTALLING SCREW
SECTION A-A
SECTION B-B
SECTION C-C
TYPICAL FOR COVER PLATE
Figure 1A-17
BODY 1A-21
6. Remove instrument location cover assembly retaining

screws and lift off cover assembly, refer Fig. 1 A-18,
disengaging the centre nozzle vent from the centre
air outlet duct assembly.
Figure 1A-18
7. Using a fine bladed screwdriver, carefully prise out

the upper and lower inserts from the right side outer
air outlet assembly illustrated in Fig. 1 A-19. Remove
the screws securing the outlet assembly and the
speaker grille to the instrument panel illustrated in
Fig. 1 A-19, removing the assembly and grille.
SCREW
(2 PLACES)
HOUSING ASM.
AIR OUTLET
VIEW[ID
Figure 1A-19
1A-22 BODY
8. Remove the combined instrument assembly illustr

ated in Fig. 1A-20, attached to the instrument panel SCREW
brackets. (4 PLACES)�'
o
I
Figure 1A-20
9. Using a fine bladed screwdriver positioned under the

edge of the exterior rear view mirror switch assembly
(where fitted) carefully prise assembly out of the
aperture in the right side instrument panel (refer
Fig. 1A-19). Disengage electrical connector, removing
switch assembly.
10. Remove the fuse cover, then the screws securing
the right side instrument panel lower illustrated in
Fig. 1 A-19, Section A-A, to the instrument panel.
11. Disengage the electrical connector from the dimmer
control, then remove the right side instrument panel
lower.
12. Remove the screws illustrated in Fig. 1A-19, View
'B', securing the dimmer control assembly to the
right side instrument panel lower, removing the
assembly.
\
REINSTALL
1.3 INSTRUMENT PANEL

COMPARTMENT
REMOVE
With the instrument panel compartment open and with
the blade of a screwdriver located between the head of
the hinge pin illustrated in Fig. 1 A-21, prise out the pin,
into the compartment. Lower the right side of the
compartment to remove.
REINSTALL
INSTRUMENT PANEL
COMPARTMENT
Figure 1A-21
,-
BODY 1A-23
1.4 INSTRUMENT PANEL LOWER •

LEFT SIDE
REMOVE
2. Remove the instrument panel compartment (refer
1.3).
3. On Berlina and Calais models, remove the transmis
sion console (refer Underbody Section, 2.2).
4. Remove the left side instrument panel lower trim
(refer 1.1, Front End Section).
5. Remove the left side shroud lower trim assembly
(refer Underbody Section, 2.3).
6. Remove the left side outer side air outlet assembly
(refer 1.2, Step 7 in this Section).
7. Remove the instrument location cover (refer 1.2,
Steps 4, 5 and 6 in this Section).
8. Remove the heater case cover, instrument panel
lower extension assembly and the heat/vent control
assembly illustrated in Fig. 1 A-22.
NUT
(4 PLACES) EXTENSION I NSTRUMENT
SCREW PANEL LOWER
SECTION A-A
'LOWER EXTENSION
$ FOR WIRING HARNESS CONNECTIONS

REFER SECTION 12
\SCREW $ HEAT/VENT/A /C
\ (2 PLACES) CONTROL ASM.
HEATER CASE COVER
Figure 1A-22
1A-24 BODY
9. Remove the steering column upper covers then,

remove the screws illustrated in Fig. 1A-23, securing
the left side instrument panel lower assembly to the
instrument panel.
INSTRUMENT PANEL
LOWER
SCREW AND
WASHER ASM. ---TIGHTEN LOWER OUTBOARD
MOUNTING SCREW LAST.
FACIA MUST BE FULLY TO
THE RIGHT ENSURING GAP
BETWEEN LEFT HAND END
OF GLOVE COMPARTMENT
AND FACIA IS CONSTANT.
GLOVE BOX TO OPERATE
FREELY WITHOUT ANY
BINDING OR ENDPLAY.
iii [Al
Figure 1A-23
10. Remove the instrument panel pad (refer 1.5 in this

Section) then disengage the left side duct from the
centre air distribution duct (refer Fig. 1A-24). Remove
the centre outlet and duct, then remove the two
screws 'A' securing the radio to the instrument panel
carrier (refer Fig. 1A-25).
11. Remove the screws securing the front mounting
bracket to the radio, illustrated in Fig. 1A-25, View
'B'. Disengage the electrical harness and antenna
connectors, then remove the left side instrument
panel lower assembly.
BODY 1A-25
VIEW [A)
CENTRE AIR
D E MIST DISTRIBUTIO N
DU CT LIS DUC T
AIR O UTL ET
DUCT L/S
D EMIST
DU C T R/S
)
Figure 1A-24
(
\.
RADIO /C A$S ETTE PACKAG E

AM/FM EL EC · TUNE
'S C REW
"(2 PLACES)
REAR M OUNTING FRONT
BRAC KET MO UNTING
BRA C KET
[ru
--
VIEW
BEF O RE INS ERTING RADI O C ECTOR MAIN

WIRING RA O f�� ANTENNA
��/ O NNEC T R
L EAD IN C
Figure 1A-25
1A-26 BODY
12. Fully insert the radio assembly removal tools

No.CMT113, simulataneously into slots on the right
and left on the radio face, as illustrated in Fig. 1A-
25a, which will release the radio assembly.
Figure 1A·25a
13. From behind the sides of the radio face, depress the
spring mechanism, which will release the removal
tools.
These tools, which are released in pairs, are
available from:
Eurovox Australia,
6 University Place,
Clayton North, Victoria, 3168.
REINSTALL
1. Install the radio into the instrument panel lower and
attach the mounting bracket to the front of the radio,
as illustrated in Fig. 1A-25, View 'B'.
2. Attach the electrical and antenna connectors to the
radio, then partially install the instrument panel lower
to the instrument panel with two screws.
3. Using a magnetic cross recess screwdriver located
within the instrument panel centre aperture, install
screws 'A' illustrated in Fig. 1A-25, View 'B', securing
the radio rear mounting bracket to the instrument
panel carrier assembly prior to reversing removal
procedures.
1.5 INSTRUMENT PANEL PAD

ASSEMBLY
REMOVE NUT
1. (2 PLACES)
Disconnect battery ground cable.
2. Using a fine bladed screwdriver, carefully prise out
the upper and lower inserts from within the outer air
outlet assemblies illustrated in Fig. 1A-26. Remove
the screws securing the air outlet assemblies and
speaker covers to the instrument panel, removing the
speaker assemblies and covers.
Figure 1A·26
BODY 1A-27
3. Using a small diameter pin punch or similar tool

inserted through holes in the inner walls of the WINDSHIELD WIPER/WASHER
instrument location cover, release the cover plates or TOUCH CONTROL SWITCH ASM.
the cruise control touch switch assembly, where
fitted. Disengage the electrical connectors, removing INSTRUMENT LOCATION
1
the switches (refer Fig. 1A-27). COVE �SSEMBLY
�
4. Remove the screws securing the touch control
satellite switches to the instrument location cover
then disengage the switches from the instrument
location cover lugs illustrated in Fig. 1A-27.
5. Remove the instrument location cover (refer 1.2
Steps 4, 5 and 6 in this Section).
Figure 1 A-27
6. Remove the combined instrument assembly illustr

ated in Fig. 1A-28, attached to the instrument panel
brackets.
7. Remove the three screw and washer assemblies
securing the rear of the pad assembly to the
instrument panel illustrated in Fig. 1A-28.
8. Remove the cover illustrated in the front centre of
the pad assembly in Fig. 1 A-28, then remove the
three screws and the nut securing the pad assembly
Cl
to the instrument panel. Raise and remove the pad
assembly rearwards.
REINSTALL
..I,
m
0
C
COMBINED INSTRUMENT ASM.
SCREW
VIEW I A! (2 PLACES) (3 PLACES)
Figure 1A-28
/ ·-
_/
BODY 1A-29
REAR COMPARTMENT LID AND TAIL GATE

INDEX
1. SERVICE OPERATIONS ................................. 1A-29 1.9 SWITCH ASSEMBLY - REAR
1.1 REAR COMPARTMENT LID ASSEMBLY - COMPARTMENT LID LAMP - SEDAN ........ 1A-36
SEDAN ............................................................... 1A-29 Remove.................................................... 1A-36
Remove.................................................... 1A-29 Reinstall ................................................... 1A-36
Reinstall................................................... 1A-29 1.10 TRIM PANEL - TAIL GATE - STATION
Adjust....................................................... 1A-29 WAGON ............................................................. 1A-36
1.2 TORQUE ROD - REAR COMPARTMENT Remove.................................................... 1A-36
LID - SEDAN .................................................... 1A-30 Reinstall................................................... 1A-36
Remove.................................................... 1A-30 1.11 GAS STRUT ASSEMBLY - TAIL GATE -
Reinstall................................................... 1A-31 STATION WAGON........................................... 1A-37
1.3 LOCK CYLINDER - REAR Remove.................................................... 1A-37
COMPARTMENT LID • SEDAN..................... 1A-31 Reinstall................................................... 1A-37
Remove .................................................... 1A-31 1.12 TAIL GATE ASSEMBLY - STATION
Reinstall...................................... �............ 1A-32 WAGON ............................................................. 1A-37
1.4 LOCK ASSEMBLY - REAR Remove.................................................... 1A-37
COMPARTMENT LID - SEDAN..................... 1A-32 Reinstall................................................... 1A-39
Remove.................................................... 1A-32 1.13 LOCK ASSEMBLY - TAIL GATE -
Reinstall................................................... 1A-32 STATION WAGON ........................................... 1A-40
1.5 SOLENOID ASSEMBLY - REAR Remove·.................................................... 1A-40
COMPARTMENT LID LOCK - SEDAN ........ 1A-32 Reinstall................................................... 1A-40
Remove.................................................... 1A-32 1.14 LOCK STRIKER BOLT - TAIL GATE -
Reinstall................................................... 1A-33 STATION WAGON........................................... 1A-40
1.6 LOCK STRIKER - REAR COMPARTMENT Description.............................................. 1A-40
LID - SEDAN .................................................... 1A-35 1.15 PUSH BUTTON & LOCK CYLINDER
Remove.................................................... 1A-35 ASSEMBLY - TAIL GATE - STATION
Reinstall.............................. .................... 1A-35 WAGON ............................................................. 1A-41
1.7 WEATHERSTRIP ASSEMBLY· REAR Remove.................................................... 1A-41
COMPARTMENT LID OPENING - SEDAN.. 1A-35 Disassemble ........................................... 1A-41
Description.............................................. 1A-35 Reassemble ............................................ 1A-41
1.8 REAR COMPARTMENT LAMP Reinstall................................................... 1A-41
C I
ASSEMBLY - SEDAN ...................................... 1A-35 1.16 WEATHERSTRIP ASSEMBLY - TAIL
Remove.................................................... 1A-35 GATE OPENING - STATION WAGON ......... 1A-42
Reinstall................................................... 1A-35 Description.............................................. 1A-42
1.1 REAR COMPARTMENT LID
ASSEMBLV • SEDAN
REMOVE
1. With the rear compartment lid raised, pencil scribe
location of hinges on the lid inner panel to facilitate
installation.
2. With the lid supported, remove the hinge to lid
attaching bolts, removing the lid assembly.
REINSTALL
ADJUST
Elongated holes in the hinges provide forward and
rearward adjustment of the lid. Vertical height adjustment
at the hinge area of the lid can be achieved as follows:
1A·30 BODY
To raise the lid at the hinge area, place a shim between

the lid inner panel and hinge at the forward attaching bolt
hole location.
NOTE: Following any adjustment of the rear compartment
lid, it is essential that the lid lock striker engages
correctly with the lid lock. Adjust the striker to ensure
positive engagement of the lock and to achieve correct
alignment between the rear compartment lid and adjacent
panels.
1.2 TORQUE ROD· REAR

COMPARTMENT LID • SEDAN
REMOVE
1. Raise and support the rear compartment lid.
2. Remove the right side torque rod by inserting the
small hooks of Tool No. KM125 over the inner end
of the rod, then lever the rod out of the retaining slot
in the centre support bracket illustrated in Fig. 1A-29.
Figure 1A-29
3. Remove the left side torque rod by inserting the

large hooks of Tool No. KM125 over the end of the
rod, then lever the rod out of the retaining slot in the
centre support bracket illustrated in Fig. 1A-30.
NOTE: It is necessary to remove the right side torque rod
prior to removal of the left side.
Figure 1A-30
BODY 1A-31
4. Disengage the outer ends of the rods from holes in

the hinges, then remove them through the side
bracket openings illustrated in Fig. 1A-31.
Figure 1A-31
REINSTALL
Reverse removal operations, ensuring that the left side
torque rod 'X' illustrated in Fig. 1A-32, is installed before
the right side torque rod 'Z'.
Figure 1A-32
1.3 LOCK CYLINDER - REAR

COMPARTMENT LID - SEDAN
.REMOVE
1. Remove the rear compartment lid lock assembly
(refer 1.4 in this Section).
1A·32 BODY
2. Using a screwdriver, prise the lock cylinder retaining

spring away from the lock cylinder housing, then
remove the lock cylinder assembly, illustrated in
Fig. 1A-33.
Figure 1A-33
REINSTALL
1. Install the lock cylind�r assembly into the rear
compartment lid, then with the retaining spring
loaded on the end of Tool No. KM206-01 (refer
Special Tools Section), · press the spring over the
lock cylinder housing until the spring engages behind
the retaining lugs on the housing.
2. Install rear compartment lid lock assembly (refer 1.4
in this Section).
1.4 LOCK ASSEMBLY· REAR

COMPARTMENT LID • SEDAN
REMOVE
With the rear compartment lid raised, remove screws 'A'
securing the lock assembly to the rear compartment lid
A
•
inner panel, as illustrated in Fig. 1A-34, Disengage
solenoid assembly actuating rod (refer Fig. 1A-35, View
'C') then remove the lock assembly.
Figure 1A-34
REINSTALL
1.5 SOLENOID ASSEMBLY· REAR

COMPARTMENT LID LOCK • SEDAN
REMOVE
1. Remove rear compartment lid lock assembly (refer
1.4 in this Section).
BODY 1A-33
2. Remove screws securing lock solenoid assembly to

rear compartment lid (refer Fig. 1 A-35, View 'C').
Disconnect solenoid lead from rear end harness then
remove solenoid assembly.
REINSTALL
Reverse removal operations, observing solenoid actuating
rod adjustment note in Fig. 1 A-35, View 'C'.
C )
)
.....
w
..
m
0
C
LEFT SIDE /
TOROUE ROD RIGHT SIDE__/ {JI 7/�
l
REASSEMBLE RIGHT SIDE ;/
h. �'\ �/ ---�-·--
ROD FIRST
VIEW�
� ·.
"-� - .,- .,
I
LOCK CYLINDER
�:;/-,,;,
' I
·,_11:i . I ,.
' 1r�:i \! , i
RETAINING SPRING
·. ·-S-:_��111))
I
•.
��((::·
SCREW AND � -::.:�)} �"J-=_
� WASHER ASM. '��-�,� '--lf/J, -,- ,, ,
fli-----
VIEW � //
STRIKER ASM. - -........__ -VIEW fE1 [El
L.!=..J
"" . -· '- ..........__ �/ _/
�/�/
ADJUST POSITION OF SOLENOID
/
�� SOLENOID ASM. /. VIEW li]
TO PROVIDE FOR APPROX 2.0 mm
"
�- �' INITIAL FREE TRAVEL
--) )
-�..._'----....._
...... ,' /
�
��". r
/r� �-�
� SCREW AND WASH:;ASM.
�
20.0 - 27.0 Nm
VIEW
.& [Q]
& 3.0-4.0 Nm
18.0 - 24.0 Nm VIEW[g

&
Figure 1A-35
··, ---- ·-".

_
....._ __,,
'-.______/
BODY 1A-35
1.6 LOCK STRIKER - REAR

COMPARTMENT LID - SEDAN
REMOVE
1. With the rear compartment lid raised, pencil scribe
location of the lock striker on the rear end inner
panel to facilitate installation.
2. Remove the screw attaching the lock striker to the
rear end inner panel illustrated in Fig. 1A-35, View
'D' removing the striker.
REINSTALL
NOTE: An elongated hole in the lock striker provides
adjustment for the striker. Following any adjustment of
the striker or rear compartment lid, it is essential that the
lid lock correctly engages the striker.
1.7 WEATHERSTRIP ASSEMBLY - REAR

COMPARTMENT LID OPENING - SEDAN
DESCRIPTION
The one piece rear compartment lid opening weatherstrip
is a bulbous rubber 'U' section fitted with an integral
retaining system. It fits firmly over the upturned flange of
the rear compartment opening. The ends are butt jointed
together with neoprene cement, adjacent to the rear
compartment lid lock striker.
NOTE: When installing the weatherstrip assembly, locate
the longer side of the 'U' section on the outside of the
( rear compartment opening upturned flange.
1.8 REAR COMPARTMENT LAMP

ASSEMBLV - SEDAN
REMOVE ./

LAMP LENS
2. With the rear compartment lid raised and using the
blade of a screwdriver located between the lamp
lens and rear compartment inner panel, carefully
prise the lamp assembly out of the lamp aperture
(refer Fig. 1A-36).
3. Disengage the electrical connector, removing the
lamp assembly.
REINSTALL
Reverse removal operations. REAR COMPARTMENT
LAMP CONNECTORS
Figure 1A-36
1A-36 BODY
1.9 SWITCH ASSEMBLY· REAR

COMPARTMENT LID LAMP • SEDAN
REMOVE
2. With the rear compartment lid raised, remove the
screw securing the switch assembly to the right side
rear quarter reinforcement panel (Fig. 1A-37).
3. Disengage the electrical connector and remove the
switch assembly.
REINSTALL
Figure 1A-37
1.10 TRIM PANEL • TAIL GATE •

STATION WAGON
REMOVE
With the tail gate raised and using a suitable trim clip
removal tool, carefully prise out the fasteners 'Z',
Fig. 1A-38, retaining the trim panel 'A' to the tail gate
inner panel.
REINSTALL
Figure 1A-38
BODY 1A-37
1.11 GAS STRUT ASSEMBLY· TAIL

GATE· STATION WAGON
REMOVE
1. With the tail gate supported in the raised position
and using a thin bladed screwdriver, partly prise out
wedge 'A', Fig. 1A-39, from the cup connecting the
top of the strut to the retaining ball. This will allow
the top of the strut to be pulled off the upper
retainer.
2. Repeat this operation at the lower end of the strut,
removing the strut assembly.
Figure 1 A·39
REINSTALL
() 1.12 TAIL GATE ASSEMBLY· STATION

WAGON
REMOVE
2. Remove the tail gate inner trim panel (refer 1.1O in
this Section).
3. With the tail gate supported, remove the lower
connections of the gas strut assemblies (refer 1.11 in
this Section).
4. From within the tail gate, disconnect the window
demist leads from the tail gate electrical harness
illustrated in Fig. 1A-40, Vie� 'E' then disconnect the
tail gate electrical harness illustrated in Fig. 1A-40,
View 'D'.
5. Disengage the rubber conduit from the top of the tail
gate inner panel, removing the harness though the
conduit aperture (Fig. 1A-40, View 'Cl ...
-,
....
BEND TANG TO ORANGE LEAD
RETAIN HARNESS w
cc,
PINK & LT. BLUE LEADS m
0
,
_____ .-- BULB C
�
�
�,� -=_:_ --. .
-- - • ·'..
� �'I
�,i
BODY HARNESS c: r ��---':.:i'
CONNECTORS ��-. · :
LAMP
� ASM.
GAS OPERATED STRUT

REAR LAMPS HARNESS
CONNECTORS
VIEW [Al
REAR LICENCE LAMP
CONNECTORS
SWITCH & LEAD ASM. REAR
VIEW� LOAD COMPARTMENT LIGHT
HEATED REAR_ WINDOW EARTH CONNECTOR

REAR BUMPER
Y��- ......... REAR WINDOW WIPER

-MOTOR CONNECTOR VIEW [Q]
(LIFTGATE OPEN)
WIPER MOTOR RETAINING () INSTALL WITH TERMINAL CRIMPS

AWAY FROM MOUNTING SURFACE
WASHER AND SCREW
VIEW 00 VIEW�
& 4-5Nm
Figure 1A-40
_/
BODY 1A-39
6. Prise out the window washer nozzle from the top of

the tail gate outer panel, disconnect the nozzle, then
withdraw the washer hose illustrated in Fig. 1 A-41 ,
View 'C' Section A-A, out from the top of the tail
gate inner panel.
7. Pencil scribe location of hinges on top of the tail
gate inner panel, then with the aid of an assistant,
remove the bolts securing the hinges to the top of
the tail gate assembly, removing the assembly.
REINSTALL
Reverse removal operations, ensuring that the tail gate
lock correctly engages the lock striker bolt. If necessary,
adjust the striker bolt to ensure correct engagement with
the tail gate lock and also to ensure correct alignment
between the tail gate and adjacent body panels.
CJ
VIEW[g
ENDGATE WIPER
ARM & BLADE
WASHER HOSE
��
SECTION A-A
ENDGATE IN OPEN POSITION
Figure 1A-41
( \
'----j,
1A-40 BODY
1.13 LOCK ASSEMBLY· TAIL GATE·

STATION WAGON
REMOVE
this Section).
2. From within the tail gate, disengage the push button
to lock connecting rod 'B' Fig. 1A-42, then remove
the screws securing the lock assembly to the tail
gate inner panel, removing the assembly.
Figure 1 A-42
REINSTALL
1.14 LOCK STRIKER BOLT· TAIL

GATE· STATION WAGON
DESCRIPTION
The tail gate lock striker bolt is mounted in a floating,
captive nut in the lower member of the tail gate opening.
This floating nut provides the lock striker bolt with
horizontal, forward, rearward and side to side adjustment.
BODY 1A-41
1.15 PUSH BUTTON & LOCK CYLINDER

ASSEMBLY· TAIL GATE· STATION
WAGON
REMOVE
this Section).
2. From within the tail gate, disengage the push button
to lock connecting rod 'B' Fig. 1A-43.
3. Remove the slotted nut retaining the push button
assembly to the tail gate, removing the assembly.
- ····----.I,
Figure 1A-43
DISASSEMBLE
To disassemble the lock cylinder from the push button
assembly, remove the following:
1. Circlip
2. Lock cylinder
3. Push button housing, removing the lock cylinder.
NOTE: The exterior lift handle is secured to the tail gate
outer panel with screws (refer Fig. 1A-43 View 'C').
These screws are accessible from within the tail gate.
REASSEMBLE
The reassembly of the push button and lock cylinder
assembly should be carried out in the sequence illustr
ated in Fig. 1A-44.
1. Push button housing
2. Seal ring
3. Lock cylinder
4. Spring
5. Washer
6. Circlip
7. Slotted nut
Figure 1A-44
( 1 REINSTALL
� j
1A-42 BODY
NOTE: A screw and lock nut attached to the push button

guide sleeve provides adjustment for the push button
operation. Loosen nut and adjust the screw so that the
tail gate lock is unlatched when the push button is 1 to
2 mm above surrounding lock surface. Tighten lock nut.
1.16 WEATHERSTRIP ASSEMBLY· TAIL

GATE OPENING· STATION WAGON
DESCRIPTION
The one piece tail gate opening weatherstrip is a bulbous
rubber 'U' section fitted with an integral retaining system.
It fits firmly over the upturned flange of the tail gate
opening. The ends are butt jointed together with
neoprene cement adjacent to the tail gate lock striker
bolt.
NOTE: When installing the weatherstrip assembly, locate
the longer side of the 'U' section on the outside of the
tail gate opening upturned flange.
BODY 1A-43
FRONT & REAR DOOR ASSEMBLIES

INDEX
() Ref.
1.
Subject
GENERAL DESCRIPTION ..............................
Page
1A·43
Ref.
2.12
Subject
DOOR LOCK CYLINDER ASSEMBLY.........
Page
1A·56
2. SERVICE OPERATIONS ................................. 1A·44 Remove .................................................... 1A-56
2.1 FRONT & REAR DOOR ASSEMBLIES ....... 1A·44 Reinstall................................................... 1A-56
Remove.................................................... 1A-44 2.13 FRONT DOOR WINDOW ASSEMBLY......... 1A·57
Adjust ....................................................... 1A·45 Reinstall................................................... 1A-57
2.2 LOCK STRIKER BOLT ASSEMBLY............. 1A·45 2.14 REAR DOOR WINDOW ASSEMBLY ........... 1A-58
Remove or Adjust ................................. 1A·45 Remove.................................................... 1A-58
Reinstall................................................... 1A-46 Reinstall................................................... 1A-59
2.3 DOOR WINDOW REGULATOR HANDLE ... 1A·46 2.15 REAR DOOR FIXED WINDOW GLASS •
Remove..........................................�......... 1A·46 SEDAN ............................................................... 1A-59
2.4 DOOR INNER TRIM PANEL .......................... 1A·47 Reinstall................................................... 1A-59
Remove.................................................... 1A-47 2.16 FRONT DOOR WINDOW REGULATOR
Reinstall................................................... 1A·47 ASSEMBLY ....................................................... 1A-60
2.5 FRONT DOOR LOCK ASSEMBLY............... 1A-47 Remove.................................................... 1A-60
Remove.................................................... 1A·47 Reinstall................................................... 1A-60
Reinstall................................................... 1A-52 2.17 REAR DOOR WINDOW REGULATOR
2.6 REAR DOOR LOCK ASSEMBLY.................. 1A·52 ASSEMBLY ....................................................... 1A·61
Remove .................................................... 1A·52 Remove.................................................... 1A-61
2.7 DOOR LOCK ACTUATOR ASSEMBLY • 2.18 FRONT & REAR DOOR WEATHERSTRIP
CALAIS .............................................................. 1A-54 ASSEMBLY ...............................'........................ 1A·62
Remove.................................................... 1A-54 Remove.................................................... 1A-62
2.8 FRONT DOOR EXTERIOR HANDLE 2.19 FRONT & REAR DOOR BELT
ASSEMBLY ....................................................... 1A·54 WEATHERSTRIP & MOULDING
Remove.................................................... 1A·54 ASSEMBLY ....................................................... 1A·63
2.9 REAR DOOR EXTERIOR HANDLE Reinstall................................................... 1A-63
( ASSEMBLY .......................................................
Remove....................................................
1A-55
1A·55
2.20 EXTERIOR REAR VIEW MIRROR
ASSEMBLY • MANUAL .................................. 1A-63
Reinstall................................................... 1A-55 Remove..... ,.............................................. 1A-63
2.10 REMOTE CONTROL LOCK INTERIOR Reinstall................................................... 1A-64
HANDLE & ROD ASSEMBLY........................ 1A·55 2.21 EXTERIOR REAR VIEW MIRROR
Remove.................................................... 1A·55 ASSEMBLY • ELECTRIC................................ 1A·64
2.11 DOOR LOCK SLIDER ASSEMBLY............... 1A·56 Reinstall................................................... 1A-64
Remove.................................................... 1A·56
Reinstall................................................... 1A-56
Front and rear door assemblies consist of outer panels· which are hemmed at ,their outer edges, over the inner panels.
These hemmed edges are then welded. A rolled upper door frame retains the sliding glass run channels. Door hinge
male sections are welded to the door facings and the female sections to the body pillars. Door check and hold open
links are located between the door assemblies and the body pillars.
On front doors, double arm scissor type window regulators attached to the glass lifter channels and door inner panels
operate the front door sliding windows. Cable type mechanisms attached to the door inner panels and glass lifter
channels operate the rear door sliding windows.
Electric motors for operating the front and rear sliding windows are optionally available on Calais and Berlina models.
Lift bar exterior door handles operate the fork type door locks in conjunction with door lock striker bolts.
A two (2) key locking system uses a primary key (black plastic coated key head) to operate all locks on the vehicle. A
secondary (all metal) key, operates the door and ignition locks only. Slider assemblies mounted on the door inner panels
operate the door locks internally.
Electric door lock actuators which operate the door locks on Calais models, are optional on Berlina models.
Door weatherstrips incorporate plastic clips which retain the weatherstrip in holes located around the outer lower edge of
(.___./) the door inner panel. The upper section of the weatherstrip is retained in a channel which is an integral part of the rolled
section upper door frame.
1A-44 BODY
2.1 FRONT & REAR DOOR
ASSEMBLIES
REMOVE
1. Tap the tapered sleeve securing the link to the door
check and hold-open assembly upwards, removing
the sleeve.
2. Using wood blocks or car jacks, support the door at
its base.
3. Remove the plastic caps from the hinge assemblies.
4. Using Tool No. AU170, hinge sleeve removal tool,
drive out the upper and lower hinge sleeves (refer TOOL No
Fig. 1A-45). Remove the door assembly. AlJ170
Figure 1A-45
NOTE: On doors fitted with electrically operated sliding

window regulators and/or electric door locks, it is
necessary to:
a. Discorinect the battery ground cable.
b. Remove the door armrest, window regulator
handle (refer 2.3 in this Section) door inner trim
panel (refer 2.4 in this Section) then carefully
peel off lower half of the water deflector from
the door inner panel.
c. . Disconnect the door electrical harness from the
main wiring harness and free harness from the
door.·
BODY 1A-45
REINSTALL ')
Apply lithium base grease to the hinge pivot sleeves prior
®
to reversing removal operations, using Tool No. AU303
illustrated in Fig. 1A-46, to install the hinge sleeves.
TOOL No AU303
Figure 1A-46
ADJUST
Attention should be given to uniform margins and
alignment between the door and surrounding parts when
door adjustments are being carried out.
Uniform margins and alignment of front and rear doors in
relation to the body opening can be achieved by setting
the appropriate door hinge.
Use Tool AU814 to set door hinges.
(
Adjust hinges in conjunction with adjustment to lock
striker to achieve an acceptable door closing effort with
correct door lock to striker engagement.
2.2 LOCK STRIKER BOLT ASSEMBLY
REMOVE OR ADJUST
1. Pencil scribe location of the striker bolt assembly
washer on the body pillar to facilitate installation.
2. Using an 8 mm allen wrench, loosen or remove the
striker bolt assembly.
l_)
1A-46 BODY
REINSTALL
Align the striker bolt assembly so that the shaft of the I
r
NYLON FORK
ff I I
striker bolt locates centrally in the nylon lock fork (refer
Fig. 1A-47) as the door is being closed. Securely tighten �
the striker bolt STRIKER BOLT
Correct engagement can be achieved by vertical or
horizontal adjustment of the door lock striker assembly.
I
Addition or delete spacers between the striker assembly
I
threaded washer and the body pillar to achieve correct
engagement of the striker to the lock.
DOOR
!
Figure 1A-47
NOTE: If a replacement door is being fitted, it is sound

practice to remove the door lock striker bolt assembly
and allow the door to hang free on the hinges. Set the
hinges as necessary to achieve correct alignment and
uniform margins, then reinstall the striker bolt and adjust.
2.3 DOOR WINDOW REGULATOR

HANDLE
REMOVE \
Insert the interior handle removal tool illustrated in Sheet steel-2x24x200
Fig. 1 A-48, between the base of the handle and the
bearing plate and in line with the arm of the handle as
illustrated in Fig. 1A-49. Disengage the horse shoe
shaped retaining spring, then remove the handle.
All dimensions are metric.
Figure 1A·48
€£--'--1 -A-
Figure 1A·49
BODY 1A-47
REINSTALL
1. Locate the retaining spring in the handle with the
open ends of the spring facing the handle arm,
pressing the spring into the engaged position.
�-�
\ 2. Place the handle bearing plate over the window
( J regulator splines with its raised face towards the
door.
3. Ensure that the handle is positioned symetrically with
the handle on the opposite door then press the
handle onto the window regulator splines until the
horse shoe shaped retaining spring engages the
groove at the base of the splines.
2.4 DOOR INNER TRIM PANEL
REMOVE
1. With the window fully lowered, remove the armrest
and the window regulator handle (refer 2.3 in this
Section).
2. On front doors, grasp the bottom and rear edge of
the exterior rear view mirror inner cover, disengaging
it from the integral pins retaining the cover to the
door inner panel extension, removing the cover.
3. Using a wide bladed screwdriver positioned between
the rear lower corner of the trim and the door inner
panel, carefully prise the rear, bottom and front
edges of the trim from the door inner panel (refer
Fig. 1A-50).
NOTE: Escutcheons surrounding the interior door lock
handle and slider assemblies will pop off as the trim
panel is released.
REINSTALL
Figure 1A-50
2.5 FRONT DOOR LOCK ASSEMBLV
REMOVE
1. With the window lowered, remove the armrest,
window regulator handle (refer 2.3 in this Section)
door inner trim panel (refer 2.4 in this Section) then
carefully peel off the water deflector from the door
inner panel.
( \
�j
1A-48 BODY
2. Using a hooked tool similar to that illustrated in

Fig. 1A-51 , under the clips securing the door belt
weatherstrip and moulding assembly, lift the rear half
of the assembly up, off the upper flange of the door
outer panel.
Figure 1A-51
3. Temporarily reinstall the window regulator handle less

retaining spring, then fully raise the window.
4. From inside the door assembly, remove the screw
securing the lower part of the lock security bracket
to the door side impact beam illustrated in Fig. 1A-
52. Tap the bottom of the security bracket upwards,
off the door outer panel.
5. Remove the lower half of the rear glass run channel
and the retainer.
6. Remove the lock assembly attaching screws (refer
Fig. 1A-52 View 'A') then disengage the remote
control lock handle assembly from the door inner
panel by carefully tapping the, handle assembly
)
forward. Disengage the rear end of the control rod
from the lock assembly (refer Fig. 1A-52, View 'D').
/ \
\� __;
_
,.,------...
,/ , -\
'\,�/' �)
COVER (EXTERIOR) HANDLE - DOOR OUTSIDE

REAR VIEW MIRROR
SLIDER ASM.
CYLINDER DOOR
LOCKING DOOR LOCK ASM.
VIEW[Q]
ARMREST
WINDOW REGULATOR
HANDLE
[QJ'
GLASS RUN
CHANNEL
[g
GLASS LIFTER CHANNEL
m
0
VIEW[A] C
VIEW[ID
.....
Figure 1A-52
1A-50 BODY
7. Disengage the slider assembly from the door inner
panel by carefully prising the upper lugs of the
assembly away from the inner panel, then tap the
slider assembly upwards, off the door inner panel.
Disengage the rear end of the control rod from the
lock assembly.
8. Prise the outside handle connecting rod from the
lock assembly.
9. Prise the lock cylinder connecting rod from the
locking lever on the end of the lock cylinder.
10. Remove the lock assembly.
NOTE: On doors fitted with electrically operated door
locks, it is necessary to:
a. Prise out the lock actuating pivot illustrated in
Fig. 1 A-53, disengage the rod from the actuating
pivot which will allow the rod to be removed with
the slider assembly control rod from the lock
assembly.
b. Disengage the lock cylinder switch assembly
from the lock cylinder.
c. Disconnect the door harness connector then
unclip and remove the harness, lock cylinder
control rod and electrical switches from the door.
/�
(
\.,.___..., �---/ /
CHANNEL ASM.
SWITCH ASM.
ROD
DOOR ASM.
DOOR ASM.
ACTUATOR
ELECTRIC
DOOR LOCK
STRAP
MOTOR-
POWER WINDOWS
FRONT DOOR REAR DOOR
m
0
C
....
Figure 1A-53 ....
1A-52 BODY
REINSTALL
Lubricate frictional surfaces of the lock assembly with
lithium grease then reverse removal operations, attaching
the control rods to the lock assembly prior to installing
the lock attaching screws.
2.6 REAR DOOR LOCK ASSEMBLV
REMOVE
inner panel.
2. Temporarily reinstall the window regulator handle,
less retaining spring and fully raise the window.
3. From inside the door, remove the lower half of the
rear glass run channel and the retainer, which is
retained over the upper door frame and is secured to
the rear door front facing and inner panel with
screws (refer Fig. 1A-54). Remove the glass run
channel retainer and security bracket retainer through
the rear aperture in the door inner panel.
4. Remove the rear door division channel adjusting stud
(refer Fig. 1A-54).
5. Remove the screws securing the door lock assembly
to the door inner panel illustrated in Fig. 1A-54, View
·c·.
6. Disengage the remote control lock handle assembly
by tapping the handle assembly forward. Disengage
the rear end of the control rod from the lock
assembly. ( \
7. Prise the outside handle connecting rod from the \ )
lock assembly.
assembly away from the inner panel, then carefully
tap the slider assembly upwards, off the door inner
· panel. Disengage the rear end of the control rod off
the lock assembly (refer Fig. 1A-54, View 'D').
9. Remove the lock assembly.
/- -......_, ,-�
\
,"__ ,/ ,�)
WEATHERSTRIP REAR DOOR

]
;_I
,.,, CHANNEL ASM.
,��-·. :-..:�-:::-: ROD - PIVOT TO LOCK
LOCK ASM. REAR DOOR

DOOR ASM. REAR
I
L PIN
6-l�R D
- �
�7
SLIDER ASM.
.,
/'
I • SCREW - DOOR
�: ',,'LOCK
l �- • , -·
IEW Im
SCREW
��1. � �1 1
�
�!I�
, ·
LOCK �.
ril�, t. t-�,\
__ ':'), ,
�
-W- ',
, �
//
I
GASKE
-j),�I�
� ·. NUT
'I / ·.
7
i, /' SEAL-LOCK
MOULDING
1r:-:�:.� j,�/
WEATJ:f ERSTRIP1 SAFETY LEVER
�·�,�', '�·,
CHANNEL REAR VIEW [g
DOOR GLASS· �)�@'p
,�-�;
ROD �� .
',,""-._ ___/
REGULATOR ASM.
rd.J�
ADJUST E \ '-cuP
·
� ,.,,.�]:. m
0
VIEW [Al CT)Jl> VIEW [ID C
VIEW�
.....
Figure 1A-54
1A-54 BODY
NOTE: On doors fitted with electrically operated door

locks, it is necessary to:
a. Disconnect battery ground cable.
b. Prise out the rod actuating pivot pin illustrated in
Fig. 1 A-53, disengage the control rod from the
actuating pivot which will allow the rod to be
removed with the slider assembly.
c. Disengage the actuating pivot to lock assembly
control rod (within the door assembly) from the
lock assembly.
REINSTALL
Lubricate frictional surfaces of the lock with lithium
grease then reverse removal operations, attaching the
control rods to the lock assembly prior to installing the
lock attaching screws.
NOTE: The rear door lock incorporates a child safety
locking system. By operating a locking lever located in
the door facing below the lock (refer Fig. 1A-54) the
doors cannot be opened from the inside regardless of
the position of the inside locking knob.
The lock is in the child safety condition when the lever is
in the 'UP' position. When the lever is 'DOWN' the door
lock operates normally.
2.7 DOOR LOCK ACTUATOR

ASSEMBLV - CALAIS
REMOVE
2. With window lowered, remove the armrest, window
regulator handle (refer 2.3 in this Section) door inner
trim panel (refer 2.4 in this Section) then carefully
peel off the front half of the water deflector from the
door inner panel.
less retaining spring, then fully raise window.
4. Prise out the lock actuating pivot pin retaining the
pivot assembly (refer Fig. 1A-53) and disengage the
rod connecting the pivot assembly to the lock
actuator assembly.
5. Disconnect the actuator to door harness electrical
connector then remove screws, securing the actuator
assembly to the door inner panel.
6. Remove the assembly through the aperture in the
door inner panel.
REINSTALL
Reverse Removal operations.
2.8 FRONT DOOR EXTERIOR HANDLE

ASSEMBLY
REMOVE
carefully peel off the rear half of the water deflector
from the door inner panel.
BODY 1A-55

Fig. 1A-55 under the clips securing the door belt
weather strip and moulding assembly, lift the rear
half of the assembly up, off the upper flange of the
/ · -"' door outer panel.
( )
Figure 1A-55

less retaining spring, then fully raise window.
5. Remove the lower half of the glass run channel and
the retainer.
6. Prise the outside handle connecting rod from the
( ! lock assembly (refer Fig. 1A-52, View 'D').
\ )
'"-� 7. Remove the nuts securing the handle assembly to
the door outer panel, removing the assembly.
REINSTALL
2.9 REAR DOOR EXTERIOR HANDLE

ASSEMBLY
REMOVE
1. Remove rear door lock assembly (refer 2.6 in this
Section).
2. Remove the nuts illustrated in Fig. 1A-54, View 'B'
securing the handle assembly to the door outer
panel, removing the assembly.
REINSTALL
2.10 REMOTE CONTROL LOCK

INTERIOR HANDLE & ROD ASSEMBLV
REMOVE
(___) 1. With the window fully lowered, remove the armrest,
window regulator handle (refer 2.3) door inner trim
panel (refer 2.4) then carefully peel off the water
deflector from the door inner panel.
1A-56 BODY
2. Remove the remote control lock assembly by careful

ly tapping the handle assembly forward, off the door
inner panel, disengage the control rod from the
plastic retainer and lock assembly, removing the
handle and rod assembly.
REINSTALL
2.11 DOOR LOCK SLIDER ASSEMBLY
REMOVE
1. With the window fully lowered, remove the armrest,
door inner trim panel (refer 2.4 in · this Section) then
inner panel.
assembly away from the inner panel, then tap the
slider assembly upwards, off the door inner panel.
3. Disengage the slider assembly off the control rod,
removing the assembly.
NOTE: On rear doors featuring electrically operated door
locks, it will be necessary to release the actuating pivot
to lock assembly control rod from its plastic retainer to
facilitate removal of the slider assembly.
REINSTALL
2.12 DOOR LOCK CYLINDER

ASSEMBLY
REMOVE
carefully peel off the upper, rear corner of the water
Fig. 1A-55 under the clips securing the door belt
weatherstrip and moulding assembly, lift the rear half
of the assembly up, off the upper flange of the door
outer panel.
less retaining spring and fully raise the window.
5. Prise the lock cylinder connecting rod from the
locking lever on the end of the lock cylinder,
illustrated in Fig. 1A-52, View 'D'.
6. Prise th� spring clip retaining the lock cylinder to the
door outer panel forwards, off the cylinder, then
remove the lock cylinder from the door outer panel.
(
REINSTALL �--j
Reverse removal operations, ensuring that the gasket
adjacent to the cylinder scalp is correctly located.
BODY 1A-57
IMPORTANT: Powdered graphite applied into the lock

cylinder via the key is the only lubricant recommended
for lock cylinders.
2.13 FRONT DOOR WINDOW

ASSEMBLY
REMOVE
inner panel.
less retaining spring, then raise the window so that
the regulator arm rollers in the glass lifter channel
are visible through the door inner panel apertures
(refer Fig. 1A-56 'A').
3. Support the window assembly in this position then
remove screws 'B' in Fig. 1A-56 securing the regul
ator cam to the door inner panel, removing the cam.
Figure 1A-56
4. Move the window assembly horizontally to disengage

the regulator arm rollers, releasing the window
assembly. Raise the window and with the rear upper
corner of the glass uppermost, remove the window
assembly through the top of the door (refer
Fig. 1A-57).
Figure 1A-57
REINSTALL
Install the window assembly through the top of the door,
maintaining sufficient pressure to retain the glass in the
rear glass run channel and, as the window is lowered,
ensure that the opposite edge of the glass is retained in
the front glass run channel. Maintain this pressure on the
glass in the run channels until the regulator arm rollers
are located in the glass lifter channel and the window
cam is installed.
NOTE: Slotted holes 'B' in Fig. 1A-56 in the door inner
panel provide adjustment for the regulator assembly cam
f , to correctly align the window assembly in a parallel
�--j; attitude.
1A-58 BODY
2.14 REAR DOOR WINDOW ASSEMBLV
REMOVE
inner panel.
less retainer spring, then raise the window so that
the front and rear clamps securing the regulator
cable to the window lifter channel are visible through
the apertures in the door inner panel (refer
Fig. 1A-58).
3. Remove the clamp attaching screws and position the
window in the bottom of the door.
Figure 1A-58
4. Remove the rear end of the upper glass run channel

adjacent to the door division channel (refer
Fig. 1A-59).
5. Remove screws 'A' securing the top of the door
division channel to the door upper frame (refer
Fig. 1A-59).
Figure 1A-59
6. Record the amount of the door division channel

adjusting stud protruding through the lock-nut to
facilitate subsequent installation (refer Fig. 1A-60).
7. Remove the lock-nut, then screw the adjusting screw
clockwise, into the door inner panel. Move the top of
the divison channel forward, off the stationary glass
and remove the division channel through the window
aperture in the door inner panel, as illustrated in
Fig. 1A-59.
Figure 1A-60
BODY 1A-59
REINSTALL
1. With the window regulator handle temporarily in
stalled, wind the regulator mechanism in a clockwise
direction until the stop is reached.
2. Register location of handle then turn the handle in
an anti-clockwise direction for two and a half (2-1/2)
revolutions.
3. Install the window assembly through the top of the
door, maintaining sufficient pressure to retain the
glass in the rear glass run channel and, as the
window is lowered, ensure that the opposite edge of
the glass is retained in the front glass run channel.
Maintain this pressure on the glass in the run
channels until the clamps attaching the control cable
to the window lifter channel are securely installed.
NOTE: Slotted holes 'B' in Fig. 1A-61 in the door inner
panel, provide adjustment for the regulator assembly cam
----
to correctly align the window assembly in a parallel
attitude.
Figure 1A-61
4. Check for correct operation of the window regulator,

then reinstall the door inner panel water deflector,
trim panel, window regulator handle and door
armrest.
2.15 REAR DOOR FIXED WINDOW

GLASS - SEDAN
REMOVE
1. Remove the rear door window assembly and door
division channel (refer 2.14 in this Section).
2. Slide the fixed window assembly forward, removing it
from the door frame as illustrated in Fig. 1A-62.
3. Remove the weatherstrip surrounding the fixed glass.
REINSTALL
Reverse removal operations. Figure 1A-62
( \
�-j
1A-60 BODY
2.16 FRONT DOOR WINDOW

REGULATOR ASSEMBLY
REMOVE
1. Remove the front door window assembly (refer 2.13
in this Section).
2. Drill out four rivets ('B' Fig. 1A-63), securing the
window regulator to the door inner panel then
remove the regulator assembly through the rear,
lower aperture in the door inner panel.
Figure 1A-63
REINSTALL
· 1. Ensure that frictional surfaces of the window regul
ator assembly and associated parts are adequately
lubricated with lithium grease.
2. Locate the regulator assembly inside of the door,
aligning the attaching holes in the assembly with the
corresponding holes in the door inner panel. Rivet
the regulator assembly to the door inner panel.
3. Reinstall the front window assembly (refer 2.13 in
this Section).
NOTE: When removing the optional electrically operated
front door window regulator, it is necessary to disconnect
the battery ground cable and the regulator assembly
connector (A) from the door electrical harness inside the
door assembly (refer Fig. 1 A-64).
Figure 1A-64
BODY 1A-61
2.17 REAR DOOR WINDOW

REGULATOR ASSEMBLY
REMOVE
1. Remove the rear door window assembly (refer 2.14
in this Section).
2. Operating inside of the door, firmly apply masking
tape to the cable around the regulator drum to retain
the cable. To facilitate installation, chalk or paint
mark one of the regulator drum gear teeth visible
through the hole directly under the regulator assemb
ly in the door inner panel.
Mark the door inner panel to coincide the mark on
I
the regulator gear teeth.
3. Loosen the cable tension pulley '1 ' in Fig. 1A-64a
and remove the cable from the guide pulleys.
C Figure 1A-64a
4. Drill out the rivets securing the regulator assembly to

the door inner panel, then remove the assembly and
cable through the rear aperture in the door inner
panel.
CAUTION: Ensure that there are no kinks in the regulator
assembly cable.
REINSTALL
1. Ensure that the frictional surfaces of the regulator
assembly and associated parts are adequately lubric
ated with lithium grease.
2. Locate the window regulator assembly inside the
door, aligning the attaching holes in the assembly
with corresponding holes in the door inner panel.
Also align the chalk or paint marks on the regulator
gear teeth with those on the door inner panel prior
to riveting the regulator assembly to the inner panel.
3. Route the regulator cable illustrated in Fig. 1A-64a,
around the tension (adjustable) number 1 pulley, so
that the cable is adjacent to the door inner panel.
Continue to install the cable around the pulleys in
the sequence shown in Fig. 1A-64a.
Number 2 guide pulley - top rear.
Number 3 guide pulley - bottom front
NOTE: Between numbers 2 and 3, the cable is adjacent
to the door outer panel.
Number 4 guide pulley - top front
1A-62 BODY
4. Temporarily tension cable on the adjustable, Number

1 pulley, remove the masking tape from the regulator
cable drum, then finally tension cable at the adjust
able pulley illustrated in Fig. 1A-64a.
5. Reinstall the rear window assembly (refer 2.14 in this
Section).
NOTE: When removing the optional electrically operated
rear door window regulator, it is necessary to carry out
the following operations:
a. Remove the window assembly (refer 2.14 in this
Section).
b. Operate the window regulator to stop (window
position fully raised).
c. Disconnect battery ground cable and regulator
assembly connector 'B' from the electrical harness in
the door (refer Fig. 1A-64b).
d. Remove the window regulator assembly as outlined
in 4 'Rear Door Window Regulator Assembly -
Remove'.
e. Reconnect the electrics and operate the window
regulator, positioning the regulator gear teeth directly
opposite the previously painted or marked gear teeth
so that the teeth can be painted or marked on the
outside. This is necessary for correctly positioning
the window in relation to the regulator assembly gear
during window installation (refer 2.14 in this Section).
Figure 1A-64b
2.18 FRONT & REAR DOOR

WEATHERSTRIP ASSEMBLY
REMOVE
1. Using a wide bladed screwdriver, carefully prise the
upper part of the weatherstrip from the door upper
frame.
2. Using the same tool, prise out the clips securing the
weatherstrip surrounding the lower half of the door
(refer Fig. 1A-65).
Figure 1A-65
\.
BODY 1A-63
REINSTALL
Reverse removal operations. FOURTH
CLIP HOLE
NOTE: If a new weatherstrip is to be installed, locate the
joint approximately 50 mm above the fourth clip hole
from the belt line, as illustrated in Fig. 1A-66.
Figure 1A-66
2.19 FRONT & REAR DOOR BELT

WEATHERSTRIP & MOULDING
ASSEMBLY
REMOVE
1. With the window fully lowered and using a hooked
tool similar to that illustrated in Fig. 1A-67, under the
clips securing the door belt weatherstrip and moul
ding assembly lift the assembly up off the upper
flange of the door outer panel.
Figure 1A-67
REINSTALL
Locate the door belt weatherstrip and moulding assembly
clips over the top of the door outer panel, then using the
palm of the hand, firmly tap the assembly down, over the
door outer upper flange.

ASSEMBLV - MANUAL
REMOVE
1. Prise out the edge of the inner cover (refer
Fig. 1A-68) then disengage the top of the cover from
the side of the upper glass run channel.
2. Remove the three screws securing the mirror
assembly to the door upper frame, then remove the
assembly.
1A-64 BODY
REINSTALL
EXTERIOR REAR VIEW MIRROR

. ASM. - MANUAL
WASHER (PART OF MIRROR ASM.)
Figure 1 A-68

ASSEMBLV - ELECTRIC
REMOVE
window regulator handle (refer 2.3 in this Section),
door inner trim panel (refer 2.4 in this Section), then
carefully peel off the front lower quarter of the water
3. From within the front of the door, disconnect the
exterior mirror electrical connectors from the door
electrical harness.
4. Prise out the front edge of the inner cover (refer
Fig. 1 A-69) then disengage the top of the cover from
the side of the upper glass run channel.
5. Remove the screws securing the mirror assembly to
the door upper frame, then remove the assembly.
REINSTALL
BODY 1A-65
EXTERIO EAR VIEW

: �
MIRR OR s • E L ECTRIC
FOR CONTIN U ATION

REFER FIG . 1A-53
SCREW (3 PLACE S)
Figure 1A-69
1A-66 BODY
NOTES
I [1
BODY 1A-67
STATIONARY GLASS
INDEX
1. GENERAL DESCRIPTION .............................. 1A-67 3.6 SHORT METHOD INSTALLATION ............... 1A-84
2. SERVICE NOTES............................................. 1A-67 Description .............................................. 1A-84
Glass Replacement Packages............ 1A-68 Reinstall ................................................... 1A-84
Reglaze - Short Method or 3.7 LONG METHOD INSTALLATION ................. 1A-87
Minor Water Leak Correction ............ 1A-68 Description .............................................. 1A-87
Reglaze - Long Method ....................... 1A-68 Reinstall ................................................... 1A-87
3. SERVICE OPERATIONS ................................. 1A-71 3.8 TAIL GATE WINDOW - STATION
3.1 WINDSHIELD GLASS ..................................... 1A-71 WAGON ............................................................. 1A-91
Remove.................................................... 1A-71 3.9 MINOR WATER LEAK CORRECTION......... 1A-91
3.2 SHORT METHOD INSTALLATION ............... 1A-73 3.10 LONG METHOD ............................................... 1A-95
Description .............................................. 1A-73 Remove.................................................... 1A-95
Reinstall................................................... 1A-73 Reinstall ................................................... 1A-96
3.3 LONG METHOD INSTALLATION ................. 1A-76 3.11 BACK WINDOW - SEDAN ............................. 1A-99
Description .............................................. 1A-76 Remove .................................................... 1A-99
Removal ................................................... 1A-76 Back Window Opening Check........... 1A-99
Body Opening Check........................... 1A-76 Reinstall ...................................................1A-100
Reinstall................................................... 1A-77 3.12 REAR QUARTER WINDOW - STATION
3.4 MINOR WATER LEAK CORRECTION......... 1A-81 WAGON ............................................................. 1A-101
3.5 REAR QUARTER WINDOW ASSEMBL V - Description .............................................. 1A-101
SEDAN ............................................................... 1A-82
Remove .................................................... 1A-82
Rear Quarter Window Aperture
Check ....................................................... 1A-84
(\ \
)
Two different installation methods are used when installing stationary glass to VL Models.
The windshield, which is laminated and features a tinted upper band, the tail gate glass on station wagons which has an
electrically heated demist facility and the quarter windows on sedans; are all bonded in the body apertures with urethane
adhesive.
The rear window on sedans and rear quarter windows on station wagons use the conventional rubber weatherstrip and
non hardening sealer method of installation.
Armour plate glass is used for all windows except the windshield.
For replacement of urethane adhesive bonded glasses, urethane adhesive kits have been developed and must be used
to maintain original installation requirements. Glass installed with urethane adhesive requires either partial or complete
removal of the urethane adhesive when replacing the glass. Partial removal of the urethane adhesive is referred to as
the 'short method'. Complete removal of the urethane is known as the 'long method'.
The short method is used where original urethane adhesive left on body opening pinchweld flanges after glass removal
can serve as a base for the new glass. This method would be used in cases of replacement of cracked windshields or
removal of glass that is still intact. The amount of urethane left in the glass opening can be controlled during glass
removal, leaving the maximum amount of original urethane intact on the body opening flange.
The long method is to be used when the original urethane adhesive left in the window opening after glass removal
cannot serve as a base for replacement glass. This method would be used in cases needing metal work or where paint
refinishing is required in the opening; or in cases where the glass has been previously replaced, using the short method.
In such instances, the build up of urethane could position the glass too high in the opening. In these cases, the original
urethane is completely removed and replaced with new urethane during glass installation.
2. SERVICE NOTES
WARNING: SAFETY GLASSES AND WORK GLOVES
MUST BE WORN AT ALL TIMES WHEN OPERATING
WITH GLASS.
NOTE: Skinning (partial curing) of the urethane com
mences after exposure to the atmosphere. At 23 degrees
celcius and 50 percent relative humidity, skinning com
mences after 30 minutes, therefore, installation of mould
ings must be completed within that time limit.
Complete curing of urethane at this temperature and
humidity takes 72 hours.
1A-68 BODY
The tools recommended for cutting out the adhesive

bonded windshield and rear quarter windows are:
1. Hot knife, Tool No. J24899-01 or,
2. Cold knife, Tool No. J24402-A.
Both of these tools are available from Kent-Moore
Australia.
When using the hot knife to cut out the bonded glass,
allow the heat of the blade to melt through the urethane.
Do not use force to pull the hot knife through the
urethane as this can break the glass and damage the hot
knife.
GLASS REPLACEMENT SERVICE PACKAGES

Two replacement service packages are available from:
Dimet,
53 Shower Street,
Preston, Victoria, 3072.
REGLAZE- SHORT METHOD OR MINOR WATER

LEAK CORRECTION
Service Package No. 92018611 is used for this method
of glass replacement or water leak correction and
comprises:-
HN1749 Urethane Adhesive (1 x 300 ml· cartridge
with plastic nozzle).
HN1747 Glass Primer (Clear).
HN1748 Glass Primer (Black).
2 Primer Applicators.
REGLAZE • LONG METHOD

Service Package No. 92018612 is used for this method
of glass replacement and comprises:-
HN1749 Urethane Adhesive (1 x 300 ml cartridge
with plastic nozzle).
HN1747 Glass Primer (Clear).
HN1748 Glass Primer (Black).
HN1752 Flange Primer.
3 Primer Applicators.
An additional 300 ml cartridge of urethane adhesive Part
No. M39097 for the Long Method Glass installation must
be ordered separately.
In addition, the items listed in the chart below will need
to be ordered separately for windshield replacement.
PART NO. DESCRIPTION QUANTITY METHOD
92031121 Top Sides Glazing Dam (5 mm high) 1 Long
92029382 Bottom Glazing Dam (9 mm high) 1 Long
92029692 Windshield Side Moulding Asm. Right and Left

Moulding Retaining Clips 6 Both
92025081 Windshield Upper Moulding 1 Both

92025082 Windshield Lower Moulding 1 Both
Urethane has a recommended shelf life of three (3)

months and should be stored in a cool place, preferably
refrigerated at approximately 5 degrees celcius.
r
BODY 1A-69
An alternative bonding material 'Silastic Windscreen

Sealant' is available in 300 ml cartridges from GM P & A
under Part No. M38977.
This 'Silastic Windscreen Sealant' (black neutral cure
silicone glass sealant) has an extended shelf life and
easier application.
IMPORTANT: This sealant must only be used for minor
water leak correction or for short method glass
replacement.
When using Silastic for short method stationary bonded
glass replacement, the procedures are the same as those
used with urethane, except that no primers are required.
However, mineral turps or Prepsol is necessary for glass
. cleaning prior to glass installation.
When used for other than short method windshield
replacement, a minimum curing time of five hours must
elapse before the vehicle is operated.
Registered Trademark - Dow Corning.
'
m
0
C
VIEW [HJ
�
UPPER MOULDING SIDE MOULDING
GROMMET
� .
VI
NON
HARDENING
SEALER
\
� LOWER CORNER
MOULDING
_/U .,,. �NON
. GROMMET HARDENING
SEALER LOWER
MOULDING
VIEW SECTION A-A
IGI VIEW QJ
Figure 1A-70
/· --·�
�---j
BODY 1A-71
3�1 WINDSHIELD GLASS

REMOVE
The windshield glass removal procedure is the same for
both the short and long installation methods with one
exception.
If the short method installation is to be used, more care
must be taken during glass removal to ensure that an
even surface of the original remaining urethane exists in
the body opening to serve as a base for the new
urethane/ silicone bead and the replacement glass.
The upper end of the windshield side mouldings include
integral pins which are retained in grommets installed in
the front body pillar (refer Fig. 1A-70, Section A-A).
The corner and side mouldings also include lugs which
are embedded in urethane. Plastic retainers, which are
clipped inside the side mouldings are also retained in 0
urethane (refer Fig. 1A-70, Views 'J' and 'H'). A 5.0 mm
diameter bead of butyl retains the corner and side
mouldings until the urethane/ silicone is sufficiently cured
(Fig. 1A-70a). INNER SURFACE
OF WINDSHIELD
SIDE MOULDING
A- A
SECTION A-A
5.0 mm DIA. BUTYL

STRIP BETWEEN CLIPS
Figure 1A-70a
The tails of the upper and lower fir tree mouldings are
embedded in urethane (refer Fig. 1A-70, View 'J').
1A-72 BODY
Individual mouldings are available from GM P&A for

service replacement. In addition, a moulding kit, compri
sing all replacement parts, is also available from GM P&A
for service use. Refer VL Series Parts Catalogue for
details.
CAUTION: Care must be taken during any operation
involving windshield removal or installation not to exert
any load on the windshield glass. Failure to observe this
may result in damage to the glass.
1. To prevent damage to paint finish and trim and to
minimise clean up, mask-up and place protective
covers over parts adjacent to the windshield.
2. Remove windshield wiper arm and blade assemblies
(refer Section 12C, Volume 5 of this Supplement).
3. Carefully prise or cut out the lower corner windshield
mouldings illustrated in Fig. 1A-70, View 'J'.
4. Carefully remove the windshield side mouldings.
NOTE: The right and left side mouldings may be removed
by inserting the finger tips between the windshield glass
and the inner edge of each side moulding and 'springing'
the mouldings from the plastic retainers (three retainers
per moulding). Careful removal of the mouldings will
enable their re-use following windshield installation.
5. Prise the ends of the upper and lower mouldings
from the urethane so that the fir tree sections can
be grasped. Firmly pull the mouldings up and out of
the urethane.
NOTE: Careful removal of the upper and lower mouldings
will enable their re-use following windshield installation.
6. Using a sharp knife, carefully cut off enough of the
plastic side moulding retainers to allow the hot or
cold knife to operate around the periphery of the
windshield.
NOTE: Complete removal of these side moulding retai
ners will greatly facilitate the use of the Hot Knife or Cold
Knife.
7. Using the Hot Knife or Cold Knife, carefully insert the
blade until the cutting edge of the blade is aligned
with the inside surface of the windshield. Turn the
knife in a clockwise direction so that the cutting
blade of the knife is located between the inside
surface of the windshield, urethane and dam (refer
Fig. 1A-71, Section A-A) then cut out the windshield.
CAUTION: Do not attempt to force the blade of the hot

knife through the urethane. Allow heat from the blade to
melt through the urethane and progress around the
periphery of the windshield without undue force.
NOTE: If the cold knife is used, cut away sufficient
urethane adjacent to the glass to allow the cutting blade SECTION A-A
of the cold knife to be positioned similarly to the hot
knife blade, inside the glass (refer Fig. 1A-71). HOT KNIFE
Figure 1A-71
BODY 1A-73
8. Carefully lift the windshield out of the body aperture.

If there is evidence of glass adhering to the
urethane, re-apply the hot or cold knife to the
problem area.
1--) 9. If the original windshield is to be reinstalled, place
\ : the windshield on a clean protected surface, holding
fixture, etc.
NOTE: The use of suction caps will greatly assist any
handling of the windshield.
10. Using a sharp scraper, carefully remove any original
urethane from the windshield. Clean the windshield
with a suitable oil free cleaning agent.
WARNING: DO NOT USE PETROLEUM BASED SOLV
ENTS TO CLEAN THE WINDSHIELD OR BODY OPE
NING FLANGE AS THE PRESENCE OF OIL WILL
PREVENT ADHESION OF THE NEW
URETHANE/SILICONE.
11. Correctly locate the windshield in the opening then
tape mask the outer top of the windshield and roof
on the right and left side, as illustrated in Fig. 1A-72.
This procedure assists the operators to align the
windshield in the correct horizontal plane during final
windshield installation.
MASKING TAPE
1�-=---------_J J
/
�-=----/,1
Figure 1A-72
() 12. Remove and place the windshield face down on a

clean protected surface or fixture.
3.2 SHORT METHOD INSTALLATION
DESCRIPTION
Short method installation involves the maximum amount
of the original urethane being left intact on the body
opening to form a sound base for the replacement
adhesive and windshield.
This method is recommended when replacing a cracked
or broken windshield, or a leak condition that cannot be
overcome by using minor water leak repair procedures.
If material other than urethane has been used for
previous servicing of the windshield, the long method
installation procedure (complete removal of adhesive) is
mandatory to achieve an effective glass to metal bond.
REINSTALL
1. Thoroughly clean the inner surface and edges of the
windshield which is to contact the new urethane,
using clean cloths and a suitable oil-free cleaning
solvent.
1A-74 BODY
2. Apply clear glass primer (HN1747) around the entire

perimeter of the windshield edge and 12 mm in
board, to the inner surface, as illustrated in
Fig. 1A-73.
NOTE: This is a wipe on/wipe off application using
oil-free clean cloths.
Figure 1A-73
3. Using the applicator included in the replacement kit,

apply glass primer (black HN1748) around the entire
perimeter of the windshield edge and 7 mm inboard
to the inner surface as illustrated in Fig. 1A-74.
NOTE: Allow this primed area to dry for 15 minutes. Do
not touch the primed surface.
Figure 1A-74
4. Using a sharp knife, cut out windshield side moulding

retaining clips. Also ensure that sufficient clearance
in the original urethane exists to accommodate the
upper and lower windshield mouldings.
5. Check for voids or looseness in original urethane.
Cut away any loose pieces of urethane and using a
suitable spatula, paddle fresh urethane or silicone
smoothly into any voids.
6. Using a hand or automatic applicator, apply a
smooth continuous bead of urethane adhesive
HN1749 between the centre and outer edge, on top
of original urethane and around entire perimeter of
the body opening. The urethane bead should be a
minimum of 6 mm in diameter.
NOTE: In cold weather, the placement of cartridges
adjacent to a source of warmth will assist the flow of
urethane when using the hand applicator.
7. With the aid of an assistant, install the windshield,
using the previously attached masking tape on the
roof and windshield to ensure accurate installation.
Press the windshield firmly into position.
8. Check effectiveness of the sealing from inside of the
vehicle. Should any gaps in the sealing exist, apply
additional urethane on the outside to fill these gaps.
Using a flat bladed tool, smooth the surface of the
urethane around the edge on the outside of the
windshield to ensure effective sealing.
9. Water test the windshield, using a moderate spray of
water.
NOTE: Do not direct a heavy stream of water onto
freshly applied urethane. If a water leak is evident, apply
additional urethane to the leak area, using a flat bladed
tool to work urethane into source of leak.
BODY 1A-75
IMPORTANT: If silicone is used, allow a minimum of one

(1) hour to permit the silicone to skin and adhere to the
original urethane prior to water testing the repair.
10. Ensure that the upper and lower mouldings and the
side moulding retaining clip cavities in the original
urethane contain sufficient urethane.
11. A 5.0 mm diameter butyl strip is applied on the inner
surface of the side mouldings as illustrated in
Fig. 1A-75. 0
NOTE: Where possible, use the original side moudings
without the original clips and place 4 'daubs' of urethane
evenly spaced to retain each moulding. The 'daubs' of
urethane should be applied to the underside of the side INNER SURFACE
OF WINDSHIELD
mouldings at the locations indicated in Fig. 1A-75. SIDE MOULDING
DAUBS OF
URETHANE
(4 PLACES) A
SECTION A-A
5.0 mm DIA. BUTYL \

STRIP
( ',) •
\" )
� 0
Figure 1A-75
12. Attach corner mouldings inside the lower end of the

windshield side mouldings, then mount the top of this
assembly into grommets located on the top of each
front body pillar (refer Fig. 1A-76, Section A-A).
NOTE: If the original upper and lower mouldings are to
be re-used, with a sharp knife, cut off the lower fir tree
section (at the first branch) or the original upper and
lower mouldings.
13. Locate one end of the windshield lower moulding
inside one of the lower corner mouldings, then
progressively install the moulding so that the edges
of the mouldings are hard against the windshield and
body. If necessary, trim off then tuck the opposite
end of the lower moulding into the opposite lower
-
corner moulding. Using the same procedure, install
the windshield upper moulding, tucking the ends
inside the top of the side mouldings as illustrated in �'
/NON HARDENING
Fig. 1A-76. GROMMET SEALER
SECTION A-A
Figure 1A-76
1A-76 BODY
14. Ensure that the windshield upper, lower and side

mouldings are firmly pressed into the urethane and
that they, as well as the lower corner mouldings, are
located hard against the windshield and body.
NOTE: It may be necessary to apply masking tape over
the top of the mouldings and onto the body to retain
these mouldings in position until the urethane/silicone
has cured sufficiently to retain them.
15. Clean off any excess urethane/silicone using Prepsol
or white spirit. Clean the windshield, then remove the
masking tape and protective covers previously
installed.
CAUTION: Ensure that door windows are partially lowe
red to eliminate pressure build up which can be caused
by slamming doors. A curing time of 5 hours is
recommended, although the vehicle may be driven after 2
hours, providing it is driven only on a sealed roads at
speeds not exceeding 80 km/h with the door windows
partially lowered.
3.3 LONG METHOD INSTALLATION
DESCRIPTION
The long method windshield replacement is used when
original urethane adhesive material cannot serve as a
base for the replacement windshield.
This method should be used on vehicles requiring metal
or paint repair to the windshield opening when original
adhesive is completely removed and replaced with new
urethane for windshield installation.
This method is also used when the windhsield has been
previously replaced, using the short method. In such
instances, the build-up of urethane could position the
windshield too high in the opening.
REMOVAL
1. Remove the windshield (refer 3.1).
2. Using a hot knife and/or sharp scraper, remove the
original urethane from around the entire perimeter of
the windshield opening flange.
BODY OPENING CHECK

1. Thoroughly check the windshield body opening flange
for any irregularities before installing the windshield.
NOTE: It may be necessary to remove the windshield
opening flange finishing lace (refer Fig. 1A-77).
FINISHING
LACE
Figure 1A-77
BODY 1A-77
2. Use the windshield as a template for checking

correct alignment between the windshield and body
opening. If necessary, reform the body opening
flange to produce a uniform flange to windshield
contour.
CAUTION: Care should be taken to ensure that glass
does not strike the windshield opening. Chipped edges
can lead to subsequent breakage of glass.
3. Correctly locate the windshield in the opening then
tape mark the outer top of the windshield and roof
on the right and left side, as illustrated in Fig. 1A-78.
lV�ll
This procedure assists the operators to align the
windshield in the correct horizontal plane during final
If
installation.
4. Remove and place the windshield face down on a
clean protected surface or fixture. MASKING TAPE
------��-�_JJ
--�--/,/
Figure 1A-78
REINSTALL
1. Using one of the applicators in the replacement kit,
apply flange primer (HN 1752) to any section of · the
windshield opening flange that has been cleaned
back to bare metal or to the painted surface (refer
Fig. 1A-79). Allow this primer to dry for 15 minutes.
Do not touch primed surfaces.
()
Figure 1A-79
NOTE: If the windshield opening flange finishing lace has

been removed, reinstall or replace the finishing lace (refer
Fig. 1A-80).
FINISHING
LACE
Figure 1A-80
I l
"'--__j
1A-78 BODY
2. Thoroughly clean the inner surface and edges of the

windshield to which the urethane is to be applied,
using clean cloths and a suitable oil free cleaning
·--------------
solvent.
3. Apply clear glass primer (HN1747) around the entire
. . ----:-----
perimeter of the windshield edge and 12 mm inboard
to the inner surface, as illustrated in Fig. 1A-81).
NOTE: This is a wipe on/wipe off application using lint
free cloths.
Figure 1A·81
4. To maintain appearance and to mm,m,se clean up,

install glazing dams, Part Nos. 92031121 for the
sides and the top and 92029382 for the bottom.
Remove the paper backing from the 7 .5 mm high
dam, then commencing at either lower corner of the
windshield, locate' the dam up one side, across the
top, then down the opposite side of the windshield,
7 mm inwards from the edge of the inner surface.
Repeat this operation across the bottom of the
windshield, using the 9 mm high dam (refer
Fig. 1A-82).
NOTE: A suitable gauge to maintain the dam 7 mm from
the edge of the windshield can be readily fabricated by
cutting a 7 mm notch in a piece of wood. Locate the
7 mm dimension of the gauge onto the inner surface of
the windshield, locating the outer edge of the dam on the
)
end of the 7 mm dimension. Figure 1A-82
5. Using one of the applicators included in the replace

ment kit, apply glass primer (black HN1748) around
the entire perimeter of the windshield edge, in
between the edge and the glazing dam as illustrated
in Fig. 1A-83.
NOTE: Allow this primed area to dry for 15 minutes. Do
not touch the primed surface.
Figure 1A-83
6. Apply urethane adhesive (HN1749) to the 7 mm wide

bonding surface in a bead approximately 17 mm high
around the entire perimeter of the windshield edge,
in between the edge and the glasing dam as
illustrated in Fig. 1A-84.
(
\"- j
Figure 1A-84
BODY 1A-79
7. With the aid of an assistant, install the windshield

using the previously attached masking tape on the
roof and windshield to ensure accurate installation.
Press the windshield firmly into position to dimens-
(--,"' ions illustrated in Fig. 1 A-85.
\ )
Figure 1A-85
8. Check effectiveness of the sealing from inside of the

vehicle. Should any gaps in the sealing exist, apply
additional urethane on the outside to fill these gaps.
Using a flat bladed tool, smooth the surface of the
urethane around the edge on the outside of the
windshield to ensure effective sealing.
9. Water test the windshield, using a moderate spray of
water.
(
freshly applied urethane. If a water leak is evident, apply
additional urethane to the leak area, using · a flat bladed
tool to work urethane into source of leak.
10. Ensure that there is sufficient urethane around the
outer edge of the windshield to retain the upper and
lower mouldings and the side mouldings.
(
�_/
)
1A-80 BODY
11. A 5.0 mm diameter butyl strip is applied on the inner

surface of the side mouldings, as illustrated in
Fig. 1A-86. 0
NOTE: Where possible, use the original side mouldings
without the original clips and place 4 'daubs' of urethane
evenly spaced to retain each moulding. The 'daubs' of
urethane should be applied to the underside of the side INNER SURFACE
mouldings at the locations indicated in Fig. 1 A-86. OF WINDSHIELD
SIDE MOULDING
DAUBS OF -,:��-!!I�
URETHANE
(4 PLACES) A
SECTION A-A
5.0 mm DIA. BUTYL

STRIP
)
Figure 1A-86
12. Attach corner mouldings inside the lower end of the

windshield side mouldings, then mount this assembly
into grommets located on the top of each front body
pillar (refer Fig. 1A-86a, Section A-A).
NOTE: If the original upper and lower mouldings are to
be re-used, with a shaft knife, cut off the lower fir tree
section (at the first branch) of the original upper and
lower mouldings.
13. Locate one end of the windshield lower moulding
inside one of the lower corner mouldings, then
progressively install the moulding so that the edges
of the mouldings are hard against the windshield and
body. If necessary, trim off then tuck the opposite
end of the lower moulding into the opposite lower
-
corner moulding. Using the same procedure, install
the windshield upper moulding, tucking the ends
inside the top of the side mouldings as illustrated in �'
/NON HARDENING
Fig. 1 A-86a. GROMMET SEALER
SECTION A-A
-Figure 1A-86a
14. Ensure that the windshield upper, lower and side

mouldings are firmly pressed into the urethane and
that they, as well as the lower corner mouldings, are
located hard against the windshield and body.
NOTE: It may be necessary to apply masking tape over
the top of the mouldings and onto the body to retain
these mouldings in position until the urethane has cured
sufficiently to retain them.
BODY 1A-81
15. Clean off any excess urethane using Prepsol or white

spirit, clean the windshield, then remove the masking
tape and protective covers previously installed.
CAUTION: Ensure that door windows are partially /owe
/-� red to eliminate pressure build up which can be caused
(, ) by slamming doors.
IMPORTANT: A curing time of 12 hours is mandatory
following long method windshield installation.
3.4 MINOR WATER LEAK CORRECTION

1. Apply protective covering and masking tape adjacent
to the leak suspect area.
To determine the precise location of the water leak,
use the air/soap bubble leak test.
2. Locate an air hose nozzle on the inside of the
windshield as illustrated in Fig. 1A-87. Have an
assistant outside the vehicle apply a soapy water
solution opposite the air source. As a medium air
pressure (60 kPa) is applied, soap bubbles will form
on the outside of, the windshield, indicating the
location of the leak.
NOTE: The soap/water solution can be applied with
either a spray applicator or brush.
Figure 1A-87
3. If the suspect leak area is not obvious, commence

the testing across the bottom, up the sides, then
across the top of the windshield until the leak
location has been determined.
4. Remove the windshield moulding (refer preceding
instructions) covering the leak location ihen, if
silicone is to be used, thoroughly dry out the repair
area with compressed air.
NOTE: If urethane is being used, it is only necessary to
remove dust, foreign matter, etc. Water activates the
curing process of urethane.
5. Using a spatula, work fresh urethane or silicone in
and around the leak area.
6. If urethane has been used, leak test the repair, using
the air/soap bubble leak test or a non pressurized
water leak test.
original urethane prior to testing the repair.
Should the leak persist, apply additional urethane/
silicone until the leak has been corrected.
7. Reinstall any of the windshield mouldings removed to
carry out the leak correction.
8. Clean windshield and adjacent paint finish, then
l_) remove the masking tape and protective covers.
1A-82 BODY
3.5 REAR QUARTER WINDOW

ASSEMBLY - SEDAN
WITH GLASS.
NOTE: , Skinning (partial curing) of urethane adhesive
commences after exposure to the atmosphere at
23 degrees celcius and 50 percent relative humidity for
30 minutes. Installation of the mouldings surrounding the
rear quarter window must be completed within that time
limit. Complete curing of the urethane at that temperature
and humidity takes 72 hours.
REMOVE
The quarter window removal procedure is similar for both
the short and long installation methods with one
exception.
If the short method installation is to be used, more care
must be taken during glass removal to ensure that an
even surface of the original remaining urethane exists on
the quarter window aperature flanges to serve as a base
for the new urethane/ silicone bead and the replacement
glass.
1. To prevent damage to paint finish and trim and to
minimise clean up, mask and place protective covers
over parts adjacent to glass.
2. Using fingers or a wide bladed screwdriver, carefully
prise off the leading edge of the rear drip moulding REAR DRIP MOULDING
from the garnish moulding (refer Fig. 1A-88, Sections
G-G and H-H).
3. Remove screw securing rear end of quarter reveal
moulding lower (refer Fig. 1A-88, Sections H-H and
J-J) and remove moulding.
SECTION H-H
QUARTER WINDOW
GARNISH MOULDING
SECTION G-G
Figure 1A-88
1,t
BODY 1A-83
4. Remove remaining screws securing garnish moulding

to rear quarter aperture (refer Fig. 1A-89) then
remove the garnish moulding which is attached to
the outer surface of the glass with four (4) short
strips of butyl, centrally spaced at top, bottom and
(,/-�\1 sides of garnish moulding (refer Fig. 1A-90) then
remove garnish moulding.
Figure 1A-89
GLASS�
Figure 1A-90
5. Locate blade of Tool No. J24402, cold knife, bet

ween the inside of the glass and urethane as
illustrated in Fig. 1A-91, then cut through urethane
around complete periphery of glass.
6. Carefully lift glass out of aperture. If there is
evidence of glass adhesion to urethane, re-apply the APPROXIMATE
cutting tool to the problem area. AREA EQUALS
ONE SQUARE
CENTIMETRE
HN1749
URETHANE
ADHESIVE
VIEW QJ
Figure 1A-91
1A-84 BODY
7. If original glass is to be reinstalled, place glass on a

protected bench or holding fixture and using a sharp
scraper, carefully remove original urethane from
glass. Clean glass with a suitable oil free cleaning
agent.
NOTE: Do not use petroleum based solvents to clean
glass or aperture flange as the presence of oil will
prevent the adhesion of new urethane/silicone.
REAR QUARTER WINDOW APERTURE CHECK

Thoroughly check rear quarter window aperture flange to
ensure that no surface irregularities exist. Correct any
that do. If short method glass installation is to be used,
check original urethane on flange for looseness or voids.
Where these exist, cut away any loose urethane and fill
in any voids or uneveness in bead, using
urethane/silicone.
3.6 SHORT METHOD INSTALLATION
DESCRIPTION
Short method installation of rear quarter glass is used
where the maximum amount of original urethane adhesive
is left intact on the body opening to form a base for the
replacement adhesive and glass. This method should be
used when replacing a cracked glass or correcting a leak
condition that cannot be overcome by using minor water
leak repair procedures. Any previous service installation
using other adhesive materials requires complete replace
ment of materials to achieve an effective glass to metal
bond.
REINSTALL
1. Thoroughly clean surface of glass to which new
urethane/silicone is to contact (including edge of
glass). Use clean cloths with a suitable oil free
cleaning solvent.
2. Using an applicator supplied in short method replace
ment kit (No. 92018611) apply HN1747 clear glass
primer around entire perimeter of glass edge and
12 mm in from edge of glass. This is a wipe on/wipe
off operation, using clean lint free cloths (refer
Fig. 1A-92, ('E').
3. Using a second applicator, apply HN1748 glass
primer (black) around entire perimeter of glass edge
and on glass bonding surface (refer Fig. 1A-92, ('G').
Allow primer to dry for 15 minutes. Avoid touching
primed area of glass.
4. Install glass with its inner surface facing upwards into
garnish moulding as illustrated in Fig. 1A-92, ('H'),
then firmly press glass onto butyl strips located on
garnish moulding recess.
BODY 1A-85
BUTYL STRIPS
(4 PLACES)
GLASS
(BLACK OUT) PRIMER
C)
Figure 1A·92
5. Apply a smooth continuous bead of urethane/silicone

between centre and outer edge on top of original
urethane and around entire perimeter of body
opening. Urethane/silicone bead should be a
minimum of 6 mm in diameter.
6. Install glass and garnish moulding assembly into rear
quarter window aperture, applying sufficient pressure
on assembly to evenly distribute urethane/silicone
between glass and aperture flange to effect a
watertight seal.
1A-86 BODY
7. Install screws securing garnish moulding to the

window aperture (refer Fig. 1 A-93).
Figure 1A-93
8. Water test the quarter window using a moderate

spray of water.
freshly applied urethane. If a water leak is evident,
remove the garnish moulding and apply additional
urethane to leak area, using a flat bladed tool to work
fresh urethane into the source of the leak. Reinstall the
garnish moulding.
original urethane prior to water testing the installation.
BODY 1A-87
9. Install screw attached quarter reveal moulding lower QTR. WINDOW GARNISH MOULDING
to lower section of garnish moulding (refer Fig. 1A-
94, H-H).
10. Locate hooked edge of rear drip moulding over
f,,--"\ rearward outer edge of garnish moulding, then with
\ I the hand, lightly tap opposite side of moulding over
garnish moulding (refer Fig. 1A-94, G-G).
G-G
REAR DRIP MOULDING
SCREW
2 PLACES
QTR. REVEAL MOULDING

TO BE INSTALLED BEFORE
H-H REAR DRIP MOULDING
� APPLY SEALER HN1044 OVER HOLES

W, TO EFFECT A WATERTIGHT SEAL.
Figure 1A-94
11. Clean window and adjacent paint finish. Then remove

the masking tape and protective covers.
3.7 LONG METHOD INSTALLATION
DESCRIPTION
The long method of glass replacement is used when
original urethane adhesive material cannot serve as a
base for replacement glass.
This method should be used on vehicles requiring metal
or paint repair to the quarter window aperture flange
when original adhesive is completely removed and
repla�ed with new urethane for glass installation.
This method is also used when the quarter window has
been previously replaced using the short method. In such
instances, the build-up of urethane/ silicone could position
the glass too far out of the opening.
REINSTALL
1. Using the cold knife and/ or sharp scraper, remove
original urethane from around entire perimeter of
quarter window aperture flange.
2. Using an applicator supplied in long method replace
ment kit No. 92018612, apply HN1752 (flange
primer) to any section of the quarter window aperture
( \
flange that is back to bare metal or has be�n
\�j cleaned back to original paint surface (refer Fig. 1A-
95, Views 'A', 'B', 'C' and 'D'). Allow primer to dry
for 30 minutes. Do not touch primed area.
1A·88 BODY
FLANGE PRIMER
VIEW [A] VIEW [ID
VIEW�
Figure 1A·95
3. Thoroughly clean inner surface of glass to which

urethane is to be applied as well as around complete
edge of aperture flange. Use clean cloths with
suitable oil free cleaning solvents.
eoov- 1A-89
4. Using applicator in long method kit, apply HN1747
clear glass primer around entire perimeter of glass
edge and 12 mm in from edge of glass. This is a
wipe on/wipe off operation, using clean lint free
cloths (refer Fig. 1A-96, Vie\f_ 'E').
5. To maintain appearance and minimise clean up,
install a foam glazing dam, Part Number 92022155 to
glass. Commencing at either lower corner of glass,
locate dam around entire perimeter of glass, 7 mm
in from edge on inner surface (refer Fig. 1A-96, View
'F').
VIEW�
E F----
()
Figure 1A-96
NOTE: A suitable gauge to maintain the dam 7 mm from

edge of glass can be readily fabricated by cutting a
7 mm notch in a piece of wood. Locate the 7 mm
dimension of the gauge onto the inner surface of the
glass, locating the outside edge of the dam on the end
of the 7 mm dimension.
6. Using a second applicator, apply HN1748 glass
primer (black) around entire perimeter of glass edge
and on glass bonding surface (refer Fig. 1A-97, View
'G'). Allow primer to dry for 15 minutes. Do not touch
primed area of glass.
7. Tidy up strips of butyl centrally located on top,
bottom and on both sides of garnish moulding (refer
Fig. 1A-97, View 'H').
8. Install glass with its inner side facing upwards into
garnish moulding as illustrated in Fig. 1A-97, View
'H'. Firmly press glass onto butyl strips located at
four places on garnish moulding recess.
9. Using a hand operated applicator with special nozzle
supplied in kit, apply a smooth continuous bead of
HN1749 urethane adhesive, 17 mm high and 7 mm
at base, around entire perimeter of inner surface of
glass (refer Fig. 1A-97, View 'J').
NOTE: In cold weather, the placement of cartridges
adjacent to a source of warmth will assist the flow of
urethane when using a hand applicator.
I
\""--___,./
1A-90 BODY
VIEW�
APPROX AREA EQUALS

ONE SOUARE
CENTIMETRE
MOULDING
) 17.0
BUTYL STRIPS
(4 PL ACES)
VIEW� VIEW [HJ
Figure 1A-97
to.
·'
Install glass and garnish moulding assembly into rear

quarter window aperture, applying sufficient pressure
on assembly to evenly distribute urethane between
glass and aperture flange to effect a watertight seal.
1. Install screws securing garnish moulding to the
quarter window aperture (refer Fig. 1A-98).
Figure 1A-98
12. Water test quarter window using a moderate spray of

water.
1
BODY 1A-91

freshly applied urethane. If a water leak is evident,
remove garnish moulding and apply additional urethane to
the leak area, using a flat bladed tool to work urethane
into source of leak, then install garnish moulding.
13. Install screw attached quarter reveal moulding lower QTR. WINDOW GARNISH MOULDING
to bottom horizontal part of garnish moulding (refer
Fig. 1A-99, H-H).
14. Locate hooked edge of rear drip moulding over
rearward outer edge of garnish moulding, then with
the hand, lightly tap opposite side of moulding over
garnish moulding (refer Fig. 1 A-99, G-G).
G-G
REAR DRIP MOULDING
SCREW
2 PLACES
OTA. REVEAL MOULDING

TO BE INSTALLED BEFOFfE
H-H REAR DRIP MOULDING
( Q APPLY SEALER HN1044 OVER HOLES

W TO EFFECT A WATERTIGHT SEAL.
Figure 1A-99
3.8 TAIL GATE WINDOW • STATION

WAGON
WITH GLASS.
NOTE: Skinning (partial curing) of urethane adhesive
commences after exposure to the atmosphere at
23 degrees celcius and 50 percent relative humidity for
30 minutes. Installation of the mouldings surrounding the
tail gate window must be completed within that time limit.
Complete curing of the urethane at that temperature and
humidity takes 72 hours.
3.9 MINOR WATER LEAK CORRECTION

To determine the precise location of the water leak, use
the air/ soap bubble leak test, which consists of:
1A-92 BODY
1. Locate an air hose nozzle in between the glass and

the finishing lace on the inside of the vehicle, as
illustrated in Fig. 1A-100. Have an assistant outside
the vehicle apply a soapy water solution opposite the
air source. As a medium air pressure (60 kPa) is
applied, soap bubbles will form on the outside of the
glass, indicating the location of the leak.
NOTE: The soap/water solution can be applied with
either a spray applicator or a brush.
FINISHING LACE
TAILGATE _j
Figure 1A-100
2. If the suspect area has not been previously

established, commence the leak test across the
bottom, up the sides, then across the top of the
glass, until the leak location has been determined.
3. Use the compressed air to remove any dust or
foreign matter that could be trapped between the
glass and finishing lace and if silicone is to be used
for the repair, ensure that the area to which the
silicone is to be applied is thoroughly dry.
NOTE: This drying off operation is not necessary if
urethane is being used, as water activates the curing
process of urethane.
4. Apply masking tape to the glass and finishing lace,
adjacent to the repair area and install coverings in
tail gate area, to minimise subsequent clean up
operations.
5. Using a silicone or urethane cartridge fitted with a
plastic nozzle with a 90 degree angle formed at the 4mm., j...
discharge end of the nozzle (refer Fig. 1A-101)
locate the nozzle in between the glass and the RESTRICTION CAUSED BY COLLAPSE
finishing lace, against the original urethane. Apply the AT CENTRE OF BEND WILL ALLOW
silicone/urethane, extending the application SUFFICIENT FLOW OF ADHESIVE.
approximately 50 mm either side of the leak source.
NOTE: To achieve the 90 degree angle in the discharge
end of the plastic nozzle, place the nozzle in hot water,
form the angle then trim the formed end to the dimension
STANDARD PLASTIC
..,_.... NOZZLE
. Figure 1A-101
IMPORTANT: If silicone is to be used for the repair,

allow a minimum of one (1) hour to permit the silicone to
skin and adhere to the original urethane.
6. Using the air/soap bubble leak test or a non
pressurised water leak test, check the repair.
BODY 1A-93
7. If the water leak persists in the repaired area and

the leak location is behind either side moulding,
carefully remove the side moulding covering the leak
by locating a sharp knife (stanley etc.) in between
/--,,. the glass and the moulding, as illustrated in Fig. 1A-
( ) 102. Cut through the side moulding lugs, then make
an additional cut down the outside of the lugs. This
will allow the moulding lugs to be removed, using
pointed nose pliers.
NOTE: If the leak source is behind the upper or lower
moulding, the long method removal operation will be
necessary. Refer subsequent procedures.
Figure 1A-102
8. Prefit the replacement moulding(s) and if necessary,

trim the original urethane to provide a correct fit,
then remove the replacement moulding.
9. Prime the retaining lugs on the inside of the side
moulding and the fir tree section of upper or lower
mouldings with HN1748 glass primer (black). This
primer requires 15 minutes curing time before
installation.
10. Using a spatula, work fresh urethane in and around
leak area and fill the channel created by the removal
of the original moulding lugs.
11. Water test the repair using light water pressure only
so as not to displace the freshly applied urethane/
silicone. Should the leak persist, apply additional
urethane/silicone until the leak has been corrected.
IMPORTANT: If silicone is to be used for the repair,
allow a minimum of one (1) hour to permit the silicone to
skin and adhere to the original urethane.
12. Apply hot-mix adhesive (Bostik, etc.) to the inside of
the side moulding as illustrated in Fig. 1A-102, then
install the moulding, applying hand pressure on the
moulding for one minute, allowing the hot-mix adhes
ive to set.
.e INDICATES LOCATION OF HOT MIX ADHESIVE

(11 PLACES)
Figure 1A-103
l)
:I
1A-94 BODY
THREADING DETAIL
SECTION A-A
TAILGATE
ASSEMBLY
BUCKLE HOOKED OVER STRAP OVER MOULDING
TAILGATE ASSEMBLY ON WINDOW SURROUND
(TOP BOTTOM)
��- RUBBER STRAP

(50 mm WIDE)
...
.... ·. . :
8
·
... . ..
�----------------780mm---------------�i
� 1-
15.0 30.0
... ,,�1
7.5 12.5
SECTION 8-8
BUCKLE DETAIL
�----Ztl�.l:5-_...,�
NOTE
38.0 DIMENSIONAL LENGTH OF RUBBER STRAP
NOMINAL - MUST PROVIDE SUFFICIENT PRESSURE
TO RETAIN SIDE MOULDINGS TO TAILGATE
UNTIL CURING OF URETHANE EFFECTIVELY
----1.0 mm M5 SHEET RETAINS THESE MOULDINGS.
PLASTIC C OATED
. I
---+---- 3.0 mm STEEL ROD
60.0
Figure 1A-104
BODY 1A-95
13. Apply rubber straps illustrated in Fig. 1A-104, Section

A-A to maintain pressure on the moulding.
NOTE: These straps, which clip over the top and bottom
of the tail gate, can be fabricated from rubber and metal
,,-� to dimensions illustrated in Fig. 1A-104.
( ) As a temporary alternative, apply masking tape over the
top of the replacement moulding to firmly retain the
moulding to the glass and tail gate. Secure the tail gate
in a horizontal attitude and apply an insulated weight on
top of the replaced moulding(s) or approximately 5 hours.
3.10 LONG METHOD
REMOVE
1. Disconnect battery ground cable and on Berlina
Model, remove tail gate window wiper arm and blade
assembly and electrical demist connectors.
2. Apply masking tape to paintwork adjacent to mould
PROTECTIVE TAPE
ings as shown in Fig. 1A-105 and place protective
covering around tail gate opening.
( - ')) Figure 1A-105
CAUTION: When working with glass, the wearing of

safety glasses and work gloves is mandatory.
3. Should the glass be broken, carefully remove all
fragments of glass from the tail gate window
aperture.
1A-96 BODY
4. Using a sharp cutting tool (Stanley knife etc.) located

as illustrated in Fig. 1A-106, 'F' and 'H', carefully cut
through urethane adjacent to moulding lugs, then pull
out moulding.
Figure 1A-106
5. Remove escutcheon and finishing lace from tail gate

window aperture. Using the Cold Knife, J24402, and
following the procedure set out in Step 7 '3.1
Windshield Glass - Remove', in this Section, carefully
cut o ut the tail gate window.
NOTE: It is not necessary to remove all traces of original
urethane. However, any original urethane remaining must
be smooth and firm.
REINSTALL
1. Where bare metal is evident, prime area with flange
primer (HN1752) and allow to dry for 30 minutes
(refer Fig. 1A-107, 'A'), then replace finishing lace.
2. Prime the edge of the glass and on the glass
bonding surface, 12 mm from the edge with clear
glass primer (HN1747). This is a wipe on/wipe off
operation (refer Fig. 1A-107, 'B').
3. Prime the lugs of the tail gate mouldings and the
edge of the glass and on the glass bonding surface,
12 mm from the edge with glass primer (black
HN1748) and allow to dry for 15 minutes (refer
Fig. 1A-107, 'C').
Figure 1A-107
BODY 1A-97
4. With the tail gate anchored in a horizontal plane,

apply an even bead of urethane adhesive (HN1749)
9 mm x 13 mm to the blading flange as shown in
Fig. 1A-108, 'B' u�ing nozzle cut as shown in
Fig. 1A-108, 'C'.
\il13.0
VIEW[[]
VIEW@]
Figure 1A-108
5. Install the glass centrally in the aperture, ensuring

that the outer surface of the glass is level with the
tail gate outer panel.
6. Apply two (2) temporary spacers 4 mm square x
13 mm long at base of glass, 50 mm in from sides
of window, to prevent glass from sliding down in the
tail gate aperture when the tail gate is closed for
subsequent water leak test.
7. With the tail gate closed, water test immediately,
using a non pressurized flow of water so as not to
( displace the freshly applied urethane. Commence the
water test across the bottom, up the sides, then
across the top of the glass. Remove temporary
spacers and replace any urethane that has been
displaced.
8. Ensure that there is sufficient urethane in the
channel surrounding the glass to retain the
mouldings, which must be installed as soon as the
water test is complete, before the urethane begins to
skin.
9. Remove the masking tape and install the lower then
upper tail gate mouldings, aligning the centre tab of
these mouldings with the centre mark on the tail
gate glass.
( \'
\
"-.. ___/
1A-98 BODY
10. Each side moulding must be installed separately

following the application of hot-mix adhesive (Bostik
etc.) to the inner face of the moulding, as illustrated
in Fig. 1A-109.
[
elNDICATES LOCATION OF HOT MIX ADHESIVE
(11 PLACES)
Figure 1A-109
11. Apply firm hand pressure to each side moulding for

approximately one minute to allow the hot-mix
adhesive to set.
12. Apply rubber straps illustrated in Fig. 1A-11O to
maintain pressure on the side mouldings.
NOTE: These straps, which clip over the top and bottom
of the tail gate can be fabricated from rubber and metal
to dimensions illustrated in Fig. 1A-104.
STRAP OVER MOULDING

ON WINDOW SURROUND
Figure 1A-110
13. As a temporary alternative, apply adhesive tape over

the side mouldings where required.
14. Leave the tail gate in a horizontal position for 24
hours, with insulated weights on top of the side
mouldings.
15. On Berlina model, install tail gate window wiper arm
and blade assembly and demist electrical connectors
and on Berlina and SL models, the battery ground
cable.
16. Clean adjacent paint finish and glass then remove
protective covering from the interior.
Components required in addition to either short or long
method glass replacement kits include the appropriate
mouldings, tail gate finishing lace and escutcheon and a
tail gate window.
i i,
BODY 1A-99
3.11 BACK WINDOW • SEDAN
REMOVE
1. Disconnect battery ground cable then disconnect
(/___""',, back window electrical demist connectors.
2. Place protective covering adjacent to back window to
protect trim and paint finish.
3. Remove the back window by applying hand pressure
from inside the vehicle, pressing the window
outwards.
WARNING: LEATHER OR THICK CLOTH GLOVES
MUST BE WORN WHEN HANDLING GLASS.
4. If moderate hand pressure fails to free the window
and weatherstrip, a steady foot pressure may be
applied, using a thick pad of felt between the foot
and the glass to protect the window. Distribute any
pressure evenly.
5. Remove and place the back window and
weatherstrip assembly face down on a clean protec
ted surface.
6. Remove the weatherstrip, then clean out any original
sealer from the glass and body flange channels in
the weatherstrip.
7. Remove original sealer from the body opening
flange.
BACK WINDOW OPENING CHECK

1. Thoroughly check the back window opening flange
for any irregularities before installation of replace
ment back window.
2. To utilize the back window as a template for
()
checking the alignment of the back window opening,
cut four rubber spacers 50 mm long from a spare
weatherstrip.
3. Place the four spacers on the opening flange at
locations shown in Fig. 1A-111 and with the aid of
an assistant, position the glass centrally in the
opening.
NOTE: Having positioned the glass on the rubber
spacers, examine the general relationship of glass to the
body opening flange.
CAUTION: Care should be taken to ensure that glass
does not strike the back window opening. Chipped edges
can lead to subsequent breakage of glass. APPLY SEALER BETWEEN CHANNEL
AND GLASS AND BETWEEN CHANNEL
AND BODY AROUND ENTIRE WINDOW
OPENING AFTER INSTALLATION TO
ENSURE A WATERTIGHT SEAL.
SECTION A-A
Figure 1A·111
4. Check and if necessary, re-form the body flange to

produce a uniform flange to glass contour.
5. Having corrected any irregularities and with the glass
still in position, mark centre line of glass and body
so that glass can be accurately located in the
opening.
1A-100 BODY
REINSTALL
1. Assemble glass retainer channel on glass with its
securing lip towards concave side of glass.
NOTE: On Calais, a reveal moulding is installed in the
weatherstrip prior to weatherstrip installation to the glass
(refer Fig. 1 A-112, Section 8-8).
MODELSVX
SECTION B-8
ct APPLY SEALER HN1075 BETWEEN CHANNEL AND

REAR WINDOW GLASS AND BETWEEN CHANNEL
AND BODY AROUND ENTIRE WINDOW OPENING
AFTER INSTALLATION OF CHANNEL AND GLASS
- TO ENSURE A WATERTIGHT SEAL
Figure 1A-112
2. Insert a strong cord inside body flange cavity of

glass retainer channel all around, leaving ends
protruding centrally at lower edge. Tape ends to
inside of window.
3. With the aid of an assistant, carefully place back
window assembly centrally in opening, using centre
line markings on glass and body.
4. While pressing the window firmly from outside, have
an assistant inside the body slowly pull the cord from
the centre position toward each lower corner of the
back window. This is to seat the lip of the glass
retainer channel over the top of the opening flange.
Then pull the cord up both sides and towards the
upper centre of back window.
5. Apply sealer between the glass and outer wall of the
rubber channel and between channel and body,
around complete perimeter of glass (refer Figs. 1 A-
111 and 1 A-112, Sections A-A and 8-8). Ensure that
the outer sealing lip of the glass retainer channel is
sealing correctly on the body.
6. Remove the protective covering then, using Prepsol
or white spirit, clean off any surplus sealer from the
back window, weatherstrip and adjacent paint finish.
BODY 1A-101
3.12 REAR QUARTER WINDOW •

STATION WAGON
/,--"'\ DESCRIPTION
1
J Removal and installation procedures for the rear quarter
windows illustrated in Fig. 1 A-113 are the same as those
used for the removal and installation of the back windows
on sedans (refer preceding instructions).
NOTE: Removal and installation of rear quarter window
reveal mouldings on station wagons necessitates removal
of the rear quarter window.
( ) '
·--------- -- SECTION A-A
e APPLY SEALER HN1075, SHOWN THUS BETWEEN

CHANNEL AND GLASS AND BETWEEN CHANNEL
AND BODY AROUND ENTIRE WINDOW OPENING
AFTER INSTALLATION TO ENSURE A WATERTIGHT
SEAL.
Figure 1A-113
1A-102 BODY
NOTES
)
BODY 1A-103
SEATS & SEAT BELT ASSEMBLIES

INDEX
1. GENERAL DESCRIPTION ..............................1A-103 2.8 REAR SEAT BACK COVER - STATION
2. SERVICE OPERATIONS.................................1A-103 WAGON .............................................................1A-110
2.1 FRONT BUCKET SEAT ASSEMBLY............1A-103 Remove ....................................................1A-110
Remove ....................................................1A-103 Reinstall ...................................................1A-112
Reinstall ...................................................1A-105 2.9 REAR SEAT BACK LOCK - STATION
2.2 FRONT SEAT ADJUSTER AND HEIGHT WAGON .............................................................1A-112
ADJUSTER ASSEMBLIES.............................. 1A-105 Remove .................................................... 1A-112
Remove ....................................................1A-105 Reinstall ................................................... 1A-112
Reinstall ...................................................1A-105 2.1O REAR SEAT BACK FLAP - STATION
2.3 LUMBAR SUPPORT ASSEMBLY - WAGON .............................................................1A-113
BERLINA AND CALAIS..................................1A-106 Remove .................................................... 1A-113
Remove ....................................................1A-106 Reinstall ................................................... 1A-114
Reinstall ...................................................1A-107 2.11 FRONT SEAT BELT RETRACTOR AND
2.4 FRONT SEAT HEAD RESTRAINT BUCKLE ASSEMBLY ...................................... 1A-114
ASSEMBLY .......................................................1A-107 Remove .................................................... 1A-114
Descrlption ..............................................1A-107 Reinstall ................................................... 1A-114
Remove ....................................................1A-107 2.12 REAR SEAT BELT RETRACTOR
Reinstall ...................................................1A-107 ASSEMBLY - SEDAN ......................................1A-115
2.5 REAR SEAT CUSHION AND BACK Remove .................................................... 1A-115
ASSEMBLIES • SEDAN ..................................1A-108 Reinstall ...................................................1A-118
Remove .................................................... 1A-108 2.13 REAR SEAT BELT RETRACTOR
Reinstall ................................................... 1A-108 ASSEMBLY - STATION WAGON ................. 1A-118
2.6 REAR SEAT CUSHION ASSEMBLY Remove .................................................... 1A-118
STATION WAGON ...........................................1A-110 Reinstall ...................................................1A-119
Remove....................................................1A-11O
Reinstall ...................................................1A-11O
2.7 REAR SEAT BACK ASSEMBLY -
STATION WAGON...........................................1A-110
Remove ....................................................1A-11O
Reinstall ...................................................1A-11O
The full foam contoured reclining bucket seats which have non adjustable see through head restraints feature cloth (knit)
covering for the base models, woven fabric on Berlina and plush velour for the Calais.
Bar control front seat 'fore and aft' adjusters are fitted to all models. A lever controlled driver's seat height adjuster is
featured on all models.
The new lumbar support control handwheel mounted on the outside of the right side front seat on Berlina and Calais
models provides infinite adjustment.
The full foam contoured rear bench seats use the same type of cover material as the front seats.
The Berlina and Calais feature fold-down centre armrest on the rear seat with non-adjustable see-through head restraints
on Calais models.
Fold-down rear seats on station wagons are similar to those used on 'VK' Series.
2.1 FRONT BUCKET SEAT ASSEMBLY
REMOVE
1. Slide the seat assembly fully rearward and remove
the screws securing the front end of the seat
adjuster to floor, illustrated in Fig. 1A-114, Sections
A-A or B-8 and D-D.
2. Slide the seat assembly fully forward and remove the
screws securing the rear end of the seat adjuster to
floor pan, illustrated in Fig. 1A-114, Sections A-A or
C-C and D-D.
3. Remove, then place seat assembly on a clean
protected surface.
..:,
....
I
....
•
m
0
C
-- ........- �
//-� SECTION 8-8

1 PLACE PASS. SEAT
SECTION A-A
4 PLACES ORV. SEAT
1f
�=
� APPLY 5.0DIA. BEAD OF NON-HARDENING
SEALER AROUND TOP EDGE OF HOLES IN
- FLOOR PAN BEFORE INSTALLATION OF SEATS.
SECTION C-C SECTION D-D

� 30-35Nm
1 PLACE PASS. SEAT 2 PLACESPAss. SEAT
Figure 1A-114
-------
,/--------
\
"-._ ____, ,___ ..,,/
'-._____../
BODY 1A-105
REINSTALL
1. Apply a 5.00 mm dia. bead of non-hardening sealer
around the holes in the floor pan as illustrated in
Fig. 1A-114, Sections A-A, 8-8, C-C and D-D.
2. Install the seat assembly, tightening the seat attach
ing screws to 30-35 Nm.
2.2 FRONT SEAT ADJUSTER AND

HEIGHT ADJUSTER ASSEMBLIES
REMOVE
1. Remove the front seat assembly (refer 2.1) then
place the assembly face down on a clean protected
surface.
2. Carefully prise off the seat back recliner control
wheel then, remove the height adjuster lever covers
3. Remove the screws securing the height adjuster
assemblies to the floor pan (refer Fig. 1A-115),
removing the assembly(ies).
r
SCREW�
HEIGHT ADJUSTER ASM.
/
ENDPIECE
r
\ � SCREW&
\
( J
SCREW�
COVER-LEVER
& 20-25Nm
COVER-HEIGHT ADJUSTER
Figure 1A-115
REINSTALL
1A-106 BODY
2.3 LUMBAR SUPPORT ASSEMBLV •

BERLINA AND CALAIS
REMOVE
1. Remove the front bucket seat assembly (refer 2.1)
then place the assembly face down on a clean
protected surface.
2. Completely slacken off the lumbar support, then
carefully prise off the lumbar support control wheel
and remove the screws securing the cover illustrated
in Fig. 1A-116.
3. From under the seat cushion, remove the elastic CARPET ASM.
straps which are looped under tension over the seat
cushion spring convolutions and which retain the
lower edge of the seat back carpet as illustrated in
Fig. 1A-116.
Figure 1A-116
4. .Remove the 'W' clip and hogrings securing the

bottom section of the front seat back cover to the
frame illustrated in Fig. 1A-117.
5. Carefully ease the seat back cover upwards until the
cover is clear of the lumbar support assembly.
Figure 1A-117
BODY 1A-107
6. Remove the hogrings securing the lower part of the

foam pad to the seat back frame, just above the
lumbar support frame, refer Fig. 1 A-118.
7. Remove the screws securing the strap retainer and
the lumbar support control assembly from the right
side of the seat back frame (refer Fig. 1A-118
Section B-B) then remove the inner end of the strap,
which is hooked through a bracket on the left side of
the seat back frame. I
I
I
I
I
I
I
I
\
' I
RETAINER
SECTION 8-B
Figure 1A-118
REINSTALL
2.4 FRONT SEAT HEAD RESTRAINT

ASSEMBLY
DESCRIPTION
Front seat head restraints are retained by spring steel
clips located in steel tubes which are welded to the seat
back frame.
REMOVE
1. Adjust the seat back to approximately 45 degrees.
2. Place a protective cover over the head restraint then
using the hand or a rubber mallet, firmly strike each
side of the head restraint upwards until the notch in
each shaft disengages the internal spring clips,
enabling the head restraint to be lifted out.
REINSTALL
Locate head restraint shafts into the holes on top of the
seat back, then push the head restraint down until the
notches in the shafts engage the internal spring clips.
1A-108 BODY
2.5 REAR SEAT CUSHION AND BACK

ASSEMBLIES - SEDAN
REMOVE
1. Depress front edge of seat cushion assembly re
arwards to disengage assembly retainer from
brackets attached to the floor (refer Fig. 1A-119,
Section A-A) remove, then place assembly on a
clean protected surface.
SECTION A-A
---
REAR
COMPARTMENT
FRONT PANEL
BRACKET
SECTION B-B
Figure 1A-119
2. On Calais models, depress top of seat back adjacent

to head restraint sleeve to gain access to the clip
retaining the sleeve (refer Fig. 1A-120, Section A-A).
Using a flat bladed screwdriver, carefully disengage
sleeve clips then lift out head restraints.
3. Twist head restraint sleeves in an anti-clockwise
direction then lift sleeves out of brackets welded to
the rear parcel shelf (refer Fig. 1A-120, Section A-A).
4. Unclinch tabs securing the seat back frame to the
rear wheelhouses (refer Fig. 1A-119, View A) lift
frame from retaining brackets attached to the rear
compartment front panel (refer Fig. 1A-119, Section
B-B) remove, then place frame assembly on a clean
protected surface.
BODY 1A-109
SLEEVE CLIP
LUGS B & C
INSERT SLEEVE INTO MOUNTING
BRACKET, ROTATE AND PUSH
SLEEVE DOWN, ENSURING THAT
LUGS A, B & C PASS THAU NOTCHES
IN TOP OF MOUNTING BRACKET &
ENGAGE AS SHOWN IN SECTIONS
AA, BB.
LUG A
MOUNTING BRACKET
SECTION A-A
LUG B
LUG C
SECTION 8-B
Figure 1A-120
REINSTALL
·I
1A-110 BODY
2.6 REAR SEAT CUSHION ASSEMBLY -

STATION WAGON
REMOVE
Depress front edge of seat cushion assembly rearwards
to disengage assembly retainer from brackets attached to
the floor (refer Fig. 1A-121, Section A-A) remove, then
place assembly on a clean protected surface.
REINSTALL SECTION A-A

---
REAR
COMPARTMENT
FRONT PANEL
BRACKET
SECTION B-B
Figure 1A-121
2.7 REAR SEAT BACK ASSEMBLY -

STATION WAGON
REMOVE
1. Remove rear seat cushion assembly (refer 2.6 in this
Section).
2. Depress the locking buttons on top of the seat back,
then remove the bolts securing the seat back
assembly to the pivot brackets.
3. Remove the seat back assembly then place on a
REINSTALL
2.8 REAR SEAT BACK C,OVER -

STATION WAGON
REMOVE
1. Remove the rear seat back assembly (refer 2. 7 in
this Section).
2. Remove the rear seat back operating knobs and
guide bushes.
BODY 1A-111
3. Disengage the cover and stiffener '1' and '2' from

retainer '3' as shown in Fig. 1 A-122.
Figure 1A-122
4. Disengage upper section of wire frame from rear

seat back 'A' Fig. 1A-123.
Figure 1A-123
5. Disengage lower section of wire frame from rear seat

back 'B' Fig. 1A-124.
C__)
Figure 1A-124
1A-112 BODY
REINSTALL
2.9 REAR SEAT BACK LOCK •

STATION WAGON
REMOVE
1. Remove seat back lock operating knobs and guide
bushes.
2. Partly remove the rear seat back cover by disenga
ging the cover and stiffener '1' and '2' from retainer
'3' Fig. 1A-122.
3. Disengage upper section of wire frame from rear
seat back, as shown in 'A' Fig. 1A-123.
4. Remove screws attaching lock to seat back, refer '1'
and '2' Fig. 1A-125 and disengage the lock actuating
rods 'A' and 'B' as shown in Fig. 1A-126.
REINSTALL
)
Figure 1A-125
BODY 1A-113
(J
Figure 1A-126
2.10 REAR SEAT BACK FLAP -

STATION WAGON
REMOVE
1. Remove torque rod by engaging the small hooks on
torque rod removal tool KM125-A, over ends of rod
and pull rod downwards, away from the flap (refer
Fig. 1A-127).
2. Disengage left hand end of rod and the flap (refer
Fig. 1A-127).
Figure 1 A-127
1A-114 BODY
REINSTALL
Insert left hand end of torque rod into flap. Engage the
right hand end of rod with flap, using tool KM 125-A, as
shown in Fig. 1 A-128.
NOTE: The torque rod removal and installation tool
KM125-A is available from Kent-Moore Aust. Pty. Ltd.
This tool is used on sedan models for removal and
installation of rear compartment lid hinge torque rods.
Figure 1A-128
2.11 FRONT SEAT BELT RETRACTOR

AND BUCKLE ASSEMBLY
REMOVE
1. With front seat located fully forward, remove cover
from bolt securing upper seat belt attachment to
centre pillar (refer Section A-A, Fig. 1 A-129) then
remove bolt and upper attachment.
2. Using a pointed tool, carefully prise out the pins
securing the seat belt retractor cover to the centre
pillar (refer Section C-C, Fig. 1 A-129).
)
3. Remove cover from bolt securing seat belt lower
attachment to floor pan, then remove bolt and lower
seat belt attachment.
4. Ease front end of rear rocker panel cover and rear
end of front rocker panel cover upwards to release
lower part of retractor cover, ease upper fastener
from centre pillar, releasing cover and seat belt
retractor (refer Fig. 1 A-129).
5. Remove cover and bolt securing seat belt buckle
assembly to transmission tunnel (refer Section B-B,
Fig. 1 A-129) then remove buckle assembly.
REINSTALL
Reverse removal operations ensuring that the lower bolt
threads are sealed with non hardening sealer and that all
seat belt attaching bolts are torqued to 35-50 Nm during
installation.
( \
I
""-_j
\
BODY 1A-115
SASH GUIDE
�i .· .---r /" LOCATE SEATBELT
fA/
SEATBELT �/ V TONGUE WITHIN
76.0 mm OF THE SPACER
TONGUE '"" --1- 0
·i.....
_ ,cc�
SASH GUIDE. BOLT
UPPER
ATTACHMENT
SEATBELT
ND R ETRACTOR i
ASM.!;
I / I/
SEAL WITH
-· / ; ' BUCKLE NON HARDENING SEALER
I
. ASM.
. ! SECTION
(
. ',, "-- ---fa"l � I A-A SECTION B-B
B
j 4iT� SE::�
FULL FORWARD POSITION THE

INBOARD PART OFBELT IS TO BE
INSTALLED AT AN ANGLE WHICH
PASSES THROUGH INTERSECTION
OF SEAT CUSHION & SEATBACK
CONTOURS.
LOWER
ATTACHMENT
BOLT
SEAL WITH
NON HARDENING
SECTION C-C SEALER SEATBELT RETRACTOR COVER
Figure 1 A-129
2.12 REAR SEAT BELT RETRACTOR

ASSEMBLY - SEDAN
REMOVE
1. On Calais models, depress top of seat back adjacent
to head restraint sleeve to gain access to clip
retaining sleeve (refer Fig. 1 A-130, Section A-A).
Using a flat bladed screwdriver, carefully disengage
sleeve clips then lift out head restraints.
2. Twist head restraint sleeves in an anti-clockwise
direction then lift sleeves out of brackets welded to
the rear parcel shelf (refer Fig. 1 A-130, Section A-A).
i !
/!
�-----.
LUGS B &C
LUG A
MOUNTING BRACKET
SECTION A-A
LUG B
LUG C
SECTION 8-B
Figure 1A·130
BODY tA-117
3. Depress front edge of seat cushion assembly re

arwards to disengage assembly retainer from
brackets attached to the floor (refer Fig. 1A-131,
Section A-A) remove, then place assembly on a
4. Unclinch tabs securing seat back frame to rear
wheelhouses (refer Fig. 1A-131, View A) lift frame
from retaining brackets attached to the rear compart
ment front panel (refer Fig. 1A-131, Section 8-8)
remove, then place frame assembly on a clean
protected surface.
SECTION A-A
REAR
COMPARTMENT
FRONT PANEL
BRACKET
INCH
\g� ER TAB
B-B
\�
SECTION
�
�
VIEW [A]
CJ
Figure 1A-131
5. From inside rear compartment, tap out fasteners

securing trim panel to rear parcel shelf (refer
Fig. 1A-132, Section A-A) disconnect retractor seat
belt guides from outer edges of rear parcel shelf
(refer Fig. 1A-133, Section A-A) partly raise rear
parcel shelf trim, disconnect speaker connectors
from rear harness, then remove rear parcel shelf
trim.
FASTENER
f/ (3 PLACES)
¥
rrrm
SECTION A-A
Figure 1A-132
6. Remove bolts securing rear seat belt lower

attachments, including lap type seat belts, to floor
pan and rear wheelhouse panels (refer Fig. 1A-133,
Section C-C and D-D).
7. Remove cover, then bolt, securing rear seat belt
upper attachment to quarter inner upper panel (refer
Fig. 1 A-133, Section B-8).
1A-118 BODY
8. From inside of rear compartment, remove bolt

securing rear seat belt retractor assembly to quarter
inner panel (refer Fig. 1A-133, Section A-A) remove
retractor assembly, feeding seat belt, buckles, etc.,
out through slot on outer edge of rear parcel shelf.
REINSTALL
Reverse removal operations, ensuring that the threads of
all seat belt lower attaching bolts are adequately sealed
with a non hardening sealer (refer Fig. 1A-133, Section
C-C and D-D) and that all rear retractor assembly
attaching bolts are torqued to 35-50 Nm during
installation.
COVER
BOLTffi
SECTION 8--8 - 2 PLACES
CZ.. ANCHOR TO BE
VERTICALLY
UPWARDS WHEN
FITT D
�
BOLT ffi )
��,�:l
.
'
I SEAL WITH NON
� : :·: HARDENING SEALER
c.,'. AXIS OF SYMMETRY
NOTCH OF ANCHOR TO BE
ENSURE WIRING HARNESS IS CLEAR TOWARDS PARALLE:L TO VEHICLE fl
;..;, 1 OF ANCHOR WHEN ANCHOR IS FITTED. FRONT OF IN FRONT VIEW
SECTION C-C - 2 PLACES
CAR VIEW A SECTION D-D
& 50-70Nm
Figure 1 A· 133
2.13 REAR SEAT BELT RETRACTOR

ASSEMBLY - STATION WAGON
REMOVE
1. Remove rear seat cushion assembly (refer 2.6 in this
Section).
2. Remove bolts securing the seat belt assembly to the
floor pan, rear wheelhouse and the rear door pillar
upper mounting attachments (refer Fig. 1A-134, Sect
ions D-D, C-C and 8-8).
3. Remove bolts securing the seat belt retractor
assembly to the rear quarter panel illustrated in
Fig. 1A-134, Section A-A, removing the assembly.
NOTE: The lap type centre seat belts are retained by the
same attachments as the buckle ends of the outer seat
belts (refer Fig. 1A-134, Section D-D).
BODY 1A-119
REINSTALL
Reverse removal operations, ensuring that the lower bolt
threads are adequately sealed with a non hardening
sealer (refer Fig. 1 A-134, Sections C-C and D-D) and that
all seat belt attaching bolts are torqued to 35-50 Nm
during installation.
I_
{
\
VIEW A
AXIS OF SYMMETRY OF
!/
ANCHOR TO BE PARALLEL
TO VEHICLE ft.. IN FRONT
VIEW. NOTCH TOWARDS
t, FRONT OF CAR
SEAL WITH NON

HARDENING SEALER
! :
�
ffiBOLT
SECTION C·-C
()
(t. ANCHOR TO BE VERTICALLY UPWARDS WHEN SEAL WITH NON
FITTED. ENSURE WIRING HARNESS IS CLEAR OF
SECTION B-8 ANCHOR WHEN ANCHOR IS FITTED.
HARDENING SEALER
ffi 50-70Nm
SECTION D-0
Figure 1A-134
l_)
1A-120 BODY
NOTES
( \
�-j
BODY 1A-121
HEADLINING AND REAR END TRIM

INDEX
1. GENERAL DESCRIPTION .............................. 1A-121 2.3 REAR PARCEL SHELF TRIM - SEDAN......1A-133
2. SERVICE OPERATIONS ................................. 1A-124 Remove.................................................... 1A-133
2.1 HEADLINING ASSEMBLY .............................. 1A-124 Reinstall ................................................... 1A-134
Remove.................................................... 1A-124 2.4 REAR QUARTER TRIM PANEL -
Reinstall ................................................... 1A-129 STATION WAGON........................................... 1A-134
2.2 MOULDING ASSEMBLY, QUARTER Remove.................................................... 1A-134
WINDOW INNER TRIM - SEDAN ................. 1A-133 Reinstall ................................................... 1A-135
Remove .................................................... 1A-133
Reinstall ................................................... 1A-133
The roof headlining which follows the contour of the roof, is supported in its curved shape by transverse listing wires
installed in grommets which are located in holes spaced at regular intervals along the roof side rails, as illustrated in
Figs. 1 A-135 and 1 A-136, Section C-C. The listing wires are inserted through a series of stiched listing pockets, each
coinciding with stitch lines visible across the headlining.
A retainer attached to the front of the headlining is
installed, under tension, into a channel, which is an
integral part of the windshield finishing lace (refer
Figs. 1 A-135 and 1 A-136, Sections A-A and B-8).
The remaining edges of the headlining are attached to
the side flanges, centre and rear pillars and on station
wagons, the rear retainer, with trim cement (refer
Figs. 1 A-135, Sections C-C and G-G and Fig. 1 A-136
Sections C-C and 1-1).
Finishing lace surrounding the door openings assists in
retaining the headlining edges.
NOTE: Clean hands are essential when working on the
body interior trim.
a.A
I
INTERMEDIATE LISTING a.A
WIRES -GREEN WINDSHIELD
I\)
r FINISHING LACE----,
FRONT LISTING WIRE
-YELLOW
REAR LISTING WIRE m
-PLAIN 0
C
SECTION 8-B
SECTION A-A
--
REAR QUARTER
DOOR OPENING SIDE LOWER TRIM
FINISHING LACE
GROMMET
(6 PLACES)
j
;fl. ' ·�:-·�
FOR INSTALLATION OF COVER
REFER SEAT SECTION
�
SECTION C-C
LISTING POCKET COAT HOOK �--�-�
SECTION E-E SECTION 0--D
ATTACH HEADLINING ASM. TO THE REAR WINDOW

() OPENING FLANGE, SIXTH WINDOW OPENING
VIEW�
FLANGES AND DOOR OPENING FLANGES. APPLY
TRIM CEMENT TO THE BODY AS REQUIRED. SECTION f-f
� ATTACH TRIM WITH TRIM CEMENT APPLIED OVER
ENTIRE CONTACTING SURFACE.
Figure 1A-135
\, .__.,/
__
(
I
.'-...,--- /
HEADLINING ASSEMBLY
INTERMEDIATE LISTING WIRE -YELLOW rWINDSHIELD FINISHING LACE
REAR LISTING WIRI=
-�LAIN
FRONT LISTING WIRE
-GREEN
SECTION 8-8
SECTION A-A
GROMMET
(8 PLACES)

Y
t-----
,,------�
DOOR OPENING �/
: ;1
.,
FINISHING LACr'if/!
·/
I1 A
": #.
�
I �.2 •''c::
LISTING POCKET
START WEATHERSTRIP
FROM LOCATING DART SECTION C-C
ON CENTRE Pl LLAR
REFER SEAT SECTION
--8VL-----
�
�
COAT HOOK J =)
r �- =
SECTION 0-0
SECTION E-E }___W)
�
SECTION 1-1
() ATTACH HEADLINING ASM. TO THE DOOR OPENING
FLANGES REAR QUARTER WINDOW OPENING m
FLANGES ENDGATE OPENING FLANGE AND ENTIRE
CONTACT SURFACE OF 'B' AND 'C' PILLARS WITH 0
TRIM CEMENT AS REQUIRED � C
'- ATTACH TRIM WITH TRIM CEMENT APPLIED OVER
<
ENTIRE CONTACT SURFACE SECTION F-F .....
I
.....
Figure 1A-136
1A-124 BODY
2.1 HEADLINING ASSEMBLY
REMOVE
BEFORE INSTALLATION OF BRACKET, SLIT
1. Place protective covering over interior trim. HEADLINING ACROSS CORNERS OF SQUARE
2. Disconnect battery ground cable and remove the roof HOLE IN FRONT ROOF FRAME.
lamp(s) (refer Section 128 Volume 5 of this
Supplement).
3. Remove the interior rear view mirror, sun visors and
where fitted, assist grips (refer Figs. 1 A-137 and
1A-138, Views 'A' and 'B', Sections A-A and B-8).
SUNVISOR ASSEMBLY
__ /· �
,&.SCREW�
MUST BE INSTALLED
'AFTER INSTALLATION WITH SOLID WEB TO
PIN HEAD MUST NOT BOTTOM
PROTRUDE BEYOND
SURFACE OF BRACKET. Lh 1.6 - 2.0 Nm
Figure 1A-137
4. Remove the upper and outer lower front seat belt

attachments and the upper rear seat belt attachm
ents (refer 2.11, 2.12 and 2.13 in 'Seat and Seat Belt
Assemblies' in this Section).
5. On sedans, remove the back window assembly and
on station wagons, the rear quarter window
assemblies (refer 3.11 and 3.12 in 'Stationary Glass'
in this Section).
6. Remove the front and rear rocker panel covers (refer
2.4 in 'Underbody' in this Section).
r-,, '\
"---//
LOCATE NUTS IN SIDE

INNER PANEL, AND
PIERCE HEADLINING-----,
FOR 19 STYLES ONLY
19 STYLES
35 STYLES
,/ 71'� v1Ew[A}
LEFT SIDE ONLY
LOCATE HOLES IN SIDE
INNER PANEL', AND
PIERCE HEAD LIN ING.
NUT TO BE INSTALLED
PRIOR TO HEADLINING
INSTALLATION
AFTER INSTALLATION OF
ASSIST GRIPS SNAP CAP
OVER SCREWS AS SHOWN.
�--<
SECTION A-A SECTION B-B
m
0
VIEW� C
RIGHT & LEFT SIDE <
2.4 - 3.4 Nm
&. ....
....
I\)
Figure 1A-138 u,
1A-126 BODY
7. Remove the door opening finishing lace and the coat

hooks (refer Fig. 1A-139).
COAT HOOK
Figure 1A-139
8. On sedans, carefully prise out the upper section of MOULDING ASSEMBLY

the quarter window inner trim moulding assembly QUARTER WINDOW
illustrated in Fig. 1A-140, Sections A-A and 8-8, to INNER TRIM
provide access to adjacent headlining.
SECTION A-A SECTION 8-8

4 PLACES R/L 1 PLACE R/L
Figure 1A-140
9. On sedans, carefully peel off edges of headlining

adjacent to the back window opening and rear
quarter windows and on station wagons, the rear
retainer and rear quarter windows (refer Fig. 1A-141,
Sections G-G and F-F and Fig. 1A-142, Sections C-C
and 1-1).
( ,�'
\\'--�-----/
(�--'
INTERMEDIATE LISTING
WIRES -GREEN WINDSHIELD
FINISHING LACE------.
FRONT LISTING WIRE
-YELLOW
REAR LISTING WIRE
- PLAIN
SECTION 8-8
SECTION A-A
�
REAR QUARTER
DOOR OPENING SIDE LOWER TRIM
· FINISHING LACE
START WEATHERSTRIP
FROM LOCATING DART
ON CENTRE PILLAR Iii
-8VL,8VX .
1
1
j �
�.�
REFER SEAT SECTION
�
SECTION C-C
LISTING POCKET COAT HOOK� \;--Ji>--�
SECTION E-E SECTION 0--0
ATTACH HEADLINING ASM. TO THE REAR WINDOW

v1Ew[AJ \J
,. OPENING FLANGE, SIXTH WINDOW OPENING m
FLANGES AND DOOR OPENING FLANGES. APPLY 0
TRIM CEMENT TO THE BODY AS REQUIRED. SECTION f-f C
� ATTACH TRIM WITH TRIM CEMENT APPLIED OVER
ENTIRE CONTACTING SURFACE.
.....
I
.....
I\)
Figure 1A-141 ---.I
.....
HEADLINING ASSEMBLY
INTERMEDIATE LISTING WIRE - YELLOW WINDSHIELD FINISHING LACE .....
REAR LISTING WIRE
- PLAIN \
FRONT LISTING WIRE
- GREEN m
0
C
SECTION 8-8
SECTION A-A
GROMMET
(8 PLACES)
START WEATHERSTRIP LISTING POCKET

FROM LOCATING DART
FOR INSTALLATION OF COVER SECTION C-C
ON CENTRE PILLAR
REFER SEAT SECTION
-- 8VL--------
�
� L___
COAT HOOK J
��--= \
SECTION D-D
SECTION E-E
SECTION 1-1
() ATTACH HEADLINING ASM. TO THE DOOR OPENING
FLANGES REAR QUARTER WINDOW OPENING
FLANGES ENDGATE OPENING FLANGE AND ENTIRE
CONTACT SURFACE OF 'B' AND 'C' PILLARS WITH
TRIM CEMENT AS REQUIRED �
-- ATTACH TRIM WITH TRIM CEMENT APPLIED OVER
ENTIRE CONTACT SURFACE
SECTION F-F
Figure 1A-142
,/----,
BODY 1A-129
1O. Carefully peel off the edges of the headlining around

the door openings, including the centre pillar and the
trailing end of the front body pillar, then carefully pull
the retainer attached to the front of the headlining,
out of the channel in the finishing lace, up the sides
and across the top of the windshield opening (refer
FiG. 1A-142, Sections A-A and 8-8).
11. Disengage ends of number 1 listing wire from
grommets in the roof side rails (refer Figs. 1A-141
and 1A-142, Section C-C, View 'A').
12. Ease back the clinch-over tabs securing number 2
listing wire to the roof support (refer Figs. 1A-141
and 1A-142, Section D-D) then disengage the ends
of the listing wire from the grommets in the roof side
rails. Repeat this operation on all but the most
rearward listing wire.
13. Ease back clinch-over tabs securing the rear listing
wire to the rear roof support, then remove the
headlining assembly from the vehicle.
REINSTALL
1. If listing wires have been removed from the headli
ning or if a new headlining is to be installed, install
listing wires· in their correct listing pockets.
NOTE: Listing wires are identified by coloured paint in the
centre of each wire as follows:
Front listing wire - Yellow
Intermediate listing wires - Green
Rear listing wire - Plain
2. Apply a 50 mm wide band of trim cement around
C ·. entire outer edge of headlining.

3. Apply trim cement to surfaces of body to which outer
)
edges of headlining are to be attached.
4. Install ends of number 3 listing wire on sedans and
'
number 4 on station wagons, into grommets located
in the roof side rail. Pierce the listing pocket in line
with the roof support clinch-over tabs, locate the tabs
through the pocket, under the listing wire, then bend
the tabs over, firmly securing the listing wire to the
roof support (refer Figs. 1A-141 and 1A-142 Sections
C-C and D-D).
Repeat this operation on number 2 listing wire on
sedans and number 2 and 3 listing wires on station
wagons.
NOTE: If a new headlining is being installed, it may be
necessary to trim listing pockets away from listing wires
sufficiently to avoid 'bunching up' of headlining material
where listing wires enter roof side rails.
5. Install ends of number 1 listing wire into the
grommets located in the roof side rails.
6. Check that headlining listing pocket stitch seams are
evenly aligned with the roof side rails and if
necessary, reposition seams to achieve this.
7. Commencing at the centre of the windshield finishing
lace, install the retainer attached to the front end of
the headlining into the finishing lace upper channel
(refer Fig. 1A-141, Section A-A), working progressi
vely to each side, then install the ends of the
retainer down, in between the instrument panel sides
and the front body pillars, continuing the installation
of the retainer, up the pillars (refer Fig. 1A-141,
Section 8-8).
8. Pulling the side edges of the headlining taut, install
(
"-._____ /
these edges firmly over the front body pillar and tops
of the door opening flanges (refer Fig. 1A-141,
Sections 8-8 and C-C).
9. Smooth out and fold edges of headlining over the
centre pillar flanges (refer Fig. 1A-141).
1A-130 BODY
10. Pierce the rear listing pocket in line with the rear roof
support clinch-over tabs. Locate the tabs through the
pocket, under the listing wire, then bend the tabs
over, firmly securing the listing wire to the rear roof
support (refer Figs. 1A-141 and 1A-142, Sections \
G-G and 1-1). )
11. Pulling the rear edge of the headlining taut, firmly
install the edge over the rear window opening flange
and quarter windows on sedans, and over the rear
retainer and rear quarter windows on Station wagons
(refer Fig. 1A-141, Section G-G and 1 A-142, Section
1-1).
12. Smooth out any wrinkles in the headlining. (It may be
necessary to release the edge of the headlining to
achieve this.) Trim off any surplus headlining and
clean off any excess trim cement.
13. On sedans, reinstall the upper section of the quarter MOULDING ASSEMBLY
window inner trim moulding assemblies (refer QUARTER WINDOW
Fig. 1A-143), the door opening finishing lace and the INNER TRIM
coat hooks.

Figure 1A-143
14. Reinstall the front and rear rocker panel covers (refer
2.4 in 'Underbody' in this Section).
15. On sedans, reinstall the back window assembly and
on station wagons, the rear quarter window
assemblies (refer 3.11 and 3.12 in 'Stationary Glass'
in this Section).
16. Reinstall the upper and outer lower front seat belt
attachments and the upper rear seat belt attachm
ents (refer 2.11, 2.12 and 2.13 in'Seats and Seat
Belt Assemblies' in this Section).
BODY 1A-131
17. Reinstall the interior rear view mirror, sun visors and
where fitted, assist grips (refer Figs. 1 A-144 and
1A-145, Views 'A' and '8', Sections A-A and 8-8).
l BEFORE INSTALLATION OF BRACKET, SLIT
HEADLINING ACROSS CORNERS OF SQUARE
HOLE IN FRONT ROOF FRAME.
·---=-
.. /· ·�
SUNVISOR ASSEMBLY &SCREW�
MUST BE INSTALLED
AFTER INSTALLATION WITH SOLID WEB TO
PIN HEAD MUST NOT BOTTOM
PROTRUDE BEYOND
SURFACE OF BRACKET. &_ 1.6- 2.0 Nm
Figure 1A-144
....
I
LOCATE NUTS IN SIDE ....
INNER PANEL, AND w
PIERCE HEADLINING----, I\)
FOR 19 STYLES ONLY m
0
C
19 STYLES
/) -7r
,/ ii � !...£).--�
VIEW�
LEFT SIDE ONLY
LOCATE HOLES IN SIDE
INNER PANEL', AND
PIERCE HEADLINING.
NUT TO BE INSTALLED
PRIOR TO HEADLINING
INSTALLATION
\
AFTER INSTALLATION OF
ASSIST GRIPS SNAP CAP
OVER SCREWS AS SHOWN.
r
VIEW [ID
RIGHT & LEFT SIDE
&. 2.4 - 3.4 Nm
Figure 1A-145
// �
'----- __./'/
BODY 1A-133
18. Reinstall the roof lamps (refer Section 128, Volume

5 of this Supplement), then reconnect the battery
ground cable.
19. Remove protective covering from the interior trim.
2.2 MOULDING ASSEMBLV, QUARTER

WINDOW INNER TRIM • SEDAN
REMOVE
1. Remove the rear seat cushion and back assemblies
and the rear seat belt upper attachment (refer 2.5
and 2.12 in 'Seats and Seat Belt Assemblies' in this
Section).
2. Remove the section of the finishing lace adjacent to MOULDING ASSEMBLY
the leading edge of the quarter window inner trim QUARTER WINDOW
moulding assembly, then using a wide bladed INNER TRIM
screwdriver located between the quarter inner panel
and inner trim moulding, adjacent to the trim
fasteners, carefully prise the trim moulding away from
the quarter inner panel (refer Fig. 1A-146, Sections
A-A and B-B). Disengage seat belt from guide and
remove inner trim moulding.
REINSTALL
CJ

Figure 1A-146
2.3 REAR PARCEL SHELF TRIM •·

SEDAN
REMOVE
1. Remove rear seat cushion and back assemblies
(refer 2.5 in 'Seats and Seat Belt Assemblies' in this
Section).
2. Remove the rear speaker cover(s) and speaker(s),
where fitted, as illustrated in Fig. 1A-147, View 'A').
1A-134 BODY
iNSTALL GRILLE WITH WIDEST SPEAKER COVER

PART AS SHOWN
SCREW
3 PLACES
SPEAKER ASSEMBLY
'SPEAKER TO BE INSTALLED
j . �ITH CONNECTIONS FACING
TOWARDS OUTSIDE (REAR)
....ll:::::::::F=•::::::,... 1
OF CA .
j .. �
RETAIN LEADS UNDER �TRIM PANEL

EXISTING TABS
(4 PLACES) NUT
THREAD LEAD THROUGH REAR

COMPARTMENT LIGHT BRACKET
ROUTE LEADS UNDER CARPET

ENSURE LEADS ARE CLEAR OF
SEAT BELT RETRACTOR AND
DECK LID HINGE-----
BODY WIRING HARNESS
Figure 1A-147
3. From inside the rear compartment, carefully tap up

and out the fasteners securing the trim to the rear REAR PARCEL SHELF TRIM
parcel shelf (refer Fig. 1 A-148, Section A-A), then
remove the trim.
REINSTALL
Reverse removal operations
TRIM FASTENER
/ (3 PLACES)
¥ frrrrr
Figure 1A-148
2.4 REAR QUARTER TRIM PANEL •

STATION WAGON
\
REMOVE
1. Ease rear seat back forward and fold the sides of
the rear compartment floor covering inwards.
BODY 1A-135
2. Remove the rear seat belt retractor assembly (refer

2.13 in 'Seats and Seat Belt Assemblies' in this
Section).
3. Remove the finishing lace from the leading edge of
,,,,------\ the rear quarter trim panel, then using a suitable
J prising tool under the head of the fasteners, carefully
prise out the fasteners and remove the trim panel
(refer Fig. 1 A-149, Section B-8).
REINSTALL
SECTION 8-B
Figure 1A-149
1A-136 BODY
NOTES
BODY 1A-137
EXTERIOR ORNAMENTATION
INDEX
1. GENERAL DESCRIPTION .............................. 1A-137 2.6 REAR COMPARTMENT LID MOULDING
2. SERVICE OPERATIONS ................................. 1A-142 ASSEMBLY - CALAIS ..................................... 1A-149
Moulding Clip Replacement................ 1A-142 Remove.................................................... 1A-149
Adhesive Bonded Nameplates Reinstall ................................................... 1A-149
and Emblems.......................................... 1A-142 2.7 FRONT BUMPER UPPER EXTENSION
2.1 FRONT PILLAR DRIP MOULDING............... 1A-146 MOULDING ASSEMBLY .................................1A-149
Remove ....................................................1A-146 Remove....................................................1A-149
Reinstall ................................................... 1A-146 Reinstall ...................................................1A-151
2.2 REAR DRIP MOULDING - SEDAN ............... 1A-146 2.8 REAR BUMPER UPPER EXTENSION
Remove.................................................... 1A-146 MOULDING ASSEMBLY - SEDAN ............... 1A-151
Reinstall ................................................... 1A-146 Remove....................................................1A-151
2.3 ROOF DRIP MOULDING ................................ 1A-147 Reinstall ...................................................1A-151
Remove.................................................... 1A-147 2.9 REAR BUMPER UPPER EXTENSION
Reinstall ................................................... 1A-147 MOULDING, RIGHT AND/OR LEFT SIDE
2.4 TAIL LAMP REVEAL MOULDING ................ 1A-147 - STATION WAGON ........................................ 1A-153
SL and Berlina Sedans ........................ 1A-147 Remove....................................................1A-153
Calais........................................................ 1A-148 Reinstall ...................................................1A-153
2.5 EXTENSION, REAR LAMP MOULDING 2.10 ROCKER PANEL MOULDING - CALAIS .... 1A-153
ASSEMBLY - SEDAN ...................................... 1A-148 Remove.................................�.................. 1A-153
Remove.................................................... 1A-148 Reinstall ................................................... 1A-153
Reinstall ................................................... 1A-148
Exterior ornamentation on 'VL' Series Models includes new windshield reveal mouldings, body side mouldings for all
models with body mouldings adjacent to the side mouldings for Calais (refer Figs. 1A-150, 1A-151 and 1A-152). These
C ) body side and body mouldings are secured to the front fender and front and rear doors with double sided adhesive tape
and urethane adhesive.
New upper extension mouldings are fitted on top of the front and rear bumper bars on all models.
New rocker panel mouldings and a rear compartment lid moulding are fitted to the Calais and tail lamp mouldings on all
sedans have been revised.
New badges and emblems are introduced on all models.
.....
REAR DRIP MOULDING ASSEMBLY
.....
(,.)
CD
m
0
C
REAR DOOR BELT REVEAL

MOULDING ASSEMBLY
REAR DOOR S1DE MOULDING ASSEMBLY
FRONT DOOR SIDE MOULDING ASSEMBLY

FRONT PILLAR DRIP
FRONT FENDER SIDE MOULDING ASSEMBLY MOULDING ASM.
TRUNK LID
MOULDING ASM.
� BODY SIDE TRANSFER

REAR LAMP EXTENSION
MOULDING ASM.
TAIL LAMP SURROUND

MOULDING ASM.
8VL19
Figure 1A· 150
___ _/
/�,
\"-..._____...'
REAR DOOR BELT REVEAL MOULDING ASM.
REAR DOOR SIDE MOULDING ASM.

ROOF DRIP MOULDING ASM.
FRONT DOOR SIDE MOULDING ASM.

FRONT FENDER SIDE
MOULDING ASM.
$ BODY SIDE TRANSFERS QUARTER REVEAL

MOULDING ASM. m
0
C
-<
.....
8VL35 I
.....
w
Figure 1A-151 U)
.....
I
.....
Q
REAR DRIP MOULDING ASSEMBLY
..
m
0
C
REAR DOOR SIDE MOULDING ASSEMBLY
REAR DOOR BELT

REVEAL MOULDING ASM.
FRONT PILLAR DRIP

MOULDING ASM.
FRONT FENDER SIDE
MOULDING ASSEMBLY
TRUNK LID
MOULDING ASSEMBLY
FRONT DOOR BELT

REVEAL MOULDING ASM.
REAR LAMP EXTENSION QUARTER REVEAL
MOULDING ASM. MOULDING ASM.
TAIL LAMP SURROUND
MOULDING ASM.
Figure 1A-152
\,�
'�,
/�
(\_,_ '---.
_____ /
APPLY NON HARDEN.ING SEALER

OVER HOLES TO EFFECT A
BUSH WATERTIGHT SEAL.
(8 PLACES)
GROMMET
(1 PLACE R/LH)
SECTION U-U
SECTION T-T SECTION S-S
DRILL 2.40 � g:6g mm DIA. HOLE.O.N

GROMMET
(1 PLACE R/LH) OFWELD STUDS AS CLOSE AS
POSSIBLE TOWELD STUD LOCATION.
CLIP m
(3 PLACES R/LH)
SECTION W-W 0
SECTION W-W FOR EMERGENCY USE ONLY C
SE�TION V-V -<
...I,
L'.t, 1.8-2.4 Nm
...I,
Figure 1A-153
.,::.
...I,
1A-142 BODY
Clips, fasteners, retainers, bushes, screws, nuts and
contact adhesive are used to secure the various exterior
mouldings, badges, emblems, etc. to 'VL' body styles.
Sections through these mouldings are illustrated in
Figs. 1A-153, 1A-154 and 1A-155.
When removing or installing exterior mouldings, the
following care should be exercised:
1. Finishes adjacent to the moulding should be covered
with masking tape to prevent damage.
2. Holes in body panels for screws, bolts, clips, etc.,
that could permit water entry into the body must be
adequately sealed with non hardening sealer or
presealed screws, nuts or clips.
MOULDING CLIP REPLACEMENT

If a weld stud on an outer panel becomes damaged or
broken off, use the following procedure to install a
replacement.
1. Drill a small hole in the panel next to the original
weld stud location.
2. Insert a self-sealing screw through original clip and
into outer panel, or replace damaged weld stud with
self-sealing screw-type weld stud.
ADHESIVE BONDED NAMEPLATES AND

EMBLEMS
Removal of these parts is more easily achieved with the
use of heat lamps positioned adjacent to the part to be
removed.
CAUTION: Ensure that the heat lamps are not too close
or the heat too intense to adversely effect paint finish.
It is essential when installing these adhesive bonded
parts that the panel to which the part is to be applied is
)
thoroughly clean and that the panel temperature is at
least 21 degrees celcius.
NOTE: Servicing of the new windshield mouldings on all
models and the rear window reveal mouldings on Calais
is included in 'Stationary Glass' in this Section.
/�,
,_,/
NOTE-EXTERIOR SURFACE TO BE INLINE

AND FLUSH BETWEEN EXTENSION
MOULDING AND REAR LAMPS.
SCREW
(2 PLACES) LAMP
REAR LAMP
NUT EXTENSION MOULDING

(2 PLACES)
SECTION X-X
SCREW
(2 PLACES)
NUT
m
0
REAR END PANEL ASM. REAR BUMPER BAR
P-P R-R
N-N C
SECTION SECTION
SECTION
-<
......
& 1.8-2.4Nm
fa APPLY NON HARDENING SEALER OVER
......
.:7 HOLES TO EFFECT A WATERTIGHT SEAL.
.,::.
Figure 1A-154 w
......
FRONT FENDER ASM. ......
�
�
SCREW m
(1 PLACE R/LH) 0
C
FRONT
PILLAR
BUSH
(1 PLACE R/LH)
SECTION A-A SECTION B-B SECTION C-C
ROOF DRIP
MOULDING ROOF DRIP'
CLIP MOULDING
(5 PLACES R/LH -SEDAN)
(8 PLACES R/LH-WAGON)
SECTION 0-D SECTION E-E SECTION f-f
APPLY NON HARDENING SEALER OVER HOLES

� TO EFFECT A WATERTIGHT SEAL.
Figure 1A-155
�. \
(- i
\"' ·"-------./ /
QTR. WINDOW GARNISH MOULDING

REAR DRIP MOULDING
g
QTR. REVEAL MOULDING
TO BE INSTALLED BEFORE
REAR DRIP MOULDING
SECTION H-H SECTION J-J

SECTION G-G
&_SCREW
(1 PLACE R/LH)
WASHER
(1 PLACES R/LH)
* CLIP
(8 PLACES R/LH FRT. DOOR)
(8 PLACES R/LH RR DOOR) 3 PLACES R/LH c5 WASHER
� (1 PLACE R/LH)
SECTION L-L SECTION M-M
SECTION K-K
m
0
C
-<
* CLIPS EQUALLY SPACED ALONG MOULDINGS � APPLY NON HARDENING SEALER OVER .....
(APPROX. 250.0 CENTRES) EXCEPT OMIT ,i(7 HOLES TO EFFECT A WATERTIGHT SEAL.
.&_ 2.4 - 3.4 Nm CLIP ON REAR VIEW MIRROR AREA I
..A,
Figure 1A-156 u,
..
1A-146 BODY
2.1 FRONT PILLAR DRIP MOULDING

REMOVE
1. With the front door open, remove the screws
securing the moulding assembly to the front body
pillar (refer Fig. 1A-157, Sections A-A and C-C).
2. Carefully prise the lower end of the moulding
assembly off the front fender where it is retained
with a clip and bush assembly (refer Fig. 1A-157,
Section 8-8), then roll the assembly off the front
body pillar.
REINSTALL
1. Locate the top of the moulding assembly over the
front end of the roof drip moulding (refer Fig. 1A- SECTION C-C SECTION 8-B
157, Section 0-0), then align the moulding clip with
the hole in the front fender. Using the hand, gently FRONT BODY Pl LLAR--
tap the moulding into the hole (refer Fig. 1A-157, MOULDING
Section 8-8). ROOF DRIP MOULDING
2. Align the holes in the moulding assembly with those
in the front body pillar and front fender, then reinstall SCREW
the self sealing screws. 1 PLACE R/LH
SECTION 0-D
FRONT
PILLAR
SECTION A-A
� APPLY NON HARDENING SEALER OVER

HOLES TO EFFECT A WATERTIGHT SEAL.
Figure 1A-157
)
2.2 REAR DRIP MOULDING - SEDAN
REMOVE QTR. WINDOW GARNISH MOULDING
Using a fabricated hooked tool or a fine bladed screwdri
ver located under the lower leading edge of the AR DRIP MOULDING
moulding, gently prise the moulding off the trailing end of '/77-�,,, .---_\
the quarter window garnish moulding assembly (refer
Fig. 1A-158, Section G-G). ,,,
SECTION G-G
Figure 1A·158
REINSTALL
Locate the top end of the moulding over the rear end of
the roof drip moulding simultaneously locating the trailing
edge of the moulding over the rear edge of the quarter
window garnish moulding assembly. Using the hand,
gently tap the leading edge of the moulding over the j
retaining lugs on the quarter window garnish moulding
assembly.
BODY 1A-147
2.3 ROOF DRIP MOULDING
REMOVE
1. On sedans, remove the rear drip moulding (refer 2.2
above) and on all models, the front pillar drip
moulding assembly (refer 2.1 above).
2. Using Tool No. 1A7 illustrated in Fig. 1A-159, under
the front or rear end of the roof drip moulding,
carefully ease the bottom of the moulding off the
roof drip gutter.
REINSTALL
Locate the top of the roof drip moulding over the roof
drip gutter and using the hand, gently tap the bottom of
the moulding into position.
Figure 1A-159
2.4 TAIL LAMP REVEAL MOULDING
SL AND BERLINA SEDANS

Remove
SCREW�
1. With the rear compartment lid open, remove the 1 PLACE R/LH
( )
screw securing the upper section of the moulding to
the rear quarter outer panel (refer Fig. 1A-160,
Section M-M).
2. Apply masking tape adjacent to the semi vertical
section of the moulding to protect paint finish, then
using pliers, grasp the outside of the push-on
retaining clips illustrated in Fig. 1A-160, Section L-L,
carefully remove the clips. The moulding will then lift
off the panel.
GASKET 0
Reinstall
SECTION M-M
Reverse removal operations, ensuring to adequately seal
the attaching clips with non hardening sealer as illustr
ated in Fig. 1A-160, Section L-L, and fitting new retaining
clips. £ 2.4-3.4 Nm
APPLY NON HARDENING SEALER OVER
HOLES TO EFFECT A WATERTIGHT SEAL.
Figure 1A-160
(' !
/
"-....., _____,.,,
J
1A-148 BODY
CALAIS
Remove
With the rear compartment lid open, remove the nuts
securing the moulding assembly to the rear quarter outer
panel (refer Fig. 1A-161, Sections S-S and R-R), remov
ing the moulding assembly.
Reinstall
Reverse removal operations, ensuring that non hardening
sealer is applied between the back panel and nuts, as
illustrated in Fig. 1A-161, Sections S-S and R-R.
SECTION R-R
& 1.8-2.4Nm SECTION S-S
Figure 1A-161
2.5 EXTENSION, REAR LAMP

MOULDING ASSEMBLY - SEDAN
REMOVE
With the rear compartment lid raised, remove the nuts
securing the extension assembly to the back panel lower
(refer Fig. 1A-162, Section P-P) and remove assembly.
To disassemble the moulding assembly, remove the
screws securing the outer to inner panels of the
assembly (refer Fig. 1 A-162, Section P-P).
REINSTALL
NUT &
2 PLACES
REAR LAMP
EXTENSION
MOU
�
ASM.
& 1.8-2.4Nm SECTION P-P
Figure 1A·162
BODY 1A-149
2.6 REAR COMPARTMENT LID

MOULDING ASSEMBLV - CALAIS
REMOVE
1. Apply masking tape adjacent to the top of the rear
compartment lid moulding.
2. Using a fine, wide bladed screwdriver located bet
ween the top of the moulding and the lid, carefully
prise the moulding pins out of the bushes located in BUSH
the lid (refer Fig. 1A-163, Section T-T). (8 PLACES)
3. With the lid raised, push the moulding dowri,
releasing the assembly from the lid.
4. Remove the plastic cups used to secure the lower
edge of the moulding to the lid by tripping the tang
inside of the clips with a small bladed screwdriver.
REINSTALL
1. Align the floating pins in the moulding assembly with
the bushes in the lid (refer Fig. 1A-163, Section T-T),
then using the hand, install the upper section of the
moulding.
2. Evenly align ends of moulding assembly with the
sides of the lid, then install the plastic clips which
will secure the lower edge of the moulding.
3. Remove the masking tape. SECTION T-T
Figure 1A-163
2.7 FRONT BUMPER UPPER
lJ EXTENSION MOULDING ASSEMBLV
REMOVE
1. With front of vehicle raised on jack stands, remove
the screws securing the ends of the centre and side
extension mouldings together (refer Fig. 1A-164, Sec
tion C-C).
2. Using pointed nose pliers, compress the inner end of
the moulding retainers securing the side extension
mouldings to the front fenders (refer Fig. 1A-164,
Section D-D) pushing out the retainers.
3. Using a small bladed screwdriver, trip the tang inside
the clips securing the centre part of the moulding
assembly to the moulding and grille mounting bracket
(refer Fig. 1A-164, Section A-A) and remove moul
ding assembly forward, off clips retaining the rear
ends of the assembly to the front fenders (refer
Fig. 1A-164, Section B-8).
...I,
I
...I,
u,
0
m
0
C
�
UMPER
FRONT BUMPER / RETAINER
I
UPPER EXTENSION FRONT BUMPER : I 3 PLACES R/LH
MOULDING SECTION 8-8
�UPPER EXTENSION lJ
MOULDING
FINISHER STRIP ASM.
B VX, BVL & V5V FINISHER STRIP ASM.
BVX, 8VL & vsV
FINISHER STRIP FRONT BUMPER MOULDING

ASM. SVX ONLY & GRILLE MOUNTING BRACKET
MOULDING TO BE FLUSH
CLIP RADIATOR GRILLE AGAINST PANEL
1 PLACE R/LH RETAINER CLIP
2 PLACES R/LH FINISHER STRIP
RETAINER CLIP ASM. 8VX ONLY
8 PLACES CENTRE
7.0 ± 1.0 SCREW &
SECTION A-A 1 PLACE R/LH
I
�-' ...........-FRONT
� BUMPER
SECTION C-C
SECTION D-D
&. . 5.5-7.5 Nm
Figure 1A-164
BODY 1A-151
REINSTALL
Reverse removal operations using new plastic clips and
retainers.
()
2.8 REAR BUMPER UPPER EXTENSION
MOULDING ASSEMBLV - SEDAN
REMOVE
1. Remove the screws securing the front ends of the
extension moulding assembly to the rear
wheelhouses (refer Fig. 1A-165, Section G-G).
2. From inside the rear compartment and using pointed
nose pliers, compress the inner end of the retainers
securing the side and centre extension mouldings to
the rear quarter and back lower panels (refer
Fig. 1A-165, Sections K-K and F-F) pushing out the
retainers.
NOTE: Removal of the left side extension moulding
retainers necessitates removal of the spare wheel.
3. Remove the nuts securing the centre of the exten
sion moulding assembly to the back panel lower
(refer Fig. 1 A-165, Section E-E) and remove the
assembly.
REINSTALL
Reverse removal operations, using new plastic retainers.
CJ
J
....
REAR TAIL LAMP
� ....
� u,
--� NUT & -
r2 PLACES
{
JlfbL· --l
I :--- m
0
]--- - �J� C
-� �,
NUT
SECTION L-L 2 PLACES
�
REAR BUMPER UPPER EXTENSION MOULDING
35 STYLES
FINISHER STRIP ASM. avx, 8VL & V5V
19 STYLES
RETAINER
FINISHER STRIP 2 PLACES R/ LH
ASM. avx ONLy SCREW
1 PLACE R/LH
RETAINING CLIP
NUT Lt 8 PLACES
1 PLACE
SECTION F-F SECTION G-G
WASHER
1 PLACE
RETAINER
SECTION E-E 3 PLACES R/LH
FINISHER STRIP
RETAINER ASM. 8VX ONLY
3 PLACES R/LH 8 MOULDING TO BE FLUSH
AGAINST PANEL
SCREW
1 PLACE R/LH -�
�AR BUMPER
SECTION J-J
SECTlt)N K-K
.& 1.8 - 2.4 Nm
Figure 1A-165
'"----/.
BODY 1A-153
2.9 REAR BUMPER UPPER EXTENSION

MOULDING, RIGHT AND/OR LEFT SIDE
- STATION WAGON
(''\J
, REMOVE
1. Remove the screw securing the front end of the
extension moulding to the rear wheelhouse (refer
Fig. 1A-165, Section J-J).
2. Remove the rear quarter trim panel (refer 2.4 in
'Headlining and Rear End Trim' in this Section).
3. Using pointed nose pliers, compress the inner end of
the retainer securing the rear end of the extension
moulding to the rear quarter panel, removing the
moulding.
REINSTALL
Reverse removal operations, using a new retainer.
2.10 ROCKER PANEL MOULDING -

CALAIS
REMOVE
1. Remove the expansion rivet securing the front end of
the moulding to the rear of the front wheel opening
(refer Fig. 1A-166) by tapping the centre of the rivet
into the rocker panel, releasing the front end of the
moulding.
2. Using the end of a prising tool or a wide bladed
screwdriver located under the head of the retaining
buttons (refer Fig. 1A-166) prise out the buttons.
()
3. Grasping the lower inner end of the front rocker
panel moulding, pull the moulding out, off the lower
clips (refer Fig. 1A-166) then lift the moulding up, off
the top of the retaining clips.
Repeat this operation on the rear rocker panel moulding.
REINSTALL
Reverse the removal operations, replacing any clips that
are broken.
EXPANSION RIVET FRONT AND REAR
Figure 1A-166
\ j
"--. ____/
1A-154 BODY
SPECIAL TOOLS
TOOL NO. REF. IN TEXT TOOL DESCRIPTION COMMENTS
FABRICATED TRIM CLIP
REMOVAL TOOL
0.5 mm
.J: 70 f
r=�� -+____,,_. · =··==· ��

'- END CONSTRUCTION
TO SUIT HANDLE
REQUIREMENTS
i
9.0 mm- _._ 75.0 mm�
I
18.0 mm
i
l . .
. ,
. _J 10.0 mm DIA
u·�tt�j · · �---- Ht------

1
f
t r.5mm 30mm
J24402 COLD KNIFE
1A7 ROOF SIDE MOULDING

REMOVAL TOOL
CMT113 RADIO - RADIO/CASSETTE PLAYER These tools are released in pairs

REMOVAL TOOLS and are available from:
Eurovox Australia
6 University Place,
Clayton North
Victoria 3168
KM125-A TRUNK LID HINGE SPRING

REMOVER AND INSTALLER
BODY 1A-155
SPECIAL TOOLS (cont'd.)

TOOL NO. REF. IN TEXT TOOL DESCRIPTION COMMENTS
KM206-01 TRUNK LID LOCK CYLINDER
RETAINING SPRING INSTALLATION TOOL
AU170 DOOR HINGE PIN REMOVAL TOOL
AU184 DOOR HINGE SETIING TOOL
AU303 DOOR HINGE SLEEVE INSTALLER
J24899-01 HOT KNIFE
l_� _ )

Section 1A'

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Section 1A'

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BODY 1A-1

IMPORTANT: Whenever items such as body side

2.1 BODY SHELL PARTS

When replacing parts such as roof panels, rear quarter or

2.2 ANTI-CORROSIVE TREATMENT

2.3 WATER AND DUST LEAK

A comprehensive coverage for fixed glass water leak

2.4 LOCK CYLINDERS AND KEYS

If the key is lost and no record of the key number is

To view this number necessitates removal of a door lock

The Dominion Lock 'Exacta' key cutting machine fitted

PARTS READILY ACCESSIBLE

Door Lock Striker Bolt/Fork Bolt

PARTS CONCEALED NECESSITATING

2.2 TRANSMISSION CONSOLE

4. Remove the caps covering the console attaching

CAP ASM CONSOLE KNOB�

5. Remove the park brake lever cover then, where

6. Disengage the electrical connectors attached to the

2.3 SHROUD LOWER TRIM ASSEMBLY

2.4 ROCKER PANEL COVER - FRONT

2.5 FLOOR COVERING ASSEMBLY -

MAIN WIRING HARNESS

DOOR HARNESS OVER

�� SEAL SEAT BELT RETRACTOR INNER CAP

6. Lift covers and remove bolts securing seat belt

8. Using a fabricated trim clip removal tool (refer 'Special

Removal and installation of the carpet assembly involves

2.7 CARPET ASSEMBL V • LOAD

ADHESIVE BACKED VELCRO TAPE.

CARPET ASSEMBLY - LOAD COMPARTMENT

1.1 INSTRUMENT PANEL LOWER TRIM

1.2 INSTRUMENT PANEL LOWER -

4. If cruise control is fitted, use a small diameter pin

BEFORE INSTALLING SWITCHES FEED SWITCH

INSERT PIN PUNCH IN HOLE

TYPICAL FOR COVER PLATE

6. Remove instrument location cover assembly retaining

7. Using a fine bladed screwdriver, carefully prise out

8. Remove the combined instrument assembly illustr­

9. Using a fine bladed screwdriver positioned under the

1.3 INSTRUMENT PANEL

1.4 INSTRUMENT PANEL LOWER •

$ FOR WIRING HARNESS CONNECTIONS

9. Remove the steering column upper covers then,

10. Remove the instrument panel pad (refer 1.5 in this

RADIO /C A$S ETTE PACKAG E

BEF O RE INS ERTING RADI O C ECTOR MAIN

12. Fully insert the radio assembly removal tools

1.5 INSTRUMENT PANEL PAD

3. Using a small diameter pin punch or similar tool

6. Remove the combined instrument assembly illustr­

COMBINED INSTRUMENT ASM.

REAR COMPARTMENT LID AND TAIL GATE

To raise the lid at the hinge area, place a shim between

1.2 TORQUE ROD· REAR

3. Remove the left side torque rod by inserting the

4. Disengage the outer ends of the rods from holes in

1.3 LOCK CYLINDER - REAR

2. Using a screwdriver, prise the lock cylinder retaining

1.4 LOCK ASSEMBLY· REAR

1.5 SOLENOID ASSEMBLY· REAR

2. Remove screws securing lock solenoid assembly to

8. Remove the combined instrument assembly illustr

6. Remove the combined instrument assembly illustr

2. Remove the remote control lock assembly by careful