Chapter 11 Bodywork and fittings - VALVULITA.COM · 2016. 4. 21. · bodywork If the scratch is very superficial, and does not penetrate to the metal of the bodywork, repair is very

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Chapter 11 Bodywork and fittingsContentsBody exterior fittings - removal and refitting 23Bonnet - removal, refitting and adjustment 8Bonnet lock - removal and refitting 10Bonnet release cable - removal and refitting 9Central locking components - removal and refitting 17Centre console - removal and refitting 27Door - removal, refitting and adjustment 11Door inner trim panel - removal and refitting 12Door handle and lock components - removal and refitting 13Door window glass and regulator - removal and refitting 14Electric window components - general information 18Exterior mirrors and associated components - removal and refitting . 19Facia panel assembly - removal and refitting 28Front bumper - removal and refitting 6General information 1

Degrees of difficulty

Interior trim - removal and refitting 26Maintenance - bodywork and underframe 2Maintenance - upholstery and carpets 3Major body damage - repair 5Minor body damage - repair 4Rear bumper - removal and refitting 7Rear quarter window (three-door models) - removal and refitting .. 21Seat belt components - removal and refitting 25Seats - removal and refitting 24Sunroof - general information 22Tailgate and support struts - removal and refitting 15Tailgate lock components - removal and refitting 16Underbody and general body check See Chapter 1Windscreen, tailgate and fixed rear quarter window glass -

general information 20

Easy, suitable fornovice with littleexperience

Fairly easy, suitablefor beginner withsome experience

Fairly difficult, suitablefor competent DIYmechanic

Difficult, suitable forexperienced DIYmechanic

Very difficult,suitable for expert DIYor professional

1 General information

The bodyshell is made of pressed-steelsections, and is available in both three- andfive-door Hatchback versions. Mostcomponents are welded together, but someuse is made of structural adhesives; the frontwings are bolted on.

The bonnet, door, and some othervulnerable panels are made of zinc-coatedmetal, and are further protected by beingcoated with an anti-chip primer prior to beingsprayed.

Extensive use is made of plastic materials,mainly in the interior, but also in exteriorcomponents. The front and rear bumpers,front grille and tailgate assembly are injection-moulded from a synthetic material which isvery strong and yet light. Plastic componentssuch as wheel arch liners are fitted to theunderside of the vehicle, to improve thebody's resistance to corrosion.

2 Maintenance -bodywork and underframe

The general condition of a vehicle'sbodywork is the one thing that significantlyaffects its value. Maintenance is easy, butneeds to be regular. Neglect, particularly afterminor damage, can lead quickly to furtherdeterioration and costly repair bills. It is

important also to keep watch on those partsof the vehicle not immediately visible, forinstance the underside, inside all the wheelarches, and the lower part of the enginecompartment.

The basic maintenance routine for thebodywork is washing - preferably with a lot ofwater, from a hose. This will remove all theloose solids which may have stuck to thevehicle. It is important to flush these off insuch a way as to prevent grit from scratchingthe finish. The wheel arches and underframeneed washing in the same way, to remove anyaccumulated mud, which will retain moistureand tend to encourage rust. Paradoxicallyenough, the best time to clean the underframeand wheel arches is in wet weather, when themud is thoroughly wet and soft. In very wetweather, the underframe is usually cleaned oflarge accumulations automatically, and this isa good time for inspection.

Periodically, except on vehicles with a wax-based underbody protective coating, it is agood idea to have the whole of theunderframe of the vehicle steam-cleaned,engine compartment included, so that athorough inspection can be carried out to seewhat minor repairs and renovations arenecessary. Steam-cleaning is available atmany garages, and is necessary for theremoval of the accumulation of oily grime,which sometimes is allowed to become thickin certain areas. If steam-cleaning facilities arenot available, there are some excellent greasesolvents available which can be brush-applied; the dirt can then be simply hosed off.

Note that these methods should not be usedon vehicles with wax-based underbodyprotective coating, or the coating will beremoved. Such vehicles should be inspectedannually, preferably just prior to Winter, whenthe underbody should be washed down, andany damage to the wax coating repaired.Ideally, a completely fresh coat should beapplied. It would also be worth consideringthe use of such wax-based protection forinjection into door panels, sills, box sections,etc, as an additional safeguard against rustdamage, where such protection is notprovided by the vehicle manufacturer.

After washing paintwork, wipe off with achamois leather to give an unspotted clearfinish. A coat of clear protective wax polishwill give added protection against chemicalpollutants in the air. If the paintwork sheen hasdulled or oxidised, use a cleaner/polishercombination to restore the brilliance of theshine. This requires a little effort, but suchdulling is usually caused because regularwashing has been neglected. Care needs tobe taken with metallic paintwork, as specialnon-abrasive cleaner/polisher is required toavoid damage to the finish. Always check thatthe door and ventilator opening drain holesand pipes are completely clear, so that watercan be drained out. Brightwork should betreated in the same way as paintwork.Windscreens and windows can be kept clearof the smeary film which often appears, by theuse of proprietary glass cleaner. Never useany form of wax or other body or chromiumpolish on glass.

11•2 Bodywork and fittings

3 Maintenance -upholstery and carpets

Mats and carpets should be brushed orvacuum-cleaned regularly, to keep them freeof grit. If they are badly stained, remove themfrom the vehicle for scrubbing or sponging,and make quite sure they are dry beforerefitting. Seats and interior trim panels can bekept clean by wiping with a damp cloth. If theydo become stained (which can be moreapparent on light-coloured upholstery), use alittle liquid detergent and a soft nail brush toscour the grime out of the grain of thematerial. Do not forget to keep the headliningclean in the same way as the upholstery.When using liquid cleaners inside the vehicle,do not over-wet the surfaces being cleaned.Excessive damp could get into the seams andpadded interior, causing stains, offensiveodours or even rot.

4 Minor body damage - repair

Note: For more detailed information aboutbodywork repair, Haynes Publishing producea book by Lindsay Porter called "The CarBodywork Repair Manual". This incorporatesinformation on such aspects as rust treatment,painting and glass-fibre repairs, as well asdetails on more ambitious repairs involvingwelding and panel beating.

Repairs of minor scratches inbodywork

If the scratch is very superficial, and doesnot penetrate to the metal of the bodywork,repair is very simple. Lightly rub the area ofthe scratch with a paintwork renovator, or avery fine cutting paste, to remove loose paintfrom the scratch, and to clear the surroundingbodywork of wax polish. Rinse the area withclean water.

Apply touch-up paint to the scratch using afine paint brush; continue to apply fine layersof paint until the surface of the paint in thescratch is level with the surroundingpaintwork. Allow the new paint at least twoweeks to harden, then blend it into thesurrounding paintwork by rubbing the scratcharea with a paintwork renovator or a very finecutting paste. Finally, apply wax polish.

Where the scratch has penetrated rightthrough to the metal of the bodywork, causing

the metal to rust, a different repair techniqueis required. Remove any loose rust from thebottom of the scratch with a penknife, thenapply rust-inhibiting paint to prevent theformation of rust in the future. Using a rubberor nylon applicator, fill the scratch withbodystopper paste. If required, this paste canbe mixed with cellulose thinners to provide avery thin paste which is ideal for filling narrowscratches. Before the stopper-paste in thescratch hardens, wrap a piece of smoothcotton rag around the top of a finger. Dip thefinger in cellulose thinners, and quickly sweepit across the surface of the stopper-paste inthe scratch; this will ensure that the surface ofthe stopper-paste is slightly hollowed. Thescratch can now be painted over as describedearlier in this Section.

Repairs of dents in bodyworkWhen deep denting of the vehicle's

bodywork has taken place, the first task is topull the dent out, until the affected bodyworkalmost attains its original shape. There is littlepoint in trying to restore the original shapecompletely, as the metal in the damaged areawill have stretched on impact, and cannot bereshaped fully to its original contour. It isbetter to bring the level of the dent up to apoint which is about 3 mm below the level ofthe surrounding bodywork. In cases where thedent is very shallow anyway, it is not worthtrying to pull it out at all. If the underside of thedent is accessible, it can be hammered outgently from behind, using a mallet with awooden or plastic head. Whilst doing this,hold a suitable block of wood firmly againstthe outside of the panel, to absorb the impactfrom the hammer blows and thus prevent alarge area of the bodywork from being"belled-out".

Should the dent be in a section of thebodywork which has a double skin, or someother factor making it inaccessible frombehind, a different technique is called for. Drillseveral small holes through the metal insidethe area - particularly in the deeper section.Then screw long self-tapping screws into theholes, just sufficiently for them to gain a goodpurchase in the metal. Now the dent can bepulled out by pulling on the protruding headsof the screws with a pair of pliers.

The next stage of the repair is the removalof the paint from the damaged area, and froman inch or so of the surrounding "sound"bodywork. This is accomplished most easilyby using a wire brush or abrasive pad on apower drill, although it can be done just aseffectively by hand, using sheets of abrasivepaper. To complete the preparation for filling,score the surface of the bare metal with ascrewdriver or the tang of a file, oralternatively, drill small holes in the affectedarea. This will provide a really good "key" forthe filler paste.

To complete the repair, see the Section onfilling and respraying.

Repairs of rust holes or gashes inbodywork

Remove all paint from the affected area,and from an inch or so of the surrounding"sound" bodywork, using an abrasive pad or awire brush on a power drill. If these are notavailable, a few sheets of abrasive paper willdo the job most effectively. With the paintremoved, you will be able to judge the severityof the corrosion, and therefore decidewhether to renew the whole panel (if this ispossible) or to repair the affected area. Newbody panels are not as expensive as mostpeople think, and it is often quicker and moresatisfactory to fit a new panel than to attemptto repair large areas of corrosion.

Remove all fittings from the affected area,except those which will act as a guide to theoriginal shape of the damaged bodywork (egheadlight shells etc). Then, using tin snips or ahacksaw blade, remove all loose metal andany other metal badly affected by corrosion.Hammer the edges of the hole inwards, inorder to create a slight depression for the fillerpaste.

Wire-brush the affected area to remove thepowdery rust from the surface of theremaining metal. Paint the affected area withrust-inhibiting paint, if the back of the rustedarea is accessible, treat this also.

Before filling can take place, it will benecessary to block the hole in some way. Thiscan be achieved by the use of aluminium orplastic mesh, or aluminium tape.

Aluminium or plastic mesh, or glass-fibrematting, is probably the best material to usefor a large hole. Cut a piece to theapproximate size and shape of the hole to befilled, then position it in the hole so that itsedges are below the level of the surroundingbodywork. It can be retained in position byseveral blobs of filler paste around itsperiphery.

Aluminium tape should be used for small orvery narrow holes. Pull a piece off the roll, trimit to the approximate size and shape required,then pull off the backing paper (if used) andstick the tape over the hole; it can beoverlapped if the thickness of one piece isinsufficient. Burnish down the edges of thetape with the handle of a screwdriver orsimilar, to ensure that the tape is securelyattached to the metal underneath.

Bodywork repairs - filling andrespraying

Before using this Section, see the Sectionson dent, deep scratch, rust holes and gashrepairs.

Many types of bodyfiller are available, butgenerally speaking, those proprietary kitswhich contain a tin of filler paste and a tube ofresin hardener are best for this type of repair.A wide, flexible plastic or nylon applicator willbe found invaluable for imparting a smoothand well-contoured finish to the surface of thefiller.

If the inside of the vehiclegets wet accidentally, it isworthwhile taking sometrouble to dry it out properly,

particularly where carpets are involved.Do not leave oil or electric heatersinside the vehicle for this purpose.

Bodywork and fittings 11•3

Mix up a little filler on a clean piece of cardor board - measure the hardener carefully(follow the maker's instructions on the pack),otherwise the filler will set too rapidly or tooslowly. Using the applicator, apply the fillerpaste to the prepared area; draw theapplicator across the surface of the filler toachieve the correct contour and to level thesurface. As soon as a contour thatapproximates to the correct one is achieved,stop working the paste - if you carry on toolong, the paste will become sticky and beginto "pick-up" on the applicator. Continue toadd thin layers of filler paste at 20-minuteintervals, until the level of the filler is justproud of the surrounding bodywork.

Once the filler has hardened, the excesscan be removed using a metal plane or file.From then on, progressively-finer grades ofabrasive paper should be used, starting with a40-grade production paper, and finishing witha 400-grade wet-and-dry paper. Always wrapthe abrasive paper around a flat rubber, cork,or wooden block - otherwise the surface ofthe filler will not be completely flat. During thesmoothing of the filler surface, the wet-and-dry paper should be periodically rinsed inwater. This will ensure that a very smoothfinish is imparted to the filler at the final stage.

At this stage, the "dent" should besurrounded by a ring of bare metal, which inturn should be encircled by the finely"feathered" edge of the good paintwork.Rinse the repair area with clean water, until allof the dust produced by the rubbing-downoperation has gone.

Spray the whole area with a light coat ofprimer - this will show up any imperfections inthe surface of the filler. Repair theseimperfections with fresh filler paste orbodystopper, and once more smooth thesurface with abrasive paper. Repeat thisspray-and-repair procedure until you aresatisfied that the surface of the filler, and thefeathered edge of the paintwork, are perfect.Clean the repair area with clean water, andallow to dry fully.

If bodystopper is used, it canbe mixed with cellulosethinners, to form a really thinpaste which is ideal for fillingsmall holes.

The repair area is now ready for finalspraying. Paint spraying must be carried outin a warm, dry, windless and dust-freeatmosphere. This condition can be createdartificially if you have access to a large indoorworking area, but if you are forced to work inthe open, you will have to pick your day verycarefully. If you are working indoors, dousingthe floor in the work area with water will helpto settle the dust which would otherwise be inthe atmosphere. If the repair area is confinedto one body panel, mask off the surroundingpanels; this will help to minimise the effects ofa slight mis-match in paint colours. Bodywork

fittings (eg chrome strips, door handles etc)will also need to be masked off. Use genuinemasking tape, and several thicknesses ofnewspaper, for the masking operations.

Before commencing to spray, agitate theaerosol can thoroughly, then spray a test area(an old tin, or similar) until the technique ismastered. Cover the repair area with a thickcoat of primer; the thickness should be builtup using several thin layers of paint, ratherthan one thick one. Using 400-grade wet-and-dry paper, rub down the surface of the primeruntil it is really smooth. While doing this, thework area should be thoroughly doused withwater, and the wet-and-dry paper periodicallyrinsed in water. Allow to dry before sprayingon more paint.

Spray on the top coat, again building up thethickness by using several thin layers of paint.Start spraying at one edge of the repair area,and then, using a side-to-side motion, workuntil the whole repair area and about 2 inchesof the surrounding original paintwork iscovered. Remove all masking material 10 to15 minutes after spraying on the final coat ofpaint.

Allow the new paint at least two weeks toharden, then, using a paintwork renovator, ora very fine cutting paste, blend the edges ofthe paint into the existing paintwork. Finally,apply wax polish.

Plastic componentsWith the use of more and more plastic body

components by the vehicle manufacturers (egbumpers, spoilers, and in some cases majorbody panels), rectification of more seriousdamage to such items has become a matterof either entrusting repair work to a specialistin this field, or renewing completecomponents. Repair of such damage by theDIY owner is not really feasible, owing to thecost of the equipment and materials requiredfor effecting such repairs. The basic techniqueinvolves making a groove along the line of thecrack in the plastic, using a rotary burr in apower drill. The damaged part is then weldedback together, using a hot-air gun to heat upand fuse a plastic filler rod into the groove.Any excess plastic is then removed, and thearea rubbed down to a smooth finish. It isimportant that a filler rod of the correct plasticis used, as body components can be made ofa variety of different types (eg polycarbonate,ABS, polypropylene).

Damage of a less serious nature (abrasions,minor cracks etc) can be repaired by the DIYowner using a two-part epoxy filler repairmaterial. Once mixed in equal proportions,this is used in similar fashion to the bodyworkfiller used on metal panels. The filler is usuallycured in twenty to thirty minutes, ready forsanding and painting.

If the owner is renewing a completecomponent himself, or if he has repaired itwith epoxy filler, he will be left with theproblem of finding a suitable paint for finishingwhich is compatible with the type of plastic

used. At one time, the use of a universal paintwas not possible, owing to the complex rangeof plastics encountered in body componentapplications. Standard paints, generallyspeaking, will not bond to plastic or rubbersatisfactorily. However, it is now possible toobtain a plastic body parts finishing kit whichconsists of a pre-primer treatment, a primerand coloured top coat. Full instructions arenormally supplied with a kit, but basically, themethod of use is to first apply the pre-primerto the component concerned, and allow it todry for up to 30 minutes. Then the primer isapplied, and left to dry for about an hourbefore finally applying the special-colouredtop coat. The result is a correctly-colouredcomponent, where the paint will flex with theplastic or rubber, a property that standardpaint does not normally posses.

5 Major body damage - repair

Where serious damage has occurred, orlarge areas need renewal due to neglect, itmeans that complete new panels will needwelding-in, and this is best left toprofessionals. If the damage is due to impact,it will also be necessary to check completelythe alignment of the bodyshell, and this canonly be carried out accurately by a Citroendealer using special jigs. If the body is leftmisaligned, it is primarily dangerous, as the carwill not handle properly, and secondly, unevenstresses will be imposed on the steering,suspension and possibly transmission,causing abnormal wear, or complete failure,particularly to such items as the tyres.

Removal1 Apply the handbrake, then jack up the frontof the vehicle and support it on axle stands.2 Remove both the right- and left-handheadlights as described in Chapter 12.3 Working through the headlamp apertures,slacken and remove the four bolts (two oneither side) securing the upper ends of thebumper to the vehicle.4 Slacken and remove the five bolts securingthe bottom edge of the bumper to the vehicle.5 Working from underneath the vehicle, undothe two bolts (one on either end) securing thelower ends of the bumper to the vehicle.Where necessary, disconnect the wiringconnectors from the front foglamps.6 Release both the left- and right-hand endsof the bumper, and pull the bumper awayfrom the vehicle in a forwards direction.

Refitting7 Refitting is a reverse of the removalprocedure, ensuring that the bumpermounting bolts are securely tightened.

6 Front bumper -removal and refitting


7.2 Unscrew the wheel brace retaining clipfrom its mounting stud in the luggage

compartment

Removal

1 Remove the luggage compartment rear trimpanels (where fitted) as described in Sec-tion 26.2 On five-door models, remove the wheelbrace, and unscrew the wheel brace clip fromthe rear right-hand corner of the luggagecompartment (see illustration). Remove theretaining nut and clip from the same positionon the left-hand side.3 Release the retaining clips and peel back

7.3 Peel back the carpet to gain access tothe rear bumper retaining bolts (arrowed)

the luggage compartment carpet, thenslacken and remove the four bumper retainingbolts (see illustration).4 Chock the front wheels, then jack up therear of the vehicle and support it on axlestands.5 Working from underneath the vehicle, undothe two bolts (one either side) securing theends of the bumper to the wheel arch liner(see illustration).6 Undo the two bolts securing the bumper tothe underside of the vehicle, then release theleft- and right-hand ends of the bumpers fromtheir mountings, and pull the bumper awayfrom the vehicle in a rearwards direction (seeillustrations).

Refitting

7 Refitting is a reverse of the removalprocedure, ensuring that all disturbedfasteners are securely tightened.

7.6a . . . and to the vehicle body . . .

Removal

1 Open the bonnet and have an assistantsupport it. Using a pencil or felt tip pen, markthe outline of each bonnet hinge relative to thebonnet, to use as a guide on refitting.2 Disconnect the windscreen washer supply

7.5 Slacken and remove the bolts securingthe rear bumper to the wheel arch liners

(arrowed)...

pipe from its non-return valve on the right-hand side. Undo the bonnet retaining boltsand, with the help of an assistant, carefully liftthe bonnet clear. Store the bonnet out of theway in a safe place (see illustrations).3 Inspect the bonnet hinges for signs ofwear and free play at the pivots, and ifnecessary renew. Each hinge is secured tothe body by two pivot bolts. On refitting,apply a smear of multi-purpose grease to theshanks of the hinge pivot bolts, and tightenthem securely.

Refitting and adjustment

4 With the aid of an assistant, offer up thebonnet and loosely fit the retaining bolts. Alignthe hinges with the marks made on removal,then tighten the retaining bolts securely, andreconnect the windscreen washer supplypipe.5 Close the bonnet, and check for alignmentwith the adjacent panels. If necessary,slacken the hinge bolts and re-align thebonnet to suit. Once the bonnet is correctlyaligned, tighten the hinge bolts to thespecified torque.6 Once the bonnet is correctly aligned, checkthat the bonnet fastens and releases in asatisfactory manner. If adjustment isnecessary, slacken the bonnet lock retainingbolts, and adjust the position of the lock tosuit. Once the lock is operating correctly,securely tighten its retaining bolts.

7.6b . . . then remove the bumper from the 8.2a Slacken and remove the bonnet-to-rear of the vehicle hinge retaining bolts . . .

8.2b . . . then, with the aid of an assistant,lift off the bonnet

7 Rear bumper -removal and refitting

8 Bonnet - removal,refitting and adjustment


9.5 Removing the bonnet release lever 10.1 Undo the three retaining screws, andretaining bolts remove the plastic cover to gain access to

the bonnet lock

securely tighten its retaining bolts and refit thelock cover.10 Refit the lower facia panel, and secure it inposition by rotating its fasteners through aquarter of a turn.

Removal1 Open the bonnet. Undo the three retainingscrews and remove the plastic cover to gainfull access to the bonnet lock.2 Unclip the bonnet release outer cable fromthe lock bracket, then release the inner cablefrom the lock lever.3 Work back along the length of the cable,noting its correct routing, and free it from theretaining clips and ties. Tie a length of stringto the end of the cable.4 From inside the vehicle, release the panelfasteners by rotating them through a quarterof a turn, and remove the driver's side lowerfacia panel.5 Slacken and remove the two retaining bolts,then free the bonnet release lever from itsretaining bracket, and withdraw the cable(see illustration). Once the cable is free, untiethe string and leave it in position in thevehicle; the string can then be used to drawthe new cable back into position.

Refitting6 Tie the inner end of the string to the end ofthe cable, then use the string to draw thebonnet release cable through into the enginecompartment. Once the cable is through,untie the string.7 Manoeuvre the bonnet release lever backinto position, and securely tighten its retainingbolts.8 Ensure the cable is correctly routed, andsecured to all the relevant retaining clips.Connect the end of the inner cable to the locklever, then clip the outer cable into position inthe lock bracket.9 Operate the bonnet release lever, andcheck that the lock operates smoothly,without any sign of undue resistance. Checkthat the bonnet fastens and releases in asatisfactory manner. If adjustment isnecessary, slacken the bonnet lock retainingbolts, and adjust the position of the lock tosuit. Once the lock is operating correctly,

Removal1 Open the bonnet. Undo the three retainingscrews and remove the plastic cover to gainfull access to the bonnet lock (seeillustration). Mark the outline of the bonnetlock on the body, to use as a guide onrefitting.2 Unclip the bonnet release outer cable fromthe lock bracket, then release the inner cablefrom the lock lever (see illustration).3 Undo the two retaining bolts, and removethe lock assembly from the vehicle.

Refitting4 Refit the lock to the vehicle, aligning it withthe marks made on removal, and securelytighten its retaining bolts.5 Connect the end of the inner cable to thelock lever, then clip the outer cable intoposition in the lock bracket.

10.2 Unclip the release cable (A), thenundo the retaining bolts (B) and remove

the bonnet lock

6 Check that the bonnet fastens and releasesin a satisfactory manner. If adjustment isnecessary, slacken the bonnet lock retainingbolts, and adjust the position of the lock tosuit. Once the lock is operating correctly,securely tighten its retaining bolts and refit thelock cover.

Removal1 Open the door, to gain access to the wiringconnector which is fitted to the front edge ofthe door.2 Where a circular wiring connector is used,unscrew the connector locking ring until itstab is located between the lugs on theconnector, then disconnect the wiringconnector from the door (see illustration).Where a rectangular connector is used, pullout the locking clip to release it, thendisconnect the connector from the door.3 Undo the two bolts securing the check linkto the pillar (see illustration). On modelswhere the bolts are not accessible, drive outthe check link roll pin using a hammer andpunch.4 Loosen the two hinge pin grub bolts. Withthe aid of an assistant, lift the door to release

11.2 On circular wiring connectors,unscrew the locking ring until its tab is

located between the connector lugs(arrowed), then pull it away from the door

11.3 Undo the check link retainingbolts . . .

9 Bonnet release cable -removal and refitting

10 Bonnet lock -removal and refitting

11 Door - removal,refitting and adjustment


11.4 . . . slacken the hinge pin grub bolts(arrowed), and lift the door upwards and

away from the vehicle12.1 Unclip the exterior mirror inner trim 12.2 Lift the door inner handle, and

panel from the door remove the escutcheon from the door

12.4 On models with electric windows,remove the switch from the armrest

it from the hinge pins, and remove it from thevehicle (see illustration).5 Examine the hinges for signs of wear ordamage. The hinges are welded to the doorand pillar; if renewal is necessary, the taskshould be entrusted to a Citroen dealer.

Refitting6 Apply a smear of multi-purpose grease tothe hinge pins, then, with the aid of anassistant, refit the door to the vehicle. Oncethe door is correctly positioned, securelytighten the grub bolts.7 Align the check link with the door pillar, andsecurely tighten its retaining bolts. Where thecheck link roll pin was removed, align the link

12.5 Depress the retaining tab, and slidethe inner lock button off its link rod

12.6 Undo the retaining screws (arrowed),and remove the armrest from the door

with its retaining bracket, and secure it inposition by tapping in the roll pin.8 Reconnect the wiring connector, andsecure it in position by tightening its retainingring, or by pressing in its retaining clip (asapplicable).

Adjustment9 Adjustment of the door position is notpossible for the home mechanic. However,small adjustments can be made by bendingthe hinge pin slightly using a special Citroenservice tool. This task should be entrusted toa Citroen dealer.

12.8 Removing the inner trim panel fromthe front door

12.10 Removing the small inner trim panelfrom the rear door

RemovalFront door1 Open the door. Carefully prise out andremove the exterior mirror inner trim panel(see illustration).2 Lift the door inner handle, then carefullyprise the escutcheon out from the door paneland remove it (see illustration).3 On models with manual windows, pull thehandle off the spindle, and remove theregulator escutcheon.4 On models with electric windows, carefullyprise the window switch out of the armrest,taking care not to mark the switch or armrest.Disconnect the wiring connector and removethe switch (see illustration).5 Lift up the inner door lock operating button,then, using a small flat-bladed screwdriver,depress the retaining tab, and slide off thebutton (see illustration).6 Slacken and remove the armrest retainingscrews, and remove the armrest from thedoor (see illustration).7 Remove the speaker as described inChapter 12.8 Release the door trim panel studs, carefullylevering between the panel and door with aflat-bladed screwdriver. Work around theoutside of the panel, and when all the studsare released, slide the panel upwards andaway from the door (see illustration).

12 Door inner trim panel -removal and refitting


12.11 Pull the window winder handle and 12.13 Undo the two retaining screws, and 12.14 Undo the two retaining screwstrim collar off the regulator spindle remove the armrest from the rear door (arrowed) located behind the speaker grille

Rear door9 Lift the door inner handle, then carefullyprise the escutcheon out from the door paneland remove it.10 Carefully prise off the small inner trimpanel from the rear of the door (seeillustration).11 Pull the window winder handle off thespindle, and remove it, along with its trimcollar (see illustration).12 Lift up the inner door lock operatingbutton, then, using a small flat-bladedscrewdriver, depress the retaining tab, andslide off the button (see illustration 12.5).13 Slacken and remove the armrest retainingscrews, and remove the armrest from thedoor (see illustration).14 Prise off the speaker grille, and slackenand remove the two retaining screws securingthe trim panel to the door (see illustration).15 Release the door trim panel studs,carefully levering between the panel and doorwith a flat-bladed screwdriver. Work aroundthe outside of the panel, and when all thestuds are released, lift the panel upwards andaway from the door (see illustration).

Refitting16 Refitting of the trim panel is the reversesequence of removal, noting the followingpoints:(a) Before refitting, check whether any of the

trim panel retaining studs were broken on

removal, and renew them as necessary,(b) To refit the inner door lock operating

button, first lock the door, to ensure thatthe link rod is in its lowest position.Position the button locating tab in thelower of the its two holes, then firmlypush the button onto the rod, until it clipsinto position and the retaining tab appearsin the upper hole (see illustration).

Removal1 Remove the door inner trim panel asdescribed in Section 12, then proceed asdescribed under the relevant sub-heading.

Interior door handle2 Unclip the interior handle from the door,and disconnect it from the link rod.

Exterior door handle3 Carefully cut the rubber insulating panelaway from the rear of the door, to gain accessto the rear of the handle.4 Undo the three screws securing the lockassembly to the door, then drop the lockassembly slightly to disengage it from thehandle.5 On five-door models, working through the

door aperture, slacken and remove theretaining nut, then free the handle from thelock assembly, and withdraw it from the door(see illustrations).6 On three-door models, slacken and removethe two bolts securing the handle to theoutside of the door, then free the handle fromthe lock assembly and remove it from thedoor.

Front door lock cylinder7 Carefully cut the rubber insulating panelaway from the rear of the door, to gain accessto the rear of the lock cylinder.8 Undo the three screws securing the lockassembly to the door, and drop the lockassembly slightly to improve access to thelock cylinder.

12.15 Unclip the inner trim panel, andremove it from the rear door

12.16 Refitting a door lock operating button.Note the locating tab (arrowed) engaged in

the lower of the two button holes

13.5a On five-door models, undo theretaining nut from the inside of the

door . . .13.5b . . . then remove the exterior handle

13 Door handle and lockcomponents -removal and refitting


13.9a Slide out the retaining clip . . .

9 Using a pair of pliers, slide out the lockcylinder retaining clip, then withdraw the lockcylinder from the outside of the door, and freeit from its link rod (see illustrations).Front door lock10 Remove the interior lock handle asdescribed in paragraph 2.11 Remove the lock cylinder as described inparagraphs 7 to 9.12 Manoeuvre the lock and link rod assemblyout through the door aperture. On modelswith central locking, it will be necessary todisconnect the wiring connector from theservo motor as the lock is removed.Rear door lock13 Remove the interior door handle asdescribed in paragraphs 1 and 2.

13.9b . . . then withdraw the lock cylinder,and disconnect it from its link rod

14 Carefully cut the rubber insulating panelaway from the rear of the door, to gain accessto the rear of the lock assembly.15 Slacken and remove the three lockretaining screws, then manoeuvre the lockand link rod assembly out through the dooraperture. On models with central locking, itwill be necessary to disconnect the wiringconnector from the servo motor as the lock isremoved (see illustrations).

Refitting16 Refitting is the reverse of the removalsequence, noting the following points:(a) Ensure that all link rods are securely held

in position by their retaining clips.(b) Apply grease to all lock and link rod pivot

points.(c) Before installing the inner trim panel,

13.15b . . . manoeuvre the lock assemblyout of the door, and (where necessary)

disconnect the wiring connector from theservo unit

14.2 Removing the rubber insulating panelfrom the front door

13.15a Undo the three retainingscrews . . .

thoroughly check the operation of all thedoor lock handles and, where applicable,the central locking system, and ensurethat the rubber insulating panel iscorrectly positioned.

Removal1 Remove the door inner trim panel asdescribed in Section 12.2 Carefully cut the rubber insulating panelaway from the edge of the door, remove thepanel, then proceed as described under therelevant sub-heading (see illustration).

Front door window glass3 With the window in the fully-raised position,slacken and remove the upper and lowerwindow guide retaining bolts, and remove theguide from the front of the door (seeillustrations).4 Temporarily refit the handle (or reconnectthe switch, as applicable), and lower thewindow glass approximately halfway.5 Working from inside the door, release theclip securing the window glass to theregulator peg by rotating it through 45°, thenslide off the clip, and free the glass from theregulator mechanism (see illustration).

14.3a Undo the two retaining bolts(arrowed)...

14.3b . . . and remove the window guidefrom the door

14.5 Remove the retaining clip asdescribed in the text, and free the window

glass from the regulator peg

14 Door window glass andregulator -removal and refitting


14.6 Removing the window glass from thefront door

6 Fully lower the glass, and free the upperwindow guide from the rear of the sealingstrip, then carefully manoeuvre the windowglass out through the top of the door (seeillustration).

Rear door window glass7 Undo the retaining screw from the inside,then remove the small outer trim panel fromthe door (see illustrations).8 Temporarily refit the handle, and lower thewindow glass.9 Working around the edge of the strip,carefully ease the sealing strip out from thedoor, and remove it from the vehicle (seeillustration).10 Release the window glass from theregulator mechanism as described above in

14.7a Undo the retaining screw . . .

paragraph 5, then carefully manoeuvre theglass out through the top of the door (seeillustrations).Window regulator11 Remove the window glass as describedabove.12 Slacken and remove the five regulatorretaining nuts, then carefully manoeuvre theregulator assembly out through the largestdoor panel aperture. On models with electricwindows, it will be necessary to disconnectthe wiring connector from the regulator motoras it becomes accessible (see illustrations).

RefittingFront door window glass13 Manoeuvre the window glass back into

14.7b . . . and remove the trim panel fromthe outside of the rear door

position through the top of the door.14 Lower the window glass to the base of thedoor, and engage the upper guide with therear of the sealing strip.15 Raise the glass, and locate it on theregulator mechanism peg. Slide the retainingclip onto the regulator peg, and secure it inposition by rotating it through 45°.16 Fully raise the window glass, then refit thefront window guide, tightening its retainingscrews securely.17 Check that the window glass can beraised and lowered smoothly, then refit therubber insulating panel to the door.18 Ensure the insulating panel is securelystuck to the door, and refit the inner trim panelas described in Section 12.

14.9 Work around the edge of the sealingstrip, freeing it from the door, and remove 14.10a Remove the retaining clip, then free

the strip the window glass from the regulator . . .14.10b . . . and remove it from the top

edge of the door

14.12a Undo the five regulator retainingnuts (arrowed)...

14.12b . . . and withdraw the regulatorassembly through the largest door panel

aperture

14.12c On models with electric windows,disconnect the wiring connector from the

motor as the regulator is removed


15.2a Undo the retaining screw (arrowed)and remove the vent grille . . .

Rear door window glass19 Manoeuvre the window glass back intoposition through the top of the door, and locateit on the regulator mechanism peg. Slide theretaining clip onto the regulator peg, andsecure it in position by rotating it through 45°.20 Engage the front edge of the sealing stripwith the upper window glass guide, then workaround the edge of the strip, and seat it backinto position in the door. Refit the outer trimpanel, and securely tighten its retaining screw.21 Check that the window glass can beraised and lowered smoothly, then refit therubber insulating panel to the door.22 Ensure the insulating panel is securelystuck to the door, and refit the inner trim panelas described in Section 12.

15.2b . . . and duct from each side of theluggage compartment

Window regulator23 Reconnect the wiring connector (whereapplicable), and manoeuvre the regulatorassembly back into position in the door. Refitthe five retaining nuts, and tighten themsecurely.24 Refit the window glass as described above.

Removal

Tailgate1 Remove both the left- and right-hand rearlight units as described in Chapter 12.

15.3b . . . withdraw the wiring looms fromthe rear of the vehicle, and free them from

underneath the tailgate sealing strip

15.4 Release the tailgate washer pipe fromunderneath the sealing strip, and

disconnect it at its non-return valve

15.3a Disconnect the tailgate wiringconnectors and earth lead connection(arrowed) - left-hand side shown . . .

2 Undo the retaining screw, and remove thevent grilles and ducts which are situated onthe left- and right-hand sides of the luggagecompartment (see illustrations).3 Disconnect the tailgate wiring connectors,situated on the left- and right-hand sides,from the main wiring loom, and unscrew thebolt securing the earth lead to the vehiclebody. Withdraw the wiring connectors fromthe rear of the body, then work back along thelength of each loom, and release them fromunderneath the outside of the tailgate sealingstrip, and from any relevant retaining clips(see illustrations).4 Release the rear screen washer supply pipefrom underneath the top of the tailgate sealingstrip, and disconnect it at its non-return valve(see illustration).5 Have an assistant support the tailgate, thenraise the spring clips and pull the supportstruts off their balljoint mountings on thetailgate. Carefully prise out the hinge pinretaining clips, then tap both hinge pins out ofposition, and remove the tailgate from thevehicle (see illustrations).6 Examine the hinge pins for signs of wear ordamage, and renew if necessary.

Support struts7 Support the tailgate in the open position,using a stout piece of wood, or with the helpof an assistant.8 Raise the spring clip, and pull the supportstrut off its balljoint mounting on the tailgate.

15.5a Remove the retaining clips . . . 15.5b . . . and withdraw the tailgate hingepins

15.8a Lift the spring clip (arrowed), andfree the support strut from the tailgate . . .

15 Tailgate and support struts -removal and refitting


15.8b . . . then prise out the retaining clip,and free the strut from the body

16.1a Undo the two retaining bolts . . , 16.1b . . . and remove the lock from thebase of the tailgate

Using a flat-bladed screwdriver, prise out theretaining clip, then carefully lever the strut offits balljoint, and remove it from the vehicle(see illustrations).

RefittingTailgate9 Refitting is a reversal of the removalprocedure, noting the following points:(a) Before refitting, apply a smear of multi-

purpose grease to the hinge pins.(b) Ensure that the hinge pins are securely

retained by their retaining clips, and thatthe support struts are securely held inposition by their spring clips.

(c) Ensure that the washer jet pipe and wiringlooms are correctly located behind thetailgate sealing strip.

Support struts10 Refitting is a reverse of the removalprocedure, ensuring that the strut is securelyretained by its spring clip and retaining clip.

RemovalTailgate lock1 Open up the tailgate, then undo the tworetaining bolts and remove the lock (seeillustrations).

Tailgate lock cylinder2 Remove the tailgate wiper motor asdescribed in Chapter 12.3 Using a pair of pliers, slide out the lockretaining clip, and withdraw the lock cylinderand handle from the tailgate (seeillustrations).

Refitting4 Refitting is a reversal of the removalprocedure.

Electronic control unit1 Open the rear ashtray, depress theretaining tang and remove the ashtray fromthe handbrake lever cover panel. Slacken andremove the rear retaining nut and the twofront retaining screws, then manoeuvre thecover panel off the handbrake lever.2 Undo the nut securing the control unit tothe handbrake lever mounting stud.Disconnect the wiring connector and removethe unit from the vehicle (see illustration).3 Refitting is the reverse of removal.

Door lock servo unit4 Remove the relevant door lock asdescribed in Section 13.

16.3a Slide out the retaining clip . . .

5 The servo unit is a bayonet fit on the lockassembly. To remove it, twist it slightly torelease it from the lock bracket, anddisengage it from the lock peg (seeillustration).6 On refitting, ensure that the servo unit issecurely clipped in position, and that it iscorrectly engaged with the lock peg.

Tailgate lock servo unit7 Remove the tailgate wiper motor asdescribed in Chapter 12.8 Undo the two retaining screws, and removethe servo unit from wiper motor bracket (seeillustration).9 Refitting is the reverse of the removalprocedure.

16.3b . . . then withdraw the lock cylinderand handle assembly from the tailgate

17.2 Central locking electronic control unitis mounted onto one of the handbrake

lever studs17.5 Removing a central locking servo unit

from a lock assembly

16 Tailgate lock components -removal and refitting

17 Central locking components- removal and refitting


17.8 Tailgate lock servo motor is retainedby two screws

Remote receiver unit10 Carefully prise the courtesy light out fromthe overhead console, and disconnect it fromits wiring connector. Remove the two consoleretaining screws, lower the console anddisconnect it from its wiring connectors.11 Release the retaining clips, and removethe receiver unit from the top of the console(see illustration).12 Refitting is the reverse of removal.

Transmitter batteries13 Using a small screwdriver, carefully prisethe two halves of the transmitter apart, andremove the two batteries, noting which wayaround they are fitted (see illustration).14 Fit the two batteries, ensuring that they

17.11 Removing the central lockingreceiver unit from the overhead console

are fitted the correct way around; the batteryand transmitter terminals are marked "+" and"-" to avoid confusion. Clip the transmitterback together.

Window switches1 Refer to Chapter 12.

Window winder motors2 The window winder electric motor is anintegral part of the regulator mechanism, andcannot be renewed separately. Refer toSection 14 for regulator removal and refittingdetails.

19.1 On manually-operated mirrors, priseoff the inner trim panel . . .

19.2a . . . then slacken and remove thetwo retaining screws . . .

17.13 Prise the two halves of the transmitterunit apart, and remove the batteries

Removal

Manually-operated mirror1 Carefully prise off the mirror interior trimpanel (see illustration).2 Unscrew the two retaining screws, thenslacken and remove the adjusting lever grubscrew, and slide the retaining plate off themirror adjusting lever (see illustrations).3 Remove the rubber insulating foam, thenslacken and remove the three retainingscrews, and remove the mirror assembly fromthe door (see illustration).

Electrically-operated mirror

4 Remove the door inner trim panel asdescribed in Section 12.5 Carefully cut the rubber insulating panelaway from the front edge of the door to gainaccess to the mirror wiring connector.Disconnect the connector from the mainwiring loom (see illustration).6 Remove the rubber insulating foam.Slacken and remove the three retainingscrews and remove the mirror assembly fromthe door (see illustrations).

19.2b . . . and the adjusting lever grubscrew. . .

19.2c . . . and remove the retaining platefrom the adjusting lever

19.3 Undo the three retaining screws(arrowed), and remove the mirror assembly

from the door

18 Electric window components -general information

19 Exterior mirrors andassociated components -removal and refitting


24.1a Undo the trim panel retainingscrews. . .

24 Seats - removal and refitting

RemovalFront seat1 Slide the seat fully backwards, then undothe two Torx bolts securing the front of theseat slides to the floor. Where necessary, toimprove access to the bolts, undo theretaining screws, and prise the trim coversback from the base of the seat (seeillustrations).2 Slide the seat fully forwards, then undo thetwo Torx bolts securing the rear of the seatslides to the floor, and remove the seat fromthe car.

Rear seat assembly3 Undo the retaining screws, and remove theplastic trim covers from each of the three seatfront mounting points. With the coversremoved, slacken and remove the seat frontretaining nuts (see illustrations).4 On models with a sliding rear seatassembly, slide the seat fully forwards, andremove the rear parcel shelf; unclip the trimcover from the base of the seat, to gainaccess to the rear mounting bolts (seeillustration). On models with a fixed rear seatassembly, remove the parcel shelf, thenrelease the trim fasteners and peel back the

24.1b . . . and peel back the trim panel toimprove access to the front seat mounting

bolts

carpet from the rear of the seat, to gainaccess to the rear mounting bolts.5 Slacken and remove the three rearmounting bolts, and recover the spacerswhich are positioned beneath the seatmounting brackets (see illustration).6 Feed the rear seat belts back through thegap between the seat back and cushion, andmanoeuvre the seat assembly out of thevehicle.

Refitting7 Refitting is a reverse of the removalprocedure, ensuring that the seat mountingbolts are securely tightened.

RemovalFront seat belt - five-door models1 Prise off the trim cap from the lower beltanchorage bolt, then slacken and remove thebolt and washers, and free the seat belt fromits lower anchorage.2 Prise the trim cover off the upper seat beltmounting bolt, then undo the bolt and releasethe seat belt.3 Undo the two retaining screws from thebase of the lower door pillar trim panel, then

24.3a Undo the retaining screws . . .

carefully prise the panel away ffomjhe pillar,and remove it from the vehicle.4 Pull the knob off the seat belt uppermounting height adjuster lever. Slacken andremove the retaining screw, then unclip theupper trim panel from the door pillar, andremove it from the vehicle.5 Slacken and remove the inertia reelretaining bolt(s), and remove the seat beltfrom the vehicle.

Front seat belt - three-door models6 Remove the relevant rear seat side trimpanel as described in Section 26.7 Prise the trim cover off the upper seat beltmounting bolt, then slacken and remove thebolt and washer(s), and release the seat belt.Unhook the belt from its guide on the doorpillar, or alternatively, drill out the rivetsecuring the seat belt guide to the door pillar.8 Slacken and remove the bolt and washerssecuring the lower seat belt mounting rail tothe floor, and disengage the rail from the belt.9 Slacken and remove the inertia reelretaining bolt(s), and remove the seat beltfrom the vehicle.

Front seat belt stalk - all models10 Remove the seat as described in Sec-tion 24.11 Slacken and remove the bolt securing thestalk to the seat, and remove the stalk.

24.3b . . . and remove the trim covers togain access to the rear seat front retaining

nuts

24.4 On models with a sliding rear seatassembly, unclip the trim panel from the

base of the seat, to gain access to the rearseat rear mounting bolts

24.5 Slacken and remove the rearmounting bolts, and recover the spacers

(arrowed) from underneath the seatmounting brackets

25 Seat belt components -removal and refitting


25.13a Rear seat side belt inertia reel bolt,and upper belt mounting bolt (arrowed) -

five-door model shown

Rear seat side belt12 Remove the lower and upper luggagecompartment side trim panels as described inSection 26.13 Slacken and remove the upper and lowerseat belt mounting bolts and washers, if notalready having done so, then undo the inertiareel retaining bolt and remove the seat beltfrom the vehicle (see illustrations).Rear seat centre belt and buckles14 On models with a sliding rear seatassembly, slide the rear seat fully forwards,then unclip the trim panel from the base of therear of the seat. On models with a fixed rearseat assembly, release the trim fasteners, andpeel back the carpet from the rear of the seat.15 Slacken and remove the bolt and washerssecuring the centre belt and/or buckleassembly to the floor, and remove it from thevehicle (see illustration).

Refitting16 Refitting is a reversal of the removalprocedure, ensuring that all the seat beltmounting bolts are securely tightened, and alldisturbed trim panels are securely retained byall the relevant retaining clips.

Interior trim panelsDoor trim panels1 Refer to Section 12.

Rear seat side trim panels -three-door models2 Remove the rear seat assembly asdescribed in Section 24.3 Unclip the speaker grille from the panelthen undo the screws securing the speaker(where fitted) and panel to the vehicle. Wherea speaker is fitted disconnect the wiringconnectors and remove the speaker.4 Slacken and remove the three otherretaining screws (two at the base of the paneland one underneath the armrest) securing thepanel to the body (see illustration).5 Peel the sealing strip away from the frontedge of the trim panel, then release the panel

25.13b Rear seat side belt lower mountingbolt

studs by carefully levering between the paneland body with a flat-bladed screwdriver. Workaround the outside of the panel and when allthe studs are released slide the panelupwards and away from the body.6 Refitting is the reversal of the removal,renewing any broken retaining clips prior torefitting the panel.

Luggage compartment rear trimpanels7 Open the tailgate. Slacken and remove thebump-stop retaining screws, and removeboth tailgate bump-stops (see illustration).8 Undo the three retaining screws securing theright- or left-hand rear luggage compartmenttrim panel to the floor, noting the correct fittedpositions of the luggage clips, and remove the

25.15 Rear seat centre belt/buckleretaining bolt

panel (see illustration). If necessary, repeat theprocedure and remove the remaining trim panel.9 Refitting is a reversal of the removalprocedure.

Luggage compartment lower side trimpanel10 Slide the rear seat fully forwards (wherepossible), and fold down the rear seat backs.11 Remove the appropriate half of the reartrim panel (where fitted) as described above.On three-door models, remove the rear seatside trim panel.12 On five-door models, if the right-handpanel is being removed, remove the wheelbrace, and unscrew the wheel brace clip fromthe rear right-hand corner of the luggagecompartment (see illustration). If the left-

26.4 Three-door model rear seat side trimpanel retaining screw locations (arrowed) -

shown with panel removed

26.7 Removing a tailgate bump-stop fromthe rear of the vehicle

26.12 On five-door models, the wheelbrace clip unscrews from the body

26 Interior trim -removal and refitting

26.8 Removing a rear trim panel from theluggage compartment (retaining screw

locations arrowed)


26.13 Removing the luggage compartmentside trim panel retaining clip (retaining

screw locations arrowed)

hand panel is being removed, remove theretaining nut and clip from the same positionon the left-hand side.13 Slide the retaining clip, located justbehind the base of the rear seat cushion, outof the trim panel (see illustration).14 Slacken and remove the four trim panelretaining screws. Carefully release the edgesof the panel from its surrounding components,then remove it from the vehicle (seeillustration). If the left-hand panel is beingremoved, it will be necessary to disconnectthe wiring connector from the luggagecompartment light as it becomes accessible.15 Refitting is the reverse of removal,ensuring that all fasteners are securelytightened.

26.14 Removing a side trim panel from the 26.19a Slacken and remove the two upperluggage compartment retaining screws (arrowed)...

Luggage compartment upper sidetrim panel

16 Remove the lower side trim panel asdescribed above.17 On three-door models, prise the trimcover off the rear seat belt upper mountingpoint, then slacken and remove the mountingbolts and washer(s), and free the belt from thepanel. Also remove the centre pillar upper trimpanel as described later in this Section.18 Undo the two upper side trim panel lowerretaining screws.19 Slacken and remove the four retainingscrews and rubber bump-stop from the rearsection of the upper panel. Peel back thetailgate sealing strip from the side of the panel

rear section, then remove the panel. Wherenecessary, disconnect the wiring connectorfrom the luggage compartment light switch asit becomes accessible (see illustrations).20 Undo the two retaining screws locatedbehind the rear section of the trim panel, thenfree the panel from the side of the body (seeillustrations). On five-door models, to removethe panel from the vehicle, slacken andremove the rear seat belt lower mounting boltand washer, and feed the belt back throughthe slot in the panel.21 Refitting is a reversal of the removalprocedure. Ensure that the tailgate wiring iscorrectly positioned beneath the sealing stripprior to pressing the sealing strip onto thevehicle.

26.19b . . . and the two lower retaining 26.19c . . . then remove the rear section of 26.20a Undo the upper retaining screw . . .screws (arrowed)... the upper trim panel

26.20b . . . and the lower retainingscrew. . .

26.20c . . . and free the upper trim panel 26.23 On refitting, ensure the windscreenfrom the luggage compartment - five-door trim pegs are correctly located in the facia

model shown (viewed through the windscreen)


26.28a On three-door models, remove thetrim cover . . .

Windscreen pillar trim panel22 Unclip the trim panel from the windscreenpillar and, where necessary, release the alarmsensor from the clip on the top of the panel.23 Prior to refitting, check the panel retainingclips, and renew any that are broken. Wherenecessary, ensure the alarm sensor wire iscorrectly routed, and refit the sensor to itsretaining clip. Clip the panel back intoposition, ensuring that the pegs on the baseof the panel are correctly located in the faciapanel (see illustration).

Front footwell side trim panel24 Undo the two retaining screws, andremove the trim panel from the side of thefootwell.25 Refitting is a reverse of the removalprocedure.

Centre door pillar trim panels -five-door models26 Refer to the information given inparagraphs 1 to 4 of Section 25.

Centre door pillar upper trim panel -three-door models27 Remove the rear seat side trim panel asdescribed earlier in this Section.28 Prise the trim cover off the upper seat beltmounting bolt, then slacken and remove thebolt and washer(s), and release the seat belt(see illustrations).29 Undo the retaining screw from the base of

26.28b . . . then undo the mounting bolt,and free the seat belt from the body

the upper trim panel (see illustration).30 Peel back the sealing strip from the frontedge of the panel, carefully prise the panelaway from the pillar, and remove it from thevehicle (see illustration).31 Refitting is a reversal of the removalprocedure.

Glovebox

32 Remove the two retaining clips, andrelease the felt undercover from the undersideof the glovebox.33 Open the glovebox. Slacken and removethe four retaining screws situated along itsupper edge, and the six retaining screwslocated along its lower edge, and slide theglovebox out of position.34 Refitting is the reverse of the removalprocedure, ensuring that the retaining screwsare securely tightened.

Carpets35 The passenger compartment floor carpetis in one piece, and is secured at its edges byscrews or clips - usually the same fastenersused to secure the various adjoining trimpanels.

36 Carpet removal and refitting is reasonablystraightforward but time-consuming, due tothe fact that all adjoining trim panels must beremoved first, as must components such asthe seats, the centre console and seat beltlower anchorages.

26.29 Slacken and remove the retainingscrew . . .

Headlining37 The headlining is clipped to the roof, andcan be withdrawn only once all fittings suchas the grab handles, sun visors, sunroof (iffitted), windscreen and rear quarter windows,and related trim panels, have been removed.The door, tailgate and sunroof aperturesealing strips will also have to be prised clear.38 Note that headlining removal requiresconsiderable skill and experience if it is to becarried out without damage, and is thereforebest entrusted to an expert.

27 Centre console -removal and refitting

Removal

Low-specification models

1 Undo retaining the two retaining screws.Free the console from the gear lever gaiterand lift it over the lever.

High-specification models

2 Undo the left-hand front side panelretaining screw. Disengage the panel from thecentre console and remove it from the vehicle(see illustration). Repeat the procedure andremove the right-hand panel.3 On models with manual transmission,carefully prise the gear lever trim panel outfrom the centre console. Where a leather

26.30 . . . free the door pillar trim panelfrom the sealing strip, and remove it from

the vehicle

27.2 Removing the centre console left-hand front side panel - retaining screw

location arrowed

27.3a On models with a leather gear levergaiter, release the pop fastener and velcro

str ip . . .


27.3b . . . then unclip the trim panel from 27.5a Depress the retaining tangthe centre console (arrowed), and slide out the ashtray . . .

27.5b . . . to gain access to the centreconsole front retaining screws (arrowed)

gaiter is fitted to the lever, release the popfastener and velcro strip, and remove thegaiter (see illustrations). Where a rubbergaiter is fitted, unscrew the knob from thegear lever, and remove the knob and gaiterassembly.4 On models with automatic transmission,carefully prise the selector lever trim panel outfrom the centre console, and fold the gaiterback over the selector lever. Slacken andremove the four screws securing the handle tothe shaft of the selector lever. Depress theselector lever handle detent knob, then rotatethe handle through 90° anti-clockwise, lift theassembly up and rotate it back 90° clockwise,to release the detent button from the selectorlever pushrod. With the handle removed,withdraw the detent button and spring fromthe handle.

5 Depress the retaining tang, and slide theashtray out from the centre facia panel, thenslacken and remove the two front centreconsole retaining screws, located behind theashtray (see illustrations).6 Slacken and remove the retaining nut fromthe rear of the centre console, thenmanoeuvre the console over the gear lever,and remove it from the vehicle (seeillustrations).

RefittingLow-specification models7 Locate the gaiter back in the console base,

then refit the two retaining screws, tighteningthem securely.

High-specification models8 Manoeuvre the centre console back intoposition over the gear lever, ensuring that theheater ducts fitted to either side of theconsole are correctly located with the heaterunit outlets at the front of the console.9 Refit the two front retaining screws and therear retaining nut, and tighten them securely.Slide the ashtray back into the centre faciapanel.10 On models with manual transmission,either screw the lever and gaiter back onto thegearchange lever, or locate the gaiter over thelever, and secure it in position with the velcrostrip and pop fastener (as applicable). Clip thegaiter trim panel back into position in thecentre console.11 On models with automatic transmission,refit the spring and detent button to theselector lever handle, and press the buttonfully into the handle. Keeping the buttondepressed, slide the handle assembly ontothe lever, then, exerting light downwardpressure on the handle, rotate the handlethrough 90° clockwise, then back 90° anti-clockwise, to engage the detent button withthe lever pushrod. Release the detent button,then refit the four handle retaining screws andtighten them securely. Check the operation ofthe selector lever detent button, then clip the

trim panel back into position in the centreconsole.12 Refit the side panels to the front of theconsole, and secure them in position withtheir retaining screws.

Note: Label each wiring connector as it isdisconnected from its relevant component.The labels will prove useful on refitting, whenrouting the wiring and feeding the wiringthrough the facia apertures.

Removal1 Disconnect the battery negative terminal.2 Remove the instrument panel assembly andclock as described in Chapter 12.3 Remove the steering column assembly asdescribed in Chapter 10.4 On high-specification models, remove thecentre console as described in Section 27. Onlow-specification models where only a smallcentre console is fitted, undo the retainingscrews and remove the heater duct cover(where fitted) from the centre of the faciaassembly.5 On carburettor models, remove the chokecable as described in Chapter 4A.6 Unclip both the left- and right-hand feltundercovers from underneath the facia, andremove them from the vehicle (seeillustration).

27.6a Undo the rear retaining n u t . . . 27.6b . . . then lift the centre console over 28.6 Removing the driver's side facia feltthe gear lever, and remove it from the vehicle undercover

28 Facia panel assembly -removal and refitting


28.7a Unclip both the left-hand switchpanel . . .

7 Carefully prise the switch panels, locatedon either side of the instrument panel, out ofthe facia, taking care not to mark either thepanel or facia. Disconnect the wiringconnectors, and remove the panels (seeillustrations).8 Where a radio/cassette player is fitted,remove it as described in Chapter 12, thenundo the two retaining screws, and removethe mounting bracket from the radio aperture(see illustrations). Where no radio/cassetteplayer is fitted, carefully prise out the storagebox from the centre of the facia panel.9 Undo the four centre vent panel retainingscrews (two located above the heatercontrols, and two directly below), then unclipthe panel and withdraw it from the facia.Disconnect the wiring connectors from thecigarette lighter and ashtray illumination bulb,and remove the centre vent panel assemblyfrom the vehicle (see illustrations).10 Undo the two heater control panelretaining screws, then release the lower panelretaining clip, and manoeuvre the panel outfrom the centre of the facia. Slacken andremove the facia mounting bolt and retainingscrew which are located behind the heatercontrol panel (see illustrations).11 Slacken and remove the retaining screwfrom each end of the facia panel (seeillustration).

28.7b . . . and right-hand switch panel, andremove them from the facia (right-hand-

drive model shown)

28.8a On models fitted with aradio/cassette player, undo the two

retaining screws (arrowed)...

28.8b . . . and remove the mountingbracket

28.9a Undo the four retaining screws(arrowed)...

28.9b . . . then unclip the centre vent panelfrom the facia . . .

28.9c . . . and disconnect the wiringconnectors from the cigarette lighter and

bulb

28.10a Undo the retaining screws, andrelease the heater control panel from thefacia (retaining clip location arrowed).. .

28.10b . . . to gain access to the faciamounting bo l t . . .

28.10c . . . and retaining screw locatedbehind the panel

11 •20 Bodywork and fittings

28.11 Removing a facia panel endretaining screw

12 Undo the two facia retaining nuts locatedon the lower edge of the instrument panelaperture (see illustration).13 Unscrew the retaining screw, locatedunderneath the inner corner of the glovebox,securing the facia in position (seeillustration).14 On right-hand-drive models, slacken andremove the retaining screw from the centre ofthe facia - accessed from underneath (seeillustration).15 Where necessary, undo the nut andrelease the earth lead from the stud at thebase of the centre of the facia (seeillustration).16 Remove the windscreen wiper motor asdescribed in Chapter 12.17 With the wiper motor removed, slackenand remove the three retaining nuts andwashers securing the facia panel to thebulkhead (see illustration).

28.12 Facia retaining nuts located beneath 28.13 Removing the facia retaining screwinstrument panel aperture situated underneath the glovebox

18 From inside the vehicle, unclip the trimpanels from the front roof pillars. Wherenecessary, release the alarm sensors from theclips on the top of each trim panel, andremove the panels.19 The facia panel is now free to be removed.Pull the panel away from the bulkhead torelease it from its retaining pins, then removethe facia assembly, noting the correct routingof the wiring harnesses, and feeding thewiring back through the facia apertures (seeillustration).

Refitting20 Refitting is a reversal of the removalprocedure, noting the following points:(a) Manoeuvre the facia into position and,

using the labels stuck on during removal,ensure the wiring is correctly routed andfed through the relevant facia apertures.

(b) Clip the facia back into position, then refitall the facia fasteners, and tighten themsecurely.

28.14 On right-hand-drive models, removethe retaining screw from beneath the

centre of the facia panel

(c) On completion, reconnect the battery andcheck that all the electrical componentsand switches function correctly. Oncarburettor models, check that the chokecontrol is operating correctly.

28.15 Undo the retaining nut, and free theearth strap from the base of the centre of

the facia panel28.17 Centre facia-to-bulkhead retaining

nut and wiring bracket28.19 Removing the facia assembly

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Chapter 11 Bodywork and fittings - VALVULITA.COM · 2016. 4. 21. · bodywork If the scratch is very superficial, and does not penetrate to the metal of the bodywork, repair is very