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Replace in reverse order. after fitting the external handle to the door,
the plunger screw (adjuster screw) should be set to give a clearance of
1.58 mm (0.063 in) between the plunger and the lock thrust plate.
Operation 3 Adjustment of door striker plate
1. Slacken the two striker plate retaining screws Do Not
remove the screws, otherwise the catch of the striker plate will fall
between the inner and outer body mouldings.
2. Adjust the striker plate (elongated holes in the body
facilitate this) until the door is flush with the body.
3. Retighten the striker plate and then check that the lock
mechanism engages properly on the catch.
Operation 4 Window frame and glass - removal
& replacement
To remove (Figure 2)
1. remove the door panel, regulator mechanism and lock
mechanism as described in Operations 1 & 2.
2. Remove the waterproof sheet completely from the door.
3. With the window fully closed, peel out the rubber silent
channel from the lower frame to expose the lower rivets.
4. Carefully drill off the rivet heads using a 3.97 mm drill (5/32
in), then tap the rivet bodies from the frame.
5. Press the rubber silent channel back in to the frame and
fully lower the window glass.
6. prise the rubber silent channel from the upper frame and
drill off the six rivet heads, tapping the rivet bodies from the frame.
7. Pull the frame slightly outwards, then remove from the
door.
8. The window glass can now be lifted out from the base of
the door.
9. Retrieve the rivet bodies from the bottom of the door and
discard.
To replace
1. Place the window glass into the base of the door.
2. Locate the window frame into the door and carefully locate
over the window glass. Ensure that the glass fits correctly in the
rubber silent channels.
3. Prise the rubber silent channel from the frame and secure
the top half of the frame to the door using six rivets.
4. Press the rubber silent channel back in to the frame and
raise the window glass.
5. Prise the rubber silent channel from the bottom of the
window frame and rivet the frame to the door.
6. Press the rubber silent channel back in to the frame
ensuring it is squarely seated.
7. Lower the window glass.
8. Refit the regulator mechanism, lock assembly, waterproof
membrane door card etc.
Operation 5 Side door weather strips - removal
& replacement
To remove and replace (Figure 2)
1. Remove the door panel as described on Operation 1.
2. Using a 3.97,, (5/32 in) drill, carefully drill off the rivet heads
holding the weather strip to the door panel. Remove the weather strip
and rivet shafts.
3. Position the new weather strip on the door panel and
secure using six 3.175 x 8.89 mm (0.125 x 0.35 in) rivets.
4. With the window fully open, carefully drill out the rivet
heads off the rivets securing the weather strip to the door frame.
5. Push the rivet heads through and remove the weather strip
from the door.
6. Clean off all adhesive or sealant from the weather strip
seating on the door.
7. Smear the back of the weather strip with adhesive/sealant
and its seating on the door and leave to go tacky.
8. Fit the weather strip and rivet in to position.
9. Re-assemble the door.
Operation 6 Side door - removal & replacement
To remove
1. Peel back the carpet from the foot well side to expose the
hinge access panel.
2. Remove the access panel (six screws).
3. With an assistant supporting the door, remove three set
screws, complete with plain washers and lock washers, securing the
lower hinge to the body. Remove the single set screw located at the
rear of the hinge box, secured to the support plate behind the body,
accessible through the access panel in the foot well. Carefully retain
all shims as they were fitted.
4. Repeat instruction 3 for the upper hinge and remove the
door, complete with hinges from the vehicle.
Replace in reverse order.
Figure 1 Door mechanism
1. Interior door handle 17. Lock washer 33. Screw
2. Bezel 18. Striker back plate 34. Lock washer
3. Insert 19. Striker cover plate 35. Nut
4. Screw 20. Striker cover travel stop 36. Regulator mounting plate
5. Screw 21. Clip 37. Screw
6. Washer 22. Screw 38. Lock washer
7. Link, lock to handle 23. Lock washer 39. Screw
8. Adjustment pin 24. Exterior handle 40. Washer
9. Insulation 25. Screw 41. Lock washer
10. Clip 26. Nut 42. Nut
11. Link, internal lock 27. Screw 43. Winder handle
12. Insulation 28. Lock washer 44. Screw
13. Spacer clip 29. Washer 45. Lock washer
14. Lock assembly 30. Screw 46. Regulator link guard
15. Backing plate 31. Lock washer 47. Rivet
16. Screw 32. Window winder regulator
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