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Operation 7 Door hinge - removal & replacement
To remove
1. Remove door as described in Operation 6.
2. Unscrew four countersunk screws and lock washers and
remove the upper hinge from the door
Note: The backing plate assembly is riveted to the door.
3. Repeat for the lower hinge.
Operation 8 Rear door (estate) - removal & replacement
To remove (Figure 4)
1. From inside the rear of the vehicle, remove three screws
securing the rear lamp access panel adjacent to the rear door lower
hinge.
2. Disconnect the snap connector for the number plate lamp,
accessible in the panel.
3. Disconnect the heated rear window wiring (if fitted).
4. Withdraw the rear door harness and grommet from the
body.
5. Remove the check link lug pivot screw and separate the link
from the lug.
6. Remove four nuts, lock washers and plain washers from the
upper and lower hinge studs on the inner face of the door aperture.
7. Support the door and, withdrawing the hinge studs from
the body, lift the door clear of the vehicle.
The rear door hinges are mounted to the door by means of two studs
secured by nuts and plain washers.
Operation 9 Rear door lock mechanism (estate) - removal
& replacement
To remove
1. Remove two countersunk screws and remove the outer
handle from the door.
2. Unscrew six countersunk wood screws and remove the
door lock from the door moulding.
3. If it is necessary to remove the dovetail, use a 3.97 mm
(5/32 in) drill bit to remove the rivet heads, then tap the shafts in to
the door.
4. The dovetail on the body is retained by four rivets and
should be removed using the method above but with a 5.56 mm (7/32
in) drill.
5. To remove the striker plate first prise out the access
grommet, then unscrew two countersunk screws securing the striker
to the body.
Figure 3 Window drop glass stop
1. Stop screw
2. Washer
3. Nut
Replace components in reverse order taking note of the following:
Secure the dovetail (female) to the body with four 4.76 x 16.50 mm
(3.175 x 0.65 in) rivets. Secure the (male) dovetail to the door using six
3.175 x 12.7 mm(0.125 x 0.5 in) rivets.
Door seals
The rubber seals are carried on a "V" shaped metal section clipped to
the body flanges. Care should be taken not to hammer the seals on to
the flange as this will cause the metal section to open up so the claw
clips will not hold. A rubber mallet is recommended for this operation.
Operation 10 Bonnet - removal & replacement
To remove (Figure 5)
1. Remove the two nuts, washers and lock washers securing
the right-hand hinge to the body.
2. Repeat item 1 for the left-hand hinge, the fixings for which
also support the lid support bar plate.
3. Withdraw the hinge studs and lift the bonnet clear,
retaining the two hinge to lid gaskets.
Refit in reverse order.
Figure 2a Door shell and trim DL models
1. Door 25. Casing board (saloon/estate) 49. Shim (2 hole)
2. Frame 26. Casing board pocket 50. Shim (1 hole)
3. Silent channel 27. Retaining bar 51. Washer
4. Frame seal 28. Casing board (van) 52. Lock washer
5. Rivet 29. Retaining plate (saloon/estate) 53. Set screw
6. Glass 30. Retaining plate (van) 54. Support plate
7. Regulator channel 31. Rivet 55. Stiffener
8. Insulation 32. Rear retaining channel (saloon/estate) 56. Set screw
9. Weather strip (outer) 33. Rear retaining channel (van) 57. Lock washer
10. Rivet 34. Rivet 58. Coach washer
11. Waterproof membrane 35. Fastener 59. Set screw
12. Tape 36. Screw(van) 60. Coach washer
13. Upper casing board (saloon/estate) 37. Washer(van) 61. Lock washer
14. Upper casing board (van) 38. Snap cap(van) 62. Nut
15. Weather strip (inner) 39. Upper hinge 63. Courtesy light switch
16. Rivet 40. Lower hinge 64. Coach washer
17. Trim strip 41. Hinge backing plate 65. Lock washer
18. Rivet 42. Rivet 66. Nut
19. Seal 43. Hinge to door plate 67. Shim
20. Door pull 44. Lock washer 68. Coach washer
21. Screw 45. Set screw 69. Lock washer
22. Screw 46. Hinge backing plate 70. Set screw
23. Lock washer 47. Backing plate 71. Door seal
24. Conical spring 48. Rivet
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