Alfa Romeo - 166 - Workshop Manual - 1998 -1998

50 Auxiliary Units 55 Electrical Equipment 70 Body r> Technical Service Manual 41 (r — f C VOLUME 3 - REPAIR PROCEDURES o 50-70 SERVICE Technical Service Manual D.M.C. - MARKETING Dl SETTORE SERVIZI POSTVENDITA Viale Alfa Romeo 20020 Arese (Ml) Fiat Auto S.p.A. Publication Nr. PA51 06/00 - 06/1998 Printed in Italy Order Nr. 604.94.975 Copyright. No parts of this document can be copied without the written consent of FIAT AUTO S.p.A. SERVICE ' '-.39T •« / 41 UPDATE SHEET VOLUME 3° - REPAIR PROCEDURES 50-70 UPDATE (DATE) 03 (10/1998) 03 (10/1998) 03 (10/1998) MODEL 166 SECTION Repair procedures GROUP SUBGR. 70 7040 7090 A (*) Insert the green sheets at the end of the corresponding subgroup (**) Annulled pages PA5106/03 10/1998 VALIDITY PAGES REPLACED ADDED n 1-80 (**) / 1-2 1-8 (*)/ 1-70 CONTENTS SERVICE DOCUMENTATION CONTENTS OF THE MANUAL Title 166 Print-out number PA5106/00 (6/1998) Folder Sections Vol. 1° - GENERAL - - 166 166 166 - AND TECHNICAL INFORMATION DIAGNOSIS TESTS FUNCTIONAL DESCRIPTION REPAIR PROCEDURES la.0T5lfaÿTB BMila.s VBiia.sveia;i Vol. 2° PA5106/00 (6/1998) Vol. 3° PA5106/00 (6/1998) Vol. 4° - ELECTRIC DIAGRAMS - - GEARBOXES PA5069 (7/1997) - la7o'T5~lla.bTB SM ifaTaWlia.s vs c«i 13.0 V6 aw if 3.0 VB cflglfa.4 JTDBMI PA5106/00 (6/1998) PA5063 (7/1997) ENGINES Validity REPAIR PROCEDURES 00-44 1 3.0 VB BM 1 1 3.0 VB CAElia.4 JTDBWI ia.OTSila.OTB aMila.s V6lia.sve~cji1 50-70 1 3.0 VSGM If3.0 VB CAgira.4 JTDGMI la.QTSiia.OTB eMiia.BVBiia.5 I3.QV6 6M VS~CAE1 II 3.0 VB CAtlla.4 JTDSMI BENCH REPAIR PROCEDURES I AR 34103 1 1 AB 34103 11 AH 34801 1 1 AR 34301 1 BENCH REPAIR PROCEDURES I C 530.5 I I CS30.6 I I AR 34808 1 /ÿN PA5106/00 6/1998 I mmi ~ ft spun Aje/fixn\/ ■n os _ REPAIR PROCEDURES Auxiliary units 50 Group index - GROUP GRAPHIC INDEX Sub-groups index Sbgrp. Description 5010 Heating/ventilation - miscellaneous 5040 Air conditioner box and components 5050 Screen washers and headlamp wash/wipe Validity GROUP GRAPHIC INDEX f'/j 3 //A \ \ ! Km 1 C=3 2 Q. Q Q i <2/ Ref. Description Sbgrp. 1 Heating/ventilation - miscellaneous 5010 2 Air conditioner box and components 5040 3 Screen washers and headlamp wash/wipe 5050 PA5106/00 06/1998 1 REPAIR PROCEDURES 50 Auxiliary units r\ r\ r 2 PA5106/00 06/1998 REPAIR PROCEDURES Heating/ventilation 111 - miscellaneous 5010 Sub-group index - SUB-GROUP GRAPHIC INDEX Assembly drawings index Cmp Description 5010A Heater pipes 501OB Heating/ventilation air pipes and ducts 5010C Air outlet and diffusers 5010D Air temperature recording system Validity SUB-GROUP GRAPHIC INDEX 2 A7,7A Li xZ> 3 © 2 At/miAiif Follow the Op. 7040D12 Engine front side cover (one) Ih or rh - r r (left and right). Follow the Op. 7040D14 Engine bay rear side cover (one) Ih or rh - r r (left and right). Follow the Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r . Follow the Op. 7055A18 Windscreen base trim I~\ I3.5 VB 1 1~370 VB 6M ifaTOTB BMl Disconnect the hose from the butterfly casing integrated with the D.V.L. 1. Disconnect the water supply pipe to the heater from the connector on the right cylinder head. l - r+r . Follow the Op. 5050B38 Windscreen wiper assembly - r+r or repair . 1. Disconnect the water supply pipe to the heater, heater side. % $ Ixt JTi I ri 7, T I r!I 'j 6' jJ i <5; y, \*cK £ h IL l.«iWI»MI V UHU1 _ A fStlHAtl* 4# S3; > Follow the Op. 1048A28 Vacuum air circuit resonator pipe - r+r . 1. Disconnect the water supply pipe to the heater from the thermostat. © |2.4 JTDBMI 1. Disconnect the electrical connection from the engine coolant temperature sensor. IDescription 1 U> Data not yet available / 57% m Connector K45 ytit |; '-It Y'S,& 2. Disconnect the water supply pipe to the heater from the thermostat. ck (o / 1 \ c Y PA5106/00 06/1998 ttblUlmAHVlnnÿl _ U> Atyilt-AI» 3 REPAIR PROCEDURES llHil Heating/ventilation - miscellaneous 5010 Connect the negativge (-) battery terminal. Remove the vehicle from the ramp. 1. Remove the water supply pipe to the heater. 5010A16 - HEATER/ENGINE LINE - R R J) Removal - 1 - !, Place the vehicle on a ramp. Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). IDescription Connector A01 B Data not yet available % 1. Undo the drain plug in the radiator and drain the engine coolant. Note: Recover the coolant using a suitable container. .o O \V n Installation - Place the water supply pipe to the heater back in its housing. - Connect the water supply pipe to the heater to the thermostat. Complete with Op. 1048A28 Vacuum air circuit resonator pipe - r+r . IS.5 VBII 3.0 V8 6M lla.O TO - Ip! 1 mm f\o'. © 6M I Connect the water supply pipe to the heater to the connector on the right cylinder head. Connect the hose to the butterfly casing inte¬ grated with the D.V.L. ia.4 JTOOMI Connect the water supply pipe to the heater to the thermostat. Connect the electrical connection to the engine coolant temperature sensor. Connect the water supply pipe to the heater, heater side. Complete with Op. 5050B38 Windscreen wiper assembly - r+r or repair . Complete with Op. 7055A18 Windscreen base trim - r+r . Complete with Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r . Complete with Op. 7040D14 Engine bay rear side cover (one) Ih or rh - r r (left and right). Complete with Op. 7040D12 Engine front side cover (one) Ih or rh - r r (left and right). Supply the engine cooling system with the recommended fluid. IType Component Description Liquid Engine cooling circuit Alfa Romeo Climafluid Super Perma¬ nent -40’C Follow the Op. 7040D12 Engine front side cover (one) Ih or rh - r r (left and right). Follow the Op. 7040D14 Engine bay rear side cover (one) Ih or rh - r r (left and right). Follow the Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r . Follow the Op. 7055A18 Windscreen base trim - r+r . Follow the Op. 5050B38 Windscreen wiper assembly - r+r or repair . 1. Disconnect the water return pipe from the heater, heater side. £2 Q.ty. C.5 V Q 4k iwruvwn// 4 \ _ n*_ AIO IMAM PA5106/00 06/1998 REPAIR PROCEDURES Heating/ventilation - miscellaneous 1. Diconnect the branch of the water return pipe from the heater from the engine coolant reser¬ voir. Follow the Op. 1048A28 resonator pipe - r+r . u Hr oe 5010 Vacuum air circuit 1. Disconnect the water return pipe from the heater from the water pump rigid inlet pipe. 1 fcs: 'v V /i o 25 i i 1 K; W/ :l /A ia.4JTPBMl 1. Disconnect the water return pipe from the heater from the water pump rigid inlet pipe. / '\i 1. Remove the water return pipe from the heater. 1 i1 % s. T £m s' al a % sp o 12.5 V6 11 3.0 V6 BM! fa.D TB_6mJ - Disconnect the hose from the butterfly, casing integrated with the D.V.L. 1. Disconnect the water return pipe from the heater from the thermostat. " /Ti i Place the water return pipe from the heater back in its housing. Connect the water return pipe from the heater to the water pump rigid inlet pipe. Complete with Op. 1048A28 Vacuum air circuit resonator pipe - r+r . B.5 VBlRTOVS I I PA5106/00 06/1998 ifm Installation - C5 Q* CM IfÿOTB BM Connect the water return pipe from the heater to the thermostat. Connect the hose to the butterfly casing inte¬ grated with the D.V.L. 5 REPAIR PROCEDURES 5010 Heating/ventilation - miscellaneous Connect the water return pipe from the heater to the water pump rigid inlet pipe. Connect the branch of the water return pipe from the heater to the engine coolant reservoir. Connect the water return pipe from the heater, heater side. Complete with Op. 5050B38 Windscreen wiper assembly - r+r or repair . Complete with Op. 7055A18 Windscreen base trim - r+r . Complete with Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r . Complete with Op. 7040D14 Engine bay rear side cover (one) Ih or rh - r r (left and right). Complete with Op. 7040D12 Engine front side cover (one) Ih or rh - r r (left and right). Supply the engine cooling system with the recommended fluid. Type Component Description Liquid Engine cooling circuit Alfa Romeo Climafluid Super Perma¬ nent -40°C Q.ty. Connect the negativge (-) battery terminal. Remove the vehicle from the ramp. r 6 PA5106/00 06/1998 REPAIR PROCEDURES Heating/ventilation - miscellaneous A 5010 501OB - Heating/ventilation air pipes and ducts VIEW OF ASSEMBLY 1 4 2 ) 3 A \ J 77 3 I] x v/ N ! \ C tt/y \ >< • w ada a, Ref. Description 1 FILTER ELEMENT (ANTI-POLLEN) 2 VENTILATION ASSEMBLY BULKHEAD 3 AIR DUCT TO REAR SEATS 4 DISTRIBUTOR/REAR SEAT OUTLET UNIT DUCTS Operations index r\ Code Validity Operation 5010B09 Purifying filter (antipollen) filter element - replace 5010B21 Climate control unit compartment - r r 5010B45 Duct from climate control system - r r Ducts (one), Ih or rh, on distribution unit for air duct beneath facia r r 5010B52 Ducts (one), Ih or rh, on air distribution unit for air duct beneath facia r r with facia removed 5010B53 Ducts (one), Ih or rh, on distribution unit for air ducts 5010B51 _ to rear seat r r 5010B54 Ducts (one). Ih or rh, on distribution unit for air ducts to rear seat r r withfacia removed PA5106/00 06/1998 iCZ3) 7 REPAIR PROCEDURES Heating/ventilation - miscellaneous 5010 OPERATIONS 5010B09 - PURIFYING FILTER (ANTIPOLLEN) FILTER ELEMENT - REPLACE Note: The fitter element should be checked once a year and preferably replaced before the hot weather. Removal the bolts (1a) and remove the filter element protective cover (1b). 2. Undo the bolts (2a) and remove the fuse protection (2b). 3. Undo the bolts (3a) and remove the filter element (3b) for the pollen filter. I.Undo 1. Remove the two buttons (1a) fixing the climate control unit housing partition using the tool (1b). H 1b Description Code Blade 1.823.015.000 2. Undo the nuts (2a) and move the relay holder bracket (2b) aside. According to the version involved, release the pipes, electric cables or other components from the climate control unit housing partition. 2b =(f»SS A__ 1b 1aÿf \ A 2a IT 2b 3b /3a PA ik JT ibES . 2a / A 2a A m PC 1 Remove the cover (1a), undo the nuts (1b) and disconnect the electrical connections (1c) and the alternator and starter motor supplies (1d) from the junction unit. / JL m IDescription 1c i Installation - - Data not yet available \Description 1d Connector Connector r*\ Data not yet available 2. Undo the nut (2a) and remove the junction unit (2b). Fit the pollen filter filter element and fix it using the bolts. Fit the fuse protection and fix it using the bolts. Fit the filter element protective cover and fix it using the bolts. 5010B21 - CLIMATE CONTROL UNIT COMPARTMENT - R R Removal - - - 8 Follow the Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r . Follow the Op. 7055A18 Windscreen base trim - r+r . Release the fuel pipes from the band on the climate control unit housing partition. Release the electric cables from the bands on the climate control unit housing partition. PA5106/00 06/1998 REPAIR PROCEDURES Heating/ventilation - miscellaneous 5010 S\\ \ M 1b 1a 2a W \ 1b \ 2b % PI icQ M 2a .5 I 5) 1a 2b IP" i \ ■s ff! 'kl o'! vww *<> 1. Remove the buttons (1a) for the climate control unit housing partition using the tool (1b). 1b Description Code Blade 1.823.015.000 Undo the bolts and the nut for the fairlead in the partition for the pipe, then move it away. 2. Remove the climate control unit housing parti¬ tion. PA5106/00 06/1998 v ✓ ibQ - 1. Undo the bolt (1a) and move aside the coolant reservoir (1b). 2. Undo the bolts (2a) for the engine coolant reservoir and power assisted fluid reservoir mounting bracket (2b) and move them aside. II I •> Installation /ÿS \ \ ag <ÿu kl i 1 L* *ll i 1b U & I 2 Place the climate control unit housing partition back in its housing afterhaving fixed the fuel pipes and the electric cables to the bands. Fix the climate control unit housing partition using the buttons. Place the fairlead for the pipes in its housing and fix it to the partition using the bolts and the nut. Place the power assisted steering fluid reservoir and the engine coolant reservoir back in their housings, then fix the mounting bracket using the bolt. Fix the engine coolant reservoir using the bolt. Place the junction unit back in its housing and fix it using the nut. Connect the electrical supply connections for the starter motor and alternator to the junction unit and fix them using the nuts. Fit the junction unit cover. According to the version involved, fix the pipes, electric cables or other components to the climate control unit housing partition. Place the relay holder bracket back in its housing and fix it using the nuts. Complete with Op. 7055A18 Windscreen base trim - r+r . Complete with Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r . 5010B45 - DUCT FROM CLIMATE CONTROL SYSTEM R R Removal Follow the Op. 7045A10 L/h or r/h front seat (one) - r+r . Follow the Op. 7040L20 Tunnel trim - r r . Follow the Op. 7040L40 Front compartment scuff strip - r r . - Only for operations to the right hand side duct. Follow the Op. 1056B79 Injection/ignition contro unit guard - r r . 1. Undo the bolts fixing the side console cover. 2. Remove the side console cover. - Only for operations to the left hand side duct. - Undo the two bolts fixing the driver's footrest and remove it. 9 REPAIR PROCEDURES Heating/ventilation - miscellaneous 5010 Remove the rubber protection and accelerator pedal travel stop. Move the floor covering aside. 3. Undo the bolts (3a) and remove the climate control unit mounting bracket (3b). 4. Disconnect and remove the air duct for the rear places coming out of the climate control casing after having removed the front end from the crossmember under the front seat. % 3a Installation Complete with Op. 5010B54 Ducts (one), Ih or rh, on distribution unit for air ducts to rear seat r r withfacia removed . Complete with Op. 7040A10 Instrument facia trim - r+r . 5010B52 - DUCTS (ONE), LH OR RH, ON AIR DISTRIBUTION UNIT FOR AIR DUCT BENEATH FACIA R R WITH FACIA REMOVED Removal the bolt (1a) and move the electrical wiring mounting bracket (1b) aside. 2. Undo the remaining bolt (2a) and remove the duct on the air distribution unit connected to the air ducts under the dashboard (2b). I.Undo Q // •4 3b 6--ÿ W/2 2 - Place the air duct for the rear places coming out of the climate control casing back in its housing. Fit the climate control unit mounting bracket and fix it using the bolts. Only for operations on the left hand side duct. Put the floor carpet back in place. Fit the accelerator pedal travel stop complete with rubber protector. Fit the driver's footrest and fix it using the two fixing bolts. Fit the side console cover and fix it using the bolts. Only for operations on the right hand side duct. Complete with Op. 1056B79 Injection/ignition contro unit guard - r r . Complete with Op. 7040L40 Front compart¬ ment scuff strip - r r . Complete with Op. 7040L20 Tunnel trim - r r . Complete with Op. 7045A10 L/h or r/h front seat (one) - r+r . 5010B51 - DUCTS (ONE), LH OR RH, ON DISTRIBUTION UNIT FOR AIR DUCT BENEATH FACIA R R Removal Follow the Op. 7040A10 Instrument facia trim r+r . - 10 ■pj ,l We I 1b Installation - 75 if/KC3 e I/' // 1 2b 2a / - Follow the Op. 5010B54 Ducts (one), Ih or rh, on distribution unit for air ducts to rear seat r r withfacia removed . '-fiY 1a Installation - - Place the duct in the air distribution unit connected to the air ducts under the dashboard back in its housing and fix it using the upper bolt. Place the electrical wiring mounting bracket back in its housing and fix it using the bolt. 5010B53 - DUCTS (ONE), LH OR RH, ON DISTRIBUTION UNIT FOR AIR DUCTS TO REAR SEAT R R Removal Follow the Op. 7040A10 Instrument facia trim r+r . Follow the Op. 5010B54 Ducts (one), Ih or rh, on distribution unit for air ducts to rear seat r r withfacia removed . Installation Complete with Op. 5010B54 Ducts (one), Ih or rh, on distribution unit for air ducts to rear seat r r withfacia removed . Complete with Op. 7040A10 Instrument facia trim - r+r . PA5106/00 06/1998 r*\ REPAIR PROCEDURES 111 Heating/ventilation - miscellaneous @jjÿ| r\ 5010 5010B54 - DUCTS (ONE), LH OR RH, ON DISTRIBUTION UNIT FOR AIR DUCTS TO REAR SEAT R R WITHFACIA REMOVED Removal 1 . Open the band for the electrical wiring. 2. Undo the bolts (2a) and remove the duct on the air distribution unit connected to the rear places air ducts (2b). mi i ~7\ JsJ y\ Pll -A C I, 2b JSfc 2a i 1 liTiTTr Installation - - Fit the duct on the air distribution unit connected to the rear places air ducts and fix them using the bolts. Tighten the band for the electrical wiring. PA5106/00 06/1998 11 REPAIR PROCEDURES Heating/ventilation - miscellaneous 5010 5010C - Air outlet and diffusers VIEW OF ASSEMBLY 2 4 5 L o tO] V '/ I i A's ri. N5 © 3 Ref. Description 1 FRONT DOOR WINDOW DE-MISTER VENT 2 CENTRAL AIR OUTLET ON FACIA 3 CONSOLE OUTLET 4 SIDE AIR OUTLET 5 REAR AIR OUTLET Operations index Code Operation 5010C26 L/h or Validity r r/h diffuser for side window de-misting (one) - r+r 5010C30 Central air outlet on fascia - r+r 5010C34 Air outlet on console - r+r 5010C38 L/h or r/h side air outlet (one) on fascia - r+r 5010C60 Lh or rh rear air outlet -one- r r OPERATIONS 5010C26 - L/H OR R/H DIFFUSER FOR SIDE WINDOW DE-MISTING (ONE) - R + R Removal Follow the Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r . Follow the Op. 5570T90 Front speaker - r r . Follow the Op. 7005C44 Interior handle panel rr. 12 Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r . Follow the Op. 7005E38 Front side door interior handle-r r . Follow the Op. 7040E24 Lower courtesy light indoor panel - r+r . Follow the Op. 7005E08 Front side door interior panel r r . 1. Undo the bolts (1a) fixing the air conduction duct (1b) to the panel. 2. Remove the fixing springs (2a) and remove the vent for demisting the side windows (2b). PA5106/00 06/1998 REPAIR PROCEDURES |m| | | Heating/ventilation - miscellaneous 5010 Rlelei rs IDescription 2b 2c Connector Data not yet available irj 1a V // y. 2a L /© /ZJT T \ \ \ Installation Place the vent for demisting the side windows back in its housing. Place the air conduction duct back in its housing. Fix the vent for demisting the side windows using the springs. Tighten the bolts fixing the conduction air duct to the panel. Complete with Op. 7005E08 Front side door interior panel r r . Complete with Op. 7040E24 Lower courtesy light indoor panel - r+r . Complete with Op. 7005E38 Front side door interior handle-r r . Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r . Complete with Op. 7005C44 Interior handle panel - r r . Complete with Op. 5570T90 Front speaker - r r . Complete with Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r . - - ✓ - (L 2a 1a - A 5010C30 - CENTRAL AIR OUTLET ON FASCIA - R + R 2b 2a 1 A •-1 r-J; 2a 2c Q Installation - - Connect the electrical connection for the anti¬ theft device on warning light, then place the dashboard centre air vent back in its housing. Fix the centre air vent in the dashboard using the bolts. Fit the interior trim, then close the cover for the upper compartment in the dashboard. Connect the negative (-) battery terminal. 5010C34 AIR OUTLET ON CONSOLE - R + R Removal - . Follow the Op. 7040L20 Tunnel trim - r r 1. Release the retaining tabs (1a) in the lower part of the console and remove the rear air outlet vent (1b). Removal - Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5S30B10 Battery - r+r ). \Description Data not yet available Connector A01B 1. Lift up the cover for the upper compartment in the dashboard and remove the interior trim. 2. Undo the bolts (2a) and remove the centre air vent in the dashboard (2b) after having discon¬ nected the electrical connection (2c) for the anti-theft device on warning light. PA5106/00 06/1998 13 REPAIR PROCEDURES I— Heating/ventilation - miscellaneous 5010 i| foToIol r\ 1b // 7' * B [K 1a V. U"V 1a 1bd L Cv Installation Fit the side air vent taking care that the reference on it coincides with the one in the housing. Complete with Op. 7040A44 Facia Ih side cover - r r or op. 7040A45 Facia rh side cover - r r . iff?/ t Installation Press fit the rear air outlet vent and check that it is correctly positioned. Complete with Op. 7040L20 Tunnel trim - r r . - 5010C38 - L/H OR R/H SIDE AIR OUTLET (ONE) ON FASCIA - R+R Removal Follow the Op. 7040A44 Facia Ih side cover - r r or op. 7040A45 Facia rh side cover - r r . 1. Remove the side air vent (1a) using the tool (1b). H 1b Description Code Blade 1.823.014.000 5010C60 - LH OR RH REAR AIR OUTLET -ONE- R R Removal Place the vehicle on a ramp. Follow the Op. 7040B20 Back trim for luggage compartment/load platform - arrange . Follow the Op. 7040B10 Load platform (luggage platform) trim - r+r . Follow the Op. 7040B13 Load compartment/ load platform right side trim - r r . 1. Remove the retaining clips for the rear air outlet vent. 2. Remove the rear air outlet vent, working via the luggage compartment. 1 2 5> Installation Fit the rear air outlet vent, working via the luggage compartment, and fix it using the clips. Remove the vehicle from the ramp. 14 PA5106/00 06/1998 r\ REPAIR PROCEDURES Heating/ventilation - miscellaneous /“ÿV Complete with Op. 7040B13 5010 Load compart¬ ment/load platform right side trim - r r . Complete with Op. 7040B10 Load platform (luggage platform) trim - r+r Complete with Op. 7040B20 Back trim for luggage compartment/load platform - arrange . Remove the vehicle from the ramp. . r*\ PA5106/00 06/1998 15 REPAIR PROCEDURES Heating/ventilation - miscellaneous 5010 1—1 5010D - Air temperature recording system VIEW OF ASSEMBLY 2 % fife . 4, m V (Ui O cA r yo' 3 © © /?ef. Description 1 OUTDOOR AIR TEMP SENSOR 2 UPPER MIXED AIR TEMPERATURE SENSOR 3 LOWER MIXED AIR TEMPERATURE SENSOR 4 PASS COMP AIR TEMP SENSOR 5 TEMPT.SENSOR SIGNAL AMPLIFICATION ECU ns Operations index Code Operation Validity 5010D12 Outside air temperature sensor on door mirror - r+r _following electrical circuit check _ 5010D17 Mixed air upper sensor - r r 5010D18 Top mixed air temperature sensor - r+r following elec_trical wiring check with heater case removed_ 5010D19 Lower mixed air temperature sensor - r+r following _electrical wiring check _ 16 PA5106/00 06/1998 REPAIR PROCEDURES Heating/ventilation - miscellaneous rs Code Operation 5010 Validity 5010D25 Upper blended air temperature sensor - r r checks on electrical circuit with facia removed _ 5010D26 Lower blended air temperature sensor - r r following checks on electrical circuit with facia removed 5010D30 Passenger compartment air temperature sensor - r+r _ following electrical wiring check operation_ 5010D56 Solar sensor - r r after checking electrical system OPERATIONS 5010D12 - OUTSIDE AIR TEMPERATURE SENSOR ON DOOR MIRROR - R+R FOLLOWING ELECTRICAL CIRCUIT CHECK 1a 2' Tj Removal Follow the Op. 7005R35 Door mirror reflector rr. Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r . I.Undo the bolts (1a) fixing the starter motor support and the bolts (1b) fixing the cover to the support. 2. Remove the outside air temperature sensor. 3. Extract and open the connection holder. 4. Disconnect the electrical connection for the outside air temperature sensor and remove it. \Description 4 ( 1a"4 1b 3 n Connector 4 Data not yet available Installation - - - Connect the electrical connection for the outside air temperature sensor. Close the connection holder. Check the operation of the outside air tempera¬ ture sensor. Place the connection holder back in its housing. Place the outside air temperature sensor back in its housing. Tighten the bolts fixing the cover to the support. Tighten the bolts fixing the starter motor support. Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r . Door mirror Complete with Op. 700SR35 reflector - r r . 5010D17 - MIXED AIR UPPER SENSOR - R R Removal Follow the Op. 7040A10 Instrument facia trim - r+r . Follow the Op. 5010D25 Upper blended air temperature sensor - r r checks on electrical circuit with facia removed . PA5106/00 06/1998 17 REPAIR PROCEDURES 5010 Heating/ventilation Installation Complete with Op. 5010D25 Upper blended air temperature sensor - r r checks on electrical - circuit with facia removed . Complete with Op. 7040A10 Instrument facia trim - r+r . 5010D18 - TOP MIXED AIR TEMPERATURE SENSOR - R+R FOLLOWING ELECTRICAL WIRING CHECK WITH HEATER CASE REMOVED miscellaneous - □ 2b Description Code Blade 1.823.015.000 2a i jjm Oj, 7 (L Removal Follow the Op. 5010D25 Upper blended air temperature sensor - r r checks on electrical circuit with facia removed . &I m i -*// Installation 1 Complete with Op. 5010D25 Upper blended air temperature sensor - r r checks on electrical circuit with facia removed . Installation 5010D19 - LOWER MIXED AIR TEMPERATURE SENSOR - R + R FOLLOWING ELECTRICAL WIRING CHECK Removal Follow the Op. 7040A10 Instrument facia trim - - r+r . Follow the Op. 5010D26 Lower blended air temperature sensor - r r following checks on electrical circuit with facia removed . Complete with Op. 5010D26 Lower blended air temperature sensor - r r following checks on electrical circuit with facia removed . Complete with Op. 7040A10 Instrument facia trim - r+r . 5010D25 - UPPER BLENDED AIR TEMPERATURE SENSOR R R CHECKS ON ELECTRICAL CIRCUIT WITH FACIA REMOVED Removal 1. Disconnect the electrical connection for upper mixed air temperature sensor. 1 - Place the upper mixed air temperature sensor back in its housing. Connect the electrical connection to the upper mixed air temperature sensor. - 5010D26 - LOWER BLENDED AIR TEMPERATURE SENSOR R R FOLLOWING CHECKS ON ELECTRICAL CIRCUIT WITH FACIA REMOVED Removal Installation - ■■I {Description Connector Upper mixed air temperature sensor K88 1. Disconnect the electrical connection for the lower mixed air temperature sensor. 1 \ Description Connector Lower mixed air temperature K87 sensor 2. Remove the lower mixed air temperature sensor (2a) using the tool (2b). H 2b Description Code Blade 1.823.015.000 the 2. Remove the upper mixed air temperature sensor (2a) using the tool (1b). 18 PA5106/00 06/1998 REPAIR PROCEDURES Heating/ventilation - miscellaneous 5010 1. Remove the protection (1a) for the passenger compartment air temperature sensor using the I m\ tool (1b). I //? 2P 3 /A 7 (L_2a c S3 Description Code 1b Blade 1.823.014.000 □a sit [V JJ X \W® 4J. \ II liTuTT \ Installation >) Place the lower mixed air temperature sensor back in its housing. Connect the electrical connection to the lower mixed air temperature sensor. - 1a 5010D30 - PASSENGER COMPARTMENT AIR TEMPER¬ ATURE SENSOR - R + R FOLLOWING ELECTRICAL WIRING CHECK OPERATION Removal Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). - IDescription 1. Undo the bolts (1 a) and remove the passenger compartment air temperature sensor (1b) after having disconnected the electrical connection (1c). 1c Description Connector Passenger compartment air temperature sensor K89 03 Connector A01B Data not yet available JJ X \ 1. Unscrew bolt (1a) and open fuse access cover (1b). r \ \W© JJ JJ \ x // ( j' \ a □ i) Installation V "\ \ 1b - - 1a 1b X PA5106/00 06/1998 - Connect the electrical connection to the passenger compartment air temperature sensor. Place the passenger compartment air tempera¬ ture sensor back in its housing and fix it using the bolts. Fit the protection for the passenger compart¬ ment air temperature sensor. Close the fuse access cover and secure using the appropriate bolt. Connect the negativge (-) battery terminal. 19 REPAIR PROCEDURES Heating/ventilation 5010 5010D56 - SOLAR SENSOR - R R AFTER CHECKING ELECTRICAL SYSTEM - miscellaneous Complete with Op. 5560B11 Analogue control panel - r+r or replace . Complete with Op. 5010C30 Central air outlet on fascia - r+r Connect the negative (-) battery terminal. . Removal Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). IDescription Connector Data not yet available A01B Follow the Op. 5010C30 Central air outlet on fascia - r+r . Follow the Op. 5560B11 Analogue control panel - r+r or replace . 1. Release the electrical wiring for the solar sensor from the fixing band. 2. Disconnect the electrical connection for the solar sensor. 2 iDescription Connector Solar sensor K90 3. Remove the solar sensor (3a) from the dash¬ board using the tool (3b). □ 3b Description Code Blade 1.823.014.000 /// /// 1 $ 3a N \ JF. U Installation - 20 Fit the solar sensor in the housing in the dash¬ board. Connect the electrical connection for the solar sensor. Fix the electrical wiring for the solar sensor using the band. PA5106/00 06/1998 REPAIR PROCEDURES Air conditioner box and components 5040 r\ Sub-group index - SUB-GROUP GRAPHIC INDEX Assembly drawings index Cmp Description 5040A Air conditioner coolant circuit 5040B System safety check devices 5040C Air conditioner box and components 5040D Air conditioner controls Validity SUB-GROUP GRAPHIC INDEX 3 4 \ trn i r Q) Q Q G, 1 Ref. Description Cmp 1 Air conditioner coolant circuit 5040A 2 System safety check devices 5040 B 3 Air conditioner box and components 5040C 4 Air conditioner controls 5040D PA5106/00 06/1998 1 REPAIR PROCEDURES Air conditioner box and components 5040 111 (ojcjoj 5040A - Air conditioner coolant circuit VIEW OF ASSEMBLY 8 1 .4 \ 7 \ y l m t 3 Q. 6‘ Q Qj 5 Ref. Description 1 COOLANT LOAD/DRAIN VALVE 2 AIR CONDITIONER ASSEMBLY COMPRESSOR 3 COMPRESSOR MOUNT (AC) 4 A/C COMPRESSOR PULLEY 5 A/C CONDENSER 6 A/C DEHYDRATING FILTER/ACCUMULATOR 7 INLET PIPE TO EVAPORATOR 8 OUTLET PIPE FROM EVAPORATOR Operations index Code Operation Validity 5040A10 Air conditioner cooling circuit - dehydrate and reload 5040A14 Air conditioner cooling circuit - check and repair any _leaks by tightening fittings _ 2 PA5106/00 06/1998 REPAIR PROCEDURES Air conditioner box and components r*N Code Operation 5040 Validity 5040A20 Air conditioner compressor - r+r - includes fluid level check and top up if necessary la.oTsi 12.0 TB BM! ia.4 JTDSMI 5040A26 Compressor mount - r r I a.o TS i la.OTB BM i ia.4 jnoaMl 12.5 V6 II 3.0 V6 6M 5040A40 Air conditioner condenser - r+r 5040A44 Air conditioner dehydrating filter/accumulator - r+r 5040A76 Delivery and return lines from evaporator - r r OPERATIONS 5040A10 - AIR CONDITIONER COOLING CIRCUIT - DEHY¬ DRATE AND RELOAD □ \mm Follow the safety instructions (See 5040A WARNINGS ) t I.Use the special draining/repressurizing equip¬ ment. 1 lES/ Description Code Air conditioner system station 1.826.004.000 a1 ! A gif □ 1 m Let the engine run with the air conditioning switched on for 10 - 15 minutes. 1. Undo the repressurizing valve plugs. 2. Before attaching the connectors to the needle valves, move the knurled ring nut upwards. Note: For improved safety, the rapid attachment connectors for the equipment connection pipes have different diameters: the one for the low pressure side is larger and the one for the high pressure side is smaller. 3. Connect the high pressure connecting pipe (HIGH) to the corresponding rapid attachment valve. 4. Connect the low pressure connecting pipe (LOW) to the corresponding rapid attachment valve. - PA5106/00 06/1998 3 REPAIR PROCEDURES Air conditioner box and components 5040 A im y,s\ sdMType 3 W r A \As ?, 2W: ws- rop h I 4 ! - evaporator Atntn/AlJ special container. The fluid is extremely hygroscopic: avoid leaving the containers open. - 1 I2.4JTDCM] Refill the system with the same amount of recommended fluid shown on the container. Oil Description Q.ty. COMPRESSO R |g.0TSinr5V6ll3.0 V8"sm1|5.0TB BM I Refill the system with the same amount of recommended fluid shown on the container. 4 Description Type Component Fluid Air conditioner R134A circuit Q.ty. In the case of damage to the compressor or other system components followed prolonged exposure to the air of the pipes (more than 6 hours), the system "WASHING" procedure has to be carried out, proceeding as follows. Clean the pipes connected to the compressor using an air line. Connect the (drained) system to the repressu¬ rizing equipment. Introduce the recommended quantity of coolant fluid at the high pressure side. Recover the coolant fluid from the low pressure side. Repeat the introduction and recover the fluid. Proceed with the system draining and repressu¬ rizing operations as described previously. PM if the system is being washed, the entire amount of fluid AIR CONDI¬ TIONER ASSEMBLY 40cm3 - condenser 40 cm3 - In the case of accidental breakages which result in the rapid draining of the system (in less than 5 minutes), it is not possible to determine the exact amount of fluid which has escaped because of the high pressure of the fluid.ln these cases, add around 50 cm3 of flmd - Start the coolant fluid repressuring procedure, following the instructions in the equipment manual. Introduce the recommended quantity of coolant fluid. m U Component Q.ty. If certain components are replaced, the following quantities of fluid must be added for each of the components replaced: - drier filter 1 5cm3 - pipes 5 cm3/m Start the procedure for draining the coolant fluid, following the instructions in the equip¬ ment manual. 1. Whilst draining the system, the fluid removed from the compressor should be collected in a SSlType Description AIR CONDI¬ TIONER ASSEMBLY COMPRESSO R Oil \/(7\Y%ÿ m Component in the system is eliminated. 1 5.4 JTOBMI Refill the system with the recommended amount of fluid. m Type Component Oil AIR CONDI¬ TIONER ASSEMBLY COMPRESSO R Description Q.ty. PA5106/00 06/1998 r\ REPAIR PROCEDURES In Air conditioner box and components l2.0TSirgTsWll3.QVB'57lla.0TB ml - Drain the fluid and eliminate the leak, tightening any slack connectors or replacing any damaged pipes or components. Refer to op.. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Refill the system with the recommended amount of fluid. T ype Component Oil AIR CONDI¬ TIONER ASSEMBLY COMPRESSO R Description Q.ty. 5040A14 - AIR CONDITIONER COOLING CIRCUIT - CHECK AND REPAIR ANY LEAKS BY TIGHTENING FITTINGS □ 5040 I a.o TS l 5040A20 - AIR CONDITIONER COMPRESSOR - R+R INCLUDES FLUID LEVEL CHECK AND TOP UP IF NECESSARY □ Follow the safety instructions (See 5040A WARNINGS) Removal Place the vehicle on a ramp. Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). Follow the safety instructions (See 5040A WARNINGS) I.Use the special draining/repressurizing equip¬ ment. IDescription ES 1 Data not yet available Description Code Air conditioner system station 1 .826.004.000 Connector A01B Follow the Op. 7040D12 Engine front side cover (one) Ih or rh - r r (right). Follow the Op. 7040D14 Engine bay rear side cover (one) Ih or rh - r r (right). Follow the Op. 1092G10 Single engine belt r r . Follow the Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Follow the Op. 5040A44 Air conditioner dehy¬ drating filter/accumulator - r+r . 1. Disconnect the electrical connection for the air electro-magnet conditioning compressor coupling. sjiJLs \ Description 1 Air conditioning compressor Connector L20 electro-magnet I ssil □ 1 2. Undo the bolt (2a) and disconnect the coolant fluid inlet and outlet pipes (2b) from the compressor. □ Seal the disconnected connectors, using suitable plugs, to prevent humidity and impurities from entering the system. 3. Undo the bolts (3a) and remove the air condi¬ tioning compressor (3b). Introduce a certain amount of R134a coolant fluid (about 200g) into the system. Use a leak detector to identify the area where the leak is coming from. PA5106/00 06/1998 5 REPAIR PROCEDURES Air conditioner box and components 5040 B o 2a m 3 » t \ 3a •1 I 3a Installation A X - •V B 2 1 1 2.0 T5 I If replacing the compressor, proceed as follows. 1. Remove the drain plug and drain the fluid from the compressor. Note: Manually rotate the compressor to facili¬ tate the removal of all the fluid. - □ c— 2b 3b N the fluid is extremely hygroscopic: avoid leaving the containers open.Avoid leaving the compressor or any other component disconnected from the system for longer than is strictly necessary. 1 . Fit the air conditioning compressor (1a) and fix it tightening the bolts (1b) to the recommended torque. u 1b Mounting Component 0 Screw AIR CONDITIONER ASSEMBLY COMPRESSOR M8 r Value (daNm) Support side 2.73.2 2. Connect the coolant fluid inlet and outlet pipes (2a) to the compressor and fix them tightening the bolt (2b) to the recommended torque. rn 1 (h u h IC, 1b Replace the O-Ring seals for the connectors. Only use green coloured seals, resistant to R134A coolant fluid.Lubricate the thread of the connectors using anti-freeze. Mounting Component 0 Screw Air condi¬ M10 Air condi¬ tioning compress or side 4.1 - 5.0 tioning compressor inlet/outlet pipes 1. Recover the fluid drained from the compressor in a suitable transparent container (quantity A). 2. Drain and recover the fluid from the new compressor (quantity B) in an identical container, following the instructions given previously. 3. Introduce the same amount of fluid removed from the compressor being replaced into the new compressor (eliminate quantity C = B - A). 6 Value (daNm) 3. Connect the electrical connection for the air conditioning electro-magnet compressor coupling. PA5106/00 06/1998 r REPAIR PROCEDURES Air conditioner box and components Follow the Op. 1080B40 Catalytic preconverter - r r . Follow the Op. 1064A44 Left hand or right hand sleeve (one) joining left hand or right hand cylinder head to turbocharger - r+r (left). Follow the Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Follow the Op. 7055B39 Front additional wheel arch half (one), Ih or rh, front element - r r (right). Follow the Op. 1092G10 Single engine belt r r . I.Undo the two nuts for the bolts fixing the air conditioning compressor. 3 m QL IU \ 1 ?>.<ÿ I ilYj m ,1a 5040 2a O' o 7/ Air conditioner dehydrating filter/accumulator - r+r . Complete with Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Complete with Op. 1092G10 Single engine belt r r. Complete with Op. 7040D14 Engine bay rear side cover (one) Ih or rh - r r (right). Complete with Op. 7040D12 Engine front side cover (one) Ih or rh - r r (right). Connect the negative (-) battery terminal. Remove the vehicle from the ramp. l a.o TB BM l 5040A20 - AIR CONDITIONER COMPRESSOR - R + R INCLUDES FLUID LEVELCHECK AND TOP UP IF NECESSARY □ - BM Qj XQ- to Id©, LlC I a.O TB 6M I Follow the Op. 1088E11 Fans with single engine duct - r+r I.Undo he nuts (1a) and the bolt (1b), then remove the heat shield (1c) for the left cylinder head exhaust manifold. 1a o <3 Follow the safety instructions (See 5040A - 1c o ./ WARNINGS) V/ Removal IS.OTB _ O la.oTsi Complete with Op. 5040A44 $\ I I Place the vehicle on a ramp. Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). IDescription Data not yet available Connector A01B Follow the Op. 7040D12 Engine front side cover (one) Ih or rh - r r (right and left). Follow the Op. 7040D30 Engine bay front beam cover - r r . Follow the Op. 7040D14 Engine bay rear side cover (one) Ih or rh - r r (right and left). Follow the Op. 7055B54 Under-engine guard rr Follow the Op. 1076B70 Exhaust pipe between pre-catalytic converter and catalytic converter rr. PA5106/00 06/1998 m m m v it I 7 e le.OTB BM 1 \ 9 / 1 1. Disconnect the electrical connection for the air conditioning compressor electro-magnet coupling. 7 REPAIR PROCEDURES Air conditioner box and components 5040 Installation Ig.OTB BM I I Description Connector Air conditioning compressor electro- magnet L20 1 2. Undo the bolt (2a) and disconnect the coolant fluid inlet and outlet pipes (2b) from the compressor. □ Seal the disconnected connectors, using suitable plugs, to prevent humidity and impurities from entering the system. If replacing the compressor, proceed as follows. 1 . Remove the drain plug and drain the fluid from the compressor. Note: Manually rotate the compressor to facili¬ tate the removal of all the fluid. - □ the fluid is extremely hygroscopic: avoid leaving the containers open.Avoid leaving the compressor or any other component disconnected from the system for longer than is strictly necessary. V :3 1 / c o G r*\ (WZ' \ D 'c Pf yr |V BM~1 '7 n u / JJJ V J I © ' N la 6M~l 1 . Recover the fluid drained from the compressor in a suitable transparent container (quantity A). 2. Drain and recover the fluid from the new compressor (quantity B) in an identical container, following the instructions given previously. 3. Introduce the same amount of fluid removed from the compressor being replaced into the new compressor (eliminate quantity C = B - A). %J 3 C— - 52 Wt 1b 8 C, 1 8.0 TB 1 . Remove the bolts (1 a) and remove the air conditioning compressor (1b). v9 u y \ 1 2.0 TB % 2b 2a c, A x1 B 2 PA5106/00 06/1998 REPAIR PROCEDURES Air conditioner box and components 5040 1 2.0 TB mil - Fit the air conditioning compressor and support it using the bolts. 1. Connect the coolant fluid inlet and outlet pipes (1a) to the compressor and fix them tightening the bolt (1a) to the recommended torque. O’ o ( SSA % rfl Replace the O-Ring seals for the connecrAl tors.Only use green coloured seals, resistant to R134A coolant fluid.Lubricate the thread of the connectors using anti-freeze. u 1b o©, _ o \o. m e~ Value Mounting Screw (daNm) Component 0 Air condi¬ M10 Air condi¬ tioning compressor tioning compress or side 4.1 - 5.0 inlet/outlet pipes 2. Connect the electrical connection for the air conditioning coupling. electro-magnet compressor v\ ilC Complete with Op. 1092G10 Single engine belt rr. Complete with Op. 7055B39 Front additional wheel arch half (one), Ih or rh, front element - r r (right). Complete with Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Complete with Op. 1064A44 Left hand or right hand sleeve (one) joining left hand or right hand cylinder head to turbocharger - r+r (left). Complete with Op. 1080B40 Catalytic pre¬ converter - r r . Complete with Op. 1076B70 Exhaust pipe between pre-catalytic converter and catalytic converter r r . Complete with Op. 7055B54 Under-engine guard - r r . Complete with Op. 7040D14 Engine bay rear side cover (one) Ih or rh - r r (right and left). Complete with Op. 7040D30 Engine bay front beam cover - r r . Complete with Op. 7040D12 Engine front side cover (one) Ih or rh - r r (right and left). Connect the negative (-) battery terminal. Remove the vehicle from the ramp. - y> * 2 iV 1 2.4 JTDBMI 1a Qlb Fit the heat shield for the left cylinder head exhaust manifold and fix it using the bolt and the nuts. Complete with Op. 1088E11 Fans with single engine duct - r+r 1. Tighten the nuts for the bolts fixing the air conditioning compressor to the recommended torque. U 1 Value (daNm) Mounting Component 0 Bolt AIR CONDI¬ TIONER ASSEMBLY COMPRESSOR M10 Support side 3.4 4.2 PA5106/00 06/1998 5040A20 - AIR CONDITIONER COMPRESSOR - R + R INCLUDES FLUID LEVELCHECK AND TOP UP IF NECESSARY □ Follow the safety instructions (See 5040A WARNINGS) Removal 1 2.4 JTPSMI Place the vehicle on a ramp. Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). 9 REPAIR PROCEDURES Air conditioner box and components 5040 Connector \Description A01B Data not yet available □ Follow the Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Follow the Op. 7040D12 Engine front side cover (one) Ih or rh - r r (left and right). Follow the Op. 7040D30 Engine bay front beam cover - r r Follow the Op. 1088Ell Fans with single engine duct - r+r . Follow the Op. 4450B10 Front or rear wheel (one) - r+r (right). Follow the Op. 7055B42 Supplementary wheel arch (one) - r+r (right). Follow the Op. 1092G10 Single engine belt r r . 1. Disconnect the electrical connection for the air conditioning electro-magnet compressor coupling. the fluid is extremely hygroscopic: avoid leaving the containers open.Avoid leaving the compressor or any other component disconnected from the system for longer than is strictly necessary. 1 th ia. IDescription 1 Connector Air conditioning compressor electro-magnet L20 I g.4 JTPSMI 2. Undo the bolts (2a) and disconnect the coolant fluid inlet and outlet pipes (2b) from the compressor. □ Seal the disconnected connectors, using suitable plugs, to prevent humidity and impurities from entering the system. 3. Undo the bolts (3a) and remove the air condi¬ tioning compressor (3b). U'y ■im r / &V—' \ 3a 7 Vi2a -< 3b ut 2 A V/ If replacing the compressor, proceed as follows. 1. Remove the drain plug and drain the fluid from the compressor. Note: Manually rotate the compressor to facili¬ tate the removal of all the fluid. 10 B 1 2b 3 r c— Installation - 1. Recover the fluid drained from the compressor in a suitable transparent container (quantity A). 2. Drain and recover the fluid from the new compressor (quantity B) in an identical container, following the instructions given previously. 3. introduce the same amount of fluid removed from the compressor being replaced into the new compressor (eliminate quantity C = B - A). 1. Fit the air conditioning compressor (1a) and fix it tightening the bolts (1b) to the recommended torque. U 1b Mounting Component 0 Screw AIR CONDI¬ TIONER ASSEMBLY COMPRESSOR M10 Value (daNm) Support side 4.3- 5.3 PA5106/00 06/1998 REPAIR PROCEDURES 1—1 Air conditioner box and components 2. Connect the coolant fluid inlet and outlet pipes (2a) to the compressor and fix them tightening the bolts (2b) to the recommended torque. Replace the O-Ring seals for the connec- rAl tors.Only use green coloured seals, resistant to R134A coolant fluid.Lubricate the thread of the connectors using anti-freeze. B 2b Mounting Component 0 Screw PIPE FRM DEHYDRAT M6 Value (daNm) Compres sor side 0.8 - 1.0 FILTR/ACCUM 1 2,5 VB I fiTO V6 BM I 5040A20 - AIR CONDITIONER COMPRESSOR - R + R INCLUDES FLUID LEVEL CHECK AND TOP UP IF NECESSARY □ r*\ 2b Mounting Component 0 Screw PIPES FROM COMPRESSOR TO CONDENSOR M6 Removal Place the vehicle on a ramp. Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). Value (daNm) Compres \Description sor side 0.8 - 1.0 im. 9 V ,v 1a )bB 3? w circuit - dehydrate and reload . Follow the Op. 5040A44 Air conditioner dehy¬ drating filter/accumulator - r+r . 1. Undo the two nuts for the bolts fixing the air conditioning compressor. O' bE |g.4 JTD8m| Complete with Op. 1092G10 Single engine belt rr. Complete with Op. 7055B42 Supplementary wheel arch (one) - r+r (right). Complete with Op. 4450B10 Front or rear wheel (one) - r+r (right). Complete with Op. 1088E11 Fans with single engine duct r+r . Complete with Op. 7040D30 Engine bay front beam cover - r r Complete with Op. 7040D12 Engine front side cover (one) Ih or rh - r r (left and right). Complete with Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Connect the negative (-) battery terminal. Remove the vehicle from the ramp. - A01B Follow the Op. 4450B10 Front or rear wheel (one) - r+r (right). Follow the Op. 7055B42 Supplementary wheel arch (one) - r+r (right). Follow the Op. 1092G10 Single engine belt r r . Follow the Op. 5040A10 Air conditioner cooling ( _ % L. III B2bÿ V/ \ Connector Data not yet available 2. Connect the electrical connection for the air electro-magnet compressor conditioning coupling. 3 Follow the safety instructions (See 5040A WARNINGS) la.s vsifa.o vs su i TO COMPRES B 5040 m. o ° % Qj o \"(C 11« 1 / o 1 LlC 1. Disconnect the electrical connection for the air electro-magnet conditioning compressor coupling. I Description 1 Air conditioning compressor electro-magnet Connector L20 2. Undo the bolt (2a) and disconnect the coolant fluid inlet and outlet pipes (2b) from the compressor. PA5106/00 06/1998 11 REPAIR PROCEDURES |n| Blgc] Air conditioner box and components 5040 rf] Seal the disconnected connectors, using suitable plugs, to prevent humidity and impurities from entering the system. \ [f] the fluid is extremely hygroscopic: avoid leaving the containers open.Avoid leaving the compressor or any other component disconnected from the system for longer than is strictly necessary. Y / 1 f oQ o 3 'c A* ' |V f 2a ~c/c to % 2b OJ C, c, la.B VBII3.0 V6 BM I 1. Remove the bolts (1a) and remove the air conditioning compressor (1b). / It (Jj "7 J ,7 m o tv V J 4 3 t \ 1a © 7 © i l/ffm 1 . Recover the fluid drained from the compressor in a suitable transparent container (quantity A). 2. Drain and recover the fluid from the new compressor (quantity B) in an identical container, following the instructions given previously. 3. Introduce the same amount of fluid removed from the compressor being replaced into the new compressor (eliminate quantity C = B - A). 3 52 m K c— - B 1b Installation 13.5 V6II 3.0 VB BM I If replacing the compressor, proceed as follows. 1. Remove the drain plug and drain the fluid from the compressor. Note: Manually rotate the compressor to facili¬ tate the removal of all the fluid. A K1 2 - 12 Fit the air conditioning compressor and support it using the bolts. 1. Connect the coolant fluid inlet and outlet pipes (1a) to the compressor and fix them tightening the bolt (1a) to the recommended torque. PA5106/00 06/1998 REPAIR PROCEDURES Air conditioner box and components □ Replace the O-Ring seals for the connec¬ tors.Only use green coloured seals, resistant to R134A coolant fluid.Lubricate the thread of the connectors using anti-freeze. O' ( 5040 ° Cs» 1b Component 0 Screw Air condi¬ tioning compressor M10 Air condi¬ tioning compress or side 4.1 - 5.0 inlet/outlet pipes 2. Connect the electrical connection for the air conditioning electro-magnet compressor coupling. v\ 5$ y o I LlC 1 2-B VB I f3.P VB BM I Complete with Op. 5040A44 Air conditioner dehydrating filter/accumulator - r+r . Complete with Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Complete with Op. 1092G10 Single engine belt rr. Complete with Op. 7055B42 Supplementary wheel arch (one) - r+r (right). Complete with Op. 4450B10 Front or rear wheel (one) - r+r (right). Connect the negative (-) battery terminal. Remove the vehicle from the ramp. Removal iv 1a Qlb l W, Oi 5040A26 - COMPRESSOR MOUNT- R R A* > 2 he _ frSS Value (daNm) Mounting 3\ L YA U i\\ o vbnnnj *> 1 3.5 V6 1 13.0 VS w 1. Tighten the nuts for the bolts fixing the air conditioning compressor to the recommended Place the vehicle on a ramp. Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). \ Description Data not yet available Connector A01B torque. u 1 Value (daNm) Mounting Component 0 Bolt AIR CONDI¬ TIONER ASSEMBLY COMPRESSOR M10 Support side 3.4 4.2 PA5106/00 06/1998 Follow the Op. 7040D12 Engine front side cover (one) Ih or rh - r r (right). Follow the Op. 7040D14 Engine bay rear side cover (one) Ih or rh - r r (right). Follow the Op. 1092G10 Single engine belt r r . Follow the Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Follow the Op. 5040A44 Air conditioner dehy¬ drating filter/accumulator - r+r . Follow the Op. 5040A20 Air conditioner compressor - r+r - includes fluid level check and top up if necessary . I.Undo the bolts (1a) and remove the air condi¬ tioning compressor support (1b). 13 REPAIR PROCEDURES Air conditioner box and components 5040 1 2.0 TB V m la.OTB Cq#c X S' 6M~I Refer to op.. 1008A46 mount - r r . Cam shaft left rigid 1 2.4 JTDBMI 5040A26 - COMPRESSOR MOUNT - R R Q Mi 1 5040A26 - COMPRESSOR MOUNT - R R Isl /A BM 1a x5 12.4 JTPBMI Refer to op.. 1008A46 Cam shaft left rigid mount - r r . Installation 2.5 VB Fit the air conditioning compressor support and fix it tightening the bolts to the recommended torque. E Value (daNm) Mounting Component 0 Screw COMPRESSOR MOUNT (AC) M10 Engine crankcase side 4.35.3 Complete with Op. 5040A20 Air conditioner compressor - r+r - includes fluid level check and top up if necessary . Complete with Op. 5040A44 Air conditioner dehydrating filter/accumulator - r+r Complete with Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Complete with Op. 1092G10 Single engine belt rr. Complete with Op. 7040D14 Engine bay rear side cover (one) Ih or rh - r r (right). Complete with Op. 7040D12 Engine front side cover (one) Ih or rh - r r (right). Connect the negative (-) battery terminal. Remove the vehicle from the ramp. . 14 5040A26 - COMPRESSOR MOUNT - R R 1 8.5 VB 113.0 VB BM I Refer to op.. 1008A46 Cam shaft left rigid - rr. 5040A40 - AIR CONDITIONER CONDENSER - R + R mount □ Follow the safety instructions (See 5040A WARNINGS) Removal Follow the Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Follow the Op. 7055B39 Front additional wheel arch half (one), Ih or rh, front element - r r . Follow the Op. 7055A43 Central front grille - r r Follow the Op. 7055A41 Front grille(one) - r r . Follow the Op. 7055B10 Front bumpers - r+r . Follow the Op. 7040D12 Engine front side cover (one) Ih or rh - r r (right and left). Follow the Op. 7040D30 Engine bay front beam cover - r r . Follow the Op. 7025A34 Bonnet lid lock (one) - r+r or repair . Follow the Op. 7090G06 Headlamp housing connection beam.following other repairs,-r r and adapt for replacement . I.Undo the bolts (1a) and disconnect the inlet and outlet pipes (1b) from the air conditioning condenser. - Recover the O-Ring seals. Note: Seal the disconnected connectors, using suitable plugs, to prevent humidity and impurities from entering the system. PA5106/00 06/1998 .o REPAIR PROCEDURES Air conditioner box and components .1) Complete with Op. 7055B39 Front additional wheel arch half (one), Ih or rh, front element - r mgs i\ 5040 r. Complete with Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . 5040A44 - AIR CONDITIONER 33 □ m is 1a 1b 1b 1a DEHYDRATING FILTER/ACCUMULATOR - R+R Removal - Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). I.Undo the bolts (1a) fixing the condenser (1b) to the engine cooling radiator and remove it. \\ 1a Follow the safety instructions (See 5040A WARNINGS) \Description Data not yet available 1b p£SSgp; m Connector A01B Follow the Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . 1. Disconnect the electrical connection for the multi-stage pressure switch. 1 \ Description Connector 4-stage pressure switch K10 2. Undo the bolts (2a) and disconnect the coolant fluid inlet and outlet pipes (2b) from the drier l filter/accumulator. <0 Installation - Place the condenser back in its housing and fix it to the engine coolant radiator using the bolts. - Connect the air conditioning condenser inlet and outlet pipes and fix them using the bolts. Note: Replace the O-Ring seals for the connectors.Only use green coloured seals. resistant to R134A coolant fluid.Lubricate the threads of the connectors using anti¬ freeze. Headlamp Complete with Op. 7090G06 housing connection beam.following other repairs,-r r and adapt for replacement . Complete with Op. 7025A34 Bonnet lid lock (one) - r+r or repair . Complete with Op. 7040D30 Engine bay front beam cover - r r . Complete with Op. 7040D12 Engine front side cover (one) Ih or rh - r r (right and left). Complete with Op. 7055B10 Front bumpers r+r . Complete with Op. 7055A41 Front grille(one) - m Seal the disconnected connectors, using suitable plugs, to prevent humidity and impurities from entering the system. 3. Undo the bolt (3a) and open the drier filter/ accumulator mounting collar (3b). 4. Remove the drier filter/accumulator. rr. Complete with Op. 7055A43 Central front grille -rr PA5106/00 06/1998 15 REPAIR PROCEDURES 5040 | stage pressure switch. Complete with Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . 4 w.r 2a :?Ja 3b 5040A76 - DELIVERY AND RETURN LINES FROM EVAPO¬ RATOR - R R o O o £ □ \V Follow the safety instructions (See 5040A WARNINGS) Removal \/ H - Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). k (top 3a-| 2b {Description Connector Data not yet available Installation Do not leave the filter with the connectors disconnected for longer than is strictly necessary. Place the drier filter/accumulator back in its housing. Close the drier filter/accumulator mounting collar and tighten it using the bolt. Connect the coolant fluid inlet and outlet pipes to the drier filter/accumulator and fix them tightening the bolts to the recommended torque. U 1 Connect the electrical connection to the multi¬ 1 m l—l Air conditioner box and components Follow the Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Follow the Op. 7055A18 Windscreen base trim - r+r . Follow the Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r . Follow the Op. 5050B38 Windscreen wiper assembly - r+r or repair . I.Undo the nuts (1a) and disconnect the coolant fluid inlet and outlet pipes (1b) from the expan¬ sion valve and the fixing bands (1c). Seal the disconnected connectors, using suitable plugs, to prevent humidity and impurities from entering the system. Replace the O-Ring seals for the connec¬ tors. Only use green coloured seals, resistant to R134A coolant fluid. Lubricate the thread of the connectors using anti-freeze. Mounting Component 0 Value (daNm) Screw Drier filter pipe toexpansion valve M6 Drier A01B lb <- & i >1 .1 i /, 1c filter/ accumu¬ lator side 0.8 1.0 A o 1a O U 16 Value Mounting Component 0 Screw Pipe from condenser to drier filter M6 (daNm) Drier filter/ accumu¬ lator side 0.81.0 1-Undo the connectors (1a) and (1b) for the evaporator inlet and outlet pipes using the spanner (1c). Q 1c Description Code Key 1.857.511.001 PA5106/00 06/1998 REPAIR PROCEDURES Air conditioner box and components Seal the disconnected connectors, using suitable plugs, to prevent humidity and impurities from entering the system. U 4a 5040 Mounting Component Connector INLET PIPE TO EVAPORATOR Value (daNm) 0 Evapo¬ rator side- 2. Disconnect the electrical connection for the intake/recirculation air flap actuator. 2 IDescription External/recirculation air intake Connector N82 U 4b Mounting Component Connector OUTLET PIPE FROM EVAPO¬ RATOR flap actuator (motor) 3. Disconnect the electrical connection for the air conditioning fan and disconnect the wiring from the fixing bands. IDescription rs 3 Connector Passenger compartment ventila¬ tion fan 4b lr Description Code Key 1 .857.51 1.001 Replace the O-Ring seals for the connec¬ 1b 4 Only use green coloured seals, resistant to R134A coolant fluid. Lubricate the threads of the connectors using anti-freeze. 4a H4c 4 1U |r 4b ,i /• m & h £ A Installation NT HK 3 /ÿ o' 3 1 . Place the evaporator inlet and outlet pipes (1a), complete with the expansion valve (1b), back in their housings. 2. Place the electrical wiring back in its housing and connect the electrical connection for the air conditioning fan. 3. Connect the electrical connection for the intake/ recirculation air flap actuator. 4. Tighten the connectors (4a) and (4b) for the evaporator inlet and outlet pipes, evaporator side to the recommended torque using the tool (4c). PA5106/00 06/1998 side- tors. 1a v Evapo¬ rator N85 4. Remove the evaporator inlet and outlet pipes (4a) complete with the expansion valve (4b). die 0 □ 4c Value (daNm) Q 2*3 1a & h K ,\ rrc 4a 2 AlbUdfStlt Fit the air conditioning protective casing and fix it with the springs. 1. Place the coolant fluid inlet and outlet pipes (1 a) back in their housings and connect them to the expansion valve tightening the nuts (1b) to the recommended torque. 17 REPAIR PROCEDURES Air conditioner box and components 5040 u 1b U 1b Mounting Component 0 Nut Drier filter pipe toexpansion valve M6 Mounting Component 0 Nut Pipe from condenser to drier filter M6 Value (daNm) Expan¬ sion valve side 0.81.0 Value (daNm) Expan¬ sion valve side 0.81.0 1a if p' o A \r i Complete with Op. 5050B38 Windscreen wiper assembly - r+r or repair . Complete with Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r . Complete with Op. 7055A18 Windscreen base trim - r+r . Complete with Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Connect the negative (-) battery terminal. 18 PA5106/00 06/1998 REPAIR PROCEDURES Air conditioner box and components 5040 5040B - System safety check devices VIEW OF ASSEMBLY 2 L 1L i 1 Ref. Description 1 AIR CONDITION SYST MULTI LEVEL PRES SWTC 2 A/C SYSTEM EXPANSION VALVE Operations index Code Validity Operation 5040B14 Air conditioner system multi-level pressure switch r+r 5040B30 Expansion valve (tube orifice) - r+r OPERATIONS 5040B14 - AIR CONDITIONER SYSTEM MULTI-LEVEL PRES¬ SURE SWITCH - R + R Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). IDescription Connector Data not yet available A01B PA5106/00 06/1998 switch. IDescription Removal - Follow the Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . 1. Disconnect the electrical connection for the air conditioning system multi-stage pressure 1 4-stage pressure switch Connector K10 2. Undo and remove the air conditioning system multi-stage pressure switch. 19 REPAIR PROCEDURES 5040 1b mm 0 1 o. A £ 2 /o r 1a A \y — )V fr k -to} installation Fit the multi-stage pressure switch and tighten it to the recommended torque. u Mounting Value (daNm) Component 0 AIR CONDITION SVST MULTI LEVEL PRES SWTC M10 0.7 - I.Undo the nuts (1a) and disconnect the coolant fluid inlet and outlet pipes (1b) from the expan¬ sion valve and the fixing bands (1c). 2. Undo the bolts (2a) and remove the expansion valve (2b) from the evaporator inlet and outlet pipes. r\ Seal the disconnected connectors, using suitable plugs, to prevent humidity and impurities from entering the system. 0.9 Connect the electrical connection to the multi¬ switch. Complete with Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Connect the negative (-) battery terminal. m PC f - i| I— Air conditioner box and components 2a stage pressure iiWÿk vv 5040B30 - EXPANSION VALVE (TUBE ORIFICE) - R + R □ Follow the Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Follow the Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r . Follow the Op. 7055A18 Windscreen base trim - r+r . I.Undo the nuts (1a) and move the relay holder bracket (1b) aside. 1c M) ,\ o rs 1*0 Installation 1. Place the expanssion valve (1a) back in its housing and fix it to the evaporator inlet and outlet pipes tightening the bolts (1b) to the recommended torque. u 1b Mounting Screw Component 0 Evaporator M6 inlet/outlet pipes 20 1b Follow the safety instructions (See 5040A WARNINGS) Removal - .I & Value (daNm) Expan¬ sion valve side 0.81.0 PA5106/00 06/1998 REPAIR PROCEDURES Air conditioner box and components 5040 Replace the O-Ring seals for the connectors.Only use green coloured seals, resistant to R134A coolant fluid. Lubricate the threads of the connectors using anti-freeze. 2. Place the coolant fluid inlet and outlet pipes (2a) back in their housings and connect them to the expansion valve tightening the nuts (2b) to the recommended torque. u 2b Mounting Component 0 Nut Drier filter pipe M6 toexpansion valve u 2b Mounting Component 0 Nut Pipe from condenser to drier filter M6 5ns I I \V< |JK Value (daNm) Expan¬ sion valve side 0.81.0 Value (daNm) Expan¬ sion valve side 0.8 1.0 HE /ÿ 2a ,\ o © 2|>Ba OED Place the relay holder bracket back in its housing and fix it using the nuts. Complete with Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Complete with Op. 5040A14 Air conditioner cooling circuit - check and repair any leaks by tightening fittings . Complete with Op. 7055A18 Windscreen base trim - r+r . Complete with Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r . r*\ PA5106100 06/1998 21 REPAIR PROCEDURES Air conditioner box and components 5040 5040C - Air conditioner box and components VIEW OF ASSEMBLY 1 JI iii i / Q to \ i H £i! X.I 3 4 iilLi Ref. Description 1 A/C CASE 2 A/C FAN MOTOR 3 A/C RADIATOR 4 EVAPORATOR I 2 Operations index Code Operation Validity 5040C10 Air conditioner box - r+r 5040C13 Air conditioner heater/distributor assembly - r r 5040C14 Air conditioner heater/distributor unit - r+r with fascia removed 5040C16 Air conditioner heater/distribution unit housing dismantle at bench 5040C24 Air conditioner box - dismantle and rebuild at bench 5040C30 Fan motor - r+r 5040C34 Fan motor - r+r with air conditioner box removed 5040C50 Air conditioner heater radiator - r+r 5040C52 Air conditioner heater radiator - r+r with fan unit disconnected 5040C64 A/c evaporator - r+r 22 PA5106/00 06/1998 REPAIR PROCEDURES Air conditioner box and components Code Operation 5040 Validity 5040C66 Air conditioner evaporator - r+r with air conditioner box removed 5040C80 Air intake and recirculation flap - r r with air condi_tioning housing disconnected _ 5040C82 Air shroud on air blender port - r r 5040C84 Air blender flap - r r OPERATIONS 5040C10 - AIR CONDITIONER BOX - R + R □ Follow the safety instructions (See 5040A - IDescription Connector External/recirculation air intake 1 N82 flap actuator (motor) WARNINGS) 2. Disconnect the electrical connection for the air conditioning fan. Removal - 1. Disconnect the electrical connection for the intake/recirculation air flap actuator. Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). IDescription Connector Data not yet available A01B Follow the Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Follow the Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r . Follow the Op. 5050B38 Windscreen wiper assembly - r+r or repair . Follow the Op. 7055A18 Windscreen base trim - r+r . Follow the Op. 5010B21 Climate control unit compartment - r r . 1 Undo the nuts (1a) and disconnect the coolant fluid inlet and outlet pipes (1b) from the expan¬ sion valve and the fixing bands (1c). . IDescription Connector Passenger compartment ventila¬ tion fan 2 N85 3. Disconnect the electrical connection for the mixed air flap actuator. \Description Connector N81 Mixed air flap actuator (motor) 3 1 * £ sf ra Seal the disconnected connectors, using RDM suitable plugs, to prevent humidity and impurities from entering the system. 10» ©23 1b N y* k\ ,\ O 1*0 to © % o □ o C02 1. Remove the springs (1a) using the tool (1b) and remove the air conditioning casing protec¬ tion (1c) disconnecting it from the rear spring. ES 1b PA5106/00 06/1998 © O’ Description Code Blade 1.823.015.000 23 REPAIR PROCEDURES 5040 2. Undo the bits (2a) and remove the air condi¬ tioning casing mounting bracket (2b). 3. Undo the bolts (3a) and remove the air condi¬ tioning casing (3b), after having released it from the mixed air flap actuator wiring. Note: Two operators are needed for this opera¬ tion. 4b 1a \ 4a 3a 3b ’i 531b 1c 111— I Air conditioner box and components 2a 2b 2a 3a SL 3 \! is \J / v / / 1 2bÿ ’=5- fiiiT / 3b loo ( A ( Installation loo 1. Place the air conditioning casing back in its housing and connect the mixed air flap actuator electrical wiring. Note: Two operators are needed for this opera¬ tion. 2. Fix the air conditioning casing firstly with bolts (2a) and then with bolt (2b). 3. Fit the air conditioning casing mounting backet (3a) and fix it using the bolts (3b). 4. Fit the air conditioning casing protection (4a) and fix it using the springs (4b). Connect the electrical connection for the mixed air flap actuator. Connect the electrical connection for the air conditioning fan. Connect the electrical connection for the intake/ recirculation air flap actuator. 1. Place the coolant fluid inlet and outlet pipes (1 a) back in their housings and connect them to the expansion valve tightening the nuts (1b) to the recommended torque. u 1b Mounting Component 0 Nut Drier filter pipe toexpansion valve M6 Mounting Component 0 Pipe from M6 Value (daNm) Expan¬ sion valve side 0.81.0 Value 1b Nut condenser to drier filter (daNm) Expan¬ sion valve side 0.8 1.0 Replace the O-Ring seals for the connec¬ tors. Only use green coloured seals, resistant to R134A coolant fluid. Lubricate the thread of the connectors using anti-freeze. 24 PA5106/00 06/1998 r\ REPAIR PROCEDURES Air conditioner box and components 1a pSi <5/ I /ÿ re Pi ,\ O © ibE/ dSb - Complete with Op. 5010B21 Climate control unit compartment - r r . Complete with Op. 7055A18 Windscreen base trim - r+r . Complete with Op. 5050B38 Windscreen wiper assembly - r+r or repair . - Complete with Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r Complete with Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload Connect the negative (-) battery terminal. 5040C13 - AIR CONDITIONER HEATER/DISTRIBUTOR ASSEMBLY - R R Removal - Follow the Op. 5010B54 Ducts (one), Ih or rh, on distribution unit for air ducts to rear seat r r withfacia removed . Follow the Op. 5010B52 Ducts (one), Ih or rh, on air distribution unit for air duct beneath facia r r with facia removed . Follow the Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Follow the Op. 5050B38 Windscreen wiper assembly - r+r or repair . Follow the Op. 7055A18 Windscreen base trim - r+r . Follow the Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r . Follow the Op. 5010B21 Climate control unit compartment - r r . Follow the Op. 5040C10 Air conditioner box r+r . Follow the Op. 5040C82 Air shroud on air blender port - r r . Follow the Op. 5505A18 Multi-function control unit - r r . Follow the Op. 5580E12 Immobiliser device ecu - r+r following electric circuit check . Follow the Op. 5010D30 Passenger compart¬ ment air temperature sensor - r+r following electrical wiring check operation . Exterior lighting Follow the Op. 5540A22 control switch - r+r . Follow the Op. 7040A44 Facia Ih side cover - r r. Follow the Op. 7040A45 Facia rh side cover - r r. PA5106/00 06/1998 - 5040 Follow the Op. 5580C26 Passenger air bag switch - r r . Follow the Op. 5010C30 Central air outlet on fascia - r+r . Follow the Op. 5560B11 Analogue control panel - r+r or replace . Follow the Op. 7040A26 Steering column trim - r+r . Follow the Op. 5550C16 Hazard warning light/ fog lamp/reversing light combined switch - r r . Follow the Op. 5040D18 Air conditioner control unit - r r . Follow the Op. 5570T80 Car radio unit - r+r . Follow the Op. 7065C42 Ashtray (one) r+r . Follow the Op. 5580C18 Air bag module - r+r . Follow the Op. 10S6B79 Injection/ignition contra unit guard - r r . Follow the Op. 4110A11 Steering wheel - r+r for replacement or check for versions with air bag . Follow the Op. 5550A12 Complete stalk unit r+r for versions with air bag . Follow the Op. 7040A31 Flap assembly - r r . Follow the Op. 7040G24 Switch for facia compartment light - r+r . Follow the Op. 5580C22 Air bag module (passenger side) - r + r . Follow the Op. 7040A67 Partition between passenger airbag and facia compartment - r r . Follow the Op. 7040A43 Cover (one only) for wiring beneath facia - r r . Follow the Op. 5505C32 (one) securing wiring connectors beneath instrument facia - r r . Follow the Op. 7040A10 Instrument facia trim r+r . Follow the Op. 5580C14 Air bag ecu - r+r . Follow the Op. 7040L20 Tunnel trim - r r . Follow the Op. 7045A10 L/h or r/h front seat (one) - r+r . Follow the Op. 7040A97 Facia trim support beam - r r . Follow the Op. 5040C14 Air conditioner heater/ distributor unit - r+r with fascia removed . Installation Air conditioner fascia removed with r+r unit heater/distributor Complete with Op. 5040C14 - Complete with Op. 7040A97 Facia trim support beam - r r . Complete with Op. 7045A10 L/h or r/h front seat (one) - r+r . Complete with Op. 7040L20 Tunnel trim - r r . Complete with Op. 5580C14 Air bag ecu - r+r . Complete with Op. 7040A10 Instrument facia trim - r+r . Complete with Op. 5505C32 (one) securing wiring connectors beneath instrument facia - r r - Complete with Op. 7040A43 Cover (one only) for wiring beneath facia - r r . Complete with Op. 7040A67 Partition between passenger airbag and facia compartment - r r . Complete with Op. 5580C22 Air bag module (passenger side) - r + r . Complete with Op. 7040G24 Switch for facia compartment light - r+r . Complete with Op. 7040A31 Flap assembly - r r. 25 REPAIR PROCEDURES 1—1 Air conditioner box and components 5040 Complete with Op. 5550A12 Complete stalk unit - r+r for versions with air bag . Complete with Op. 4110A11 Steering wheel r+r for replacement or check for versions with air bag . Complete with Op. 1056B79 Injection/ignition contro unit guard - r r . Complete with Op. 5580C18 Air bag module - r+r . Complete with Op. 7065C42 Ashtray (one) r+r Complete with Op. 5570T80 Car radio unit - r+r Complete with Op. 5040D18 Air conditioner control unit r r . Complete with Op. 5550C16 Hazard warning light/fog lamp/reversing light combined switch - r r . Complete with Op. 7040A26 Steering column trim - r+r . Complete with Op. 5560B11 Analogue control panel - r+r or replace . Complete with Op. 5010C30 Central air outlet on fascia - r+r . Complete with Op. 5580C26 Passenger air bag switch - r r . Complete with Op. 7040A45 Facia rh side cover - | | Follow the Op. 7045A10 L/h or r/h front seat (one) - r+r . 1 . Move the floor covering and undo the nut fixing the steering column universal joint protection. 2. Remove the universal joint protection. 3. Undo the bolt fixing the steering column to the power steering box pinion. 4. Push back the steering column joint. m 4 3 *3 2 Q> /, '© mi rr. Complete with Op. 7040A44 Facia Ih side cover - r r . Complete with Op. 5540A22 Exterior lighting 1 - control switch - r+r . Passenger with Op. 5010D30 compartment air temperature sensor - r+r following electrical wiring check operation . Complete with Op. 5580E12 Immobiliser device ecu - r+r following electric circuit check . Complete with Op. 5505A18 Multi-function control unit - r r . Complete with Op. 5040C82 Air shroud on air blender port - r r . Complete with Op. 5040C10 Air conditioner box - r+r . Complete with Op. 5010B21 Climate control unit compartment - r r . Complete with Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r . Complete with Op. 7055A18 Windscreen base trim - r+r . Complete with Op. 5050B38 Windscreen wiper assembly - r+r or repair . Complete with Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Complete with Op. 5010B52 Ducts (one), Ih or rh, on air distribution unit for air duct beneath facia r r with facia removed . Complete with Op. 5010B54 Ducts (one), Ih or rh, on distribution unit for air ducts to rear seat r r withfacia removed . Complete 5040C14 1. Remove the protections (1a) and disconnect the electrical connections (1b) for the right and left door wiring. IDescription 1b Connector Front left door connection {Description Connector Front right door connection 1b D30 D31 2. Using the tool (2a), undo the bolts (2b) and release the electrical connections (2c) from their housings in the bodyshell. ES 2a Description Code Key 1.822.132.000 AIR CONDITIONER HEATER/DISTRIBUTOR UNIT R + R WITH FASCIA REMOVED - Removal Follow the Op. 5580C14 Air bag ecu - r+r . Follow the Op. 7040L20 Tunnel trim - r r . 26 A PA5106/00 06/1998 r*N REPAIR PROCEDURES Air conditioner box and components 1a 2a © 5040 2 c4a \ 1MB o 2ci u 2 III 1a £ A / 4b a i 2b| \ Qlb 1cQ 1. Disconnect electrical connection (1a) between engine wiring and facia wiring, electrical connection (1b) between facia wiring and roof wiring - and electrical connection (1c) between facia wiring and rear service wiring. IDescription 1a Data not yet available IDescription 1b Dashboard/courtesy lights Q 3b g 1. Remove the element from the heater unit moving it sideways without damaging the pipes. MLH. I Connector D01 3a M SHi Connector D42 connection \Description 1c Dashboard/rear left connection D25A 2. Release the Air Bag wiring from the bands connecting it to the dashboard wiring. 3. Disconnect the electrical connection from the brake pedal switch (3a) and the electrical connection from the clutch pedal switch (3b). IDescription 3a Brake pedal switch \Description 3b Clutch pedal switch vv Connector Connector 1 \K 1. Unscrew the nuts retaining the facia frame to the body. 2. Remove the complete dashboard supporting frame. Note: Two operators are needed for this opera¬ tion. 1 30 Connector 131 4. Undo the nut (4a) and remove the steering column strut (4b). PA5106/00 06/1998 27 REPAIR PROCEDURES Air conditioner box and components 5040 - 2 - !— 1<— Ffa I— I - - P - L - 7 - V/ a - wr / 7 / I.Undo the bolts fixing the heater to the bodyshell. 2. Remove the sleeve for the cables between the dashboard and the heater from its housing. 3. Open the two rear bands for the wiring, releasing it from the heater unit. 4. Undo the rear fixing bolt. 5. Remove the heater unit/air conditioning distrib¬ utor. 1 m & 2 |—li| I 1 Place the complete dashboard supporting frame back in its housing and fix it using the nuts. Place the element back in its housing in the heater unit. Place the steering column strut back in its housing and fix it using the nut. Connect the electrical connections to the clutch pedal switch and to the brake pedal switch. Fix the Air Bag electrical wiring to the dash¬ board wiring using the connecting bands. Connect the electrical connection joining the dashboard wiring and the rear services wiring. Connect the electrical connection joining the dashboard wiring and the roof wiring. Connect the electrical connection joining the engine wiring and the dashboard wiring. Fix the electrical connections for the door wiring in their housings and fix them with the bolts using the tool. H Description Code Key 1 .822.1 32.000 Connect the electrical connections for the right and left door wiring and fit the protections. Place the steering column joint back in its housing. Tighten the bolts fixing the steering column to the power steerign box pinion to the recom¬ mended torque. o Mounting Component 0 Nut STEERING SHAFTS M16 Value (daNm) 2.6 - 3.2 Fit the steering column universal joint guard and secure it with its nuts. Put the floor carpet back in place. Complete with Op. 5580C14 Air bag ecu - r+r . Complete with Op. 7040L20 Tunnel trim - r r . Complete with Op. 7045A10 L/h or r/h front seat (one) - r+r . 5 3 l(4 3 r? ■\ Installation - - 28 Place the heater unit/air conditioning distributor back in its housing and fix it using the rear bolt. Place the electrical wiring back in its housing and fix it using the rear bands. Tighten the bolts fixing the heater to the bodyshell. PA5106/00 06/1998 REPAIR PROCEDURES Air conditioner box and components 5040C16 - AIR CONDITIONER HEATER/DISTRIBUTION UNIT HOUSING - DISMANTLE AT BENCH 5040 1. Remove the springs (1a) and undo the bolts (1b) fixing the two halves of the heater/distrib¬ utor unit casing. 1b Removal 7s 1. Undo the bolts (1a) and remove the distribution air flap motor (1b) complete with bracket. Tfi 1a % vzL 1b r(t i I St T AV 1b o ■y) u / L / m 9\ 2b F 3 5 WA. II F i )Jj 1b 1 . Separate the two halves of the heater/distributor unit casing. 2. Remove the air distribution half flaps (2a) and the centre duct (2b). 1 . Remove the upper mixed air temperature sensor. 2. Removge the lower mixed air temperature sensor. 3. Cut the seals where they are matched to the half casings. « \ 1a 1a V c ftn& 1 2a e..' 1 2a I 2 tubtiumPti vway/ / pis? (//// 40 Installation Place the air distribution half flaps and the back in their housings, then join together the two halves of the heater/distributor casing and fix them using the bolts and springs. - Fit the lower mixed air temperature sensor. - Fit the upper mixed air temperature sensor. Fit the air distribution flap motor complete with bracket and fix it using the bolts. Note: Check that the actuator and the flap oper¬ ating bearing are correctly matched. - centre duct PA5106/00 06/1998 29 REPAIR PROCEDURES Air conditioner box and components 5040 5040C24 - AIR CONDITIONER BOX - DISMANTLE AND REBUILD AT BENCH Installation Complete with Op. 5040C34 Fan motor - r+r with air conditioner box removed . Complete with Op. 5040C10 Air conditioner box - r+r . Complete with Op. 5010B21 Climate control unit compartment - r r . Complete with Op. 7055A18 Windscreen base Removal Follow the Op. 5040C66 Air conditioner evap¬ orator - r+r with air conditioner box removed . Follow the Op. 5040C34 Fan motor - r+r with air conditioner box removed . Follow the Op. 5040C80 Air intake and recircu¬ lation flap - r r with air conditioning housing disconnected . 1. Undo the bolts (1a) and separate the upper half of the fan casing (1b) from the lower half (1c). 2. Recover the duct. r\ - r+r . assembly - r+r or repair . trim Complete with Op. 5050B38 Windscreen wiper Complete with Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r . Complete with Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . 5040C34 - FAN MOTOR - R + R WITH AIR CONDITIONER BOX REMOVED Removal 1b 1. Release the electrical connection for the air conditioning fan from the fixing on the casing. 2. Undo the bolts (2a) and remove the air condi¬ tioning fan (2b). 2 !> 1c foil Installation - Fit the upper half of the casing, complete with duct, on the lower half and fix it using the bolts. Complete with Op. 5040C80 Air intake and recirculation flap - r r with air conditioning housing disconnected . Complete with Op. 5040C34 Fan motor - r+r with air conditioner box removed . Complete with Op. 5040C66 Air conditioner evaporator r+r with air conditioner box removed . 5040C30 - FAN MOTOR - R+R Removal - Follow the Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Follow the Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r . Follow the Op. 5050B38 Windscreen wiper assembly - r+r or repair . Follow the Op. 7055A18 Windscreen base trim - r+r . Follow the Op. 5010B21 Climate control unit compartment -rr. 1 r+r . - - Fit the fan and fix it using the bolts. Fix the electrical connection for the air condi¬ tioning fan to the casing. 5040C50 - AIR CONDITIONER HEATER RADIATOR - R + R □ Follow the safety instructions ( See 5040A WARNINGS) Removal - r+r with - 30 2b Installation Follow the Op. 5040C10 Air conditioner box - Follow the Op. 5040C34 Fan motor air conditioner box removed . & Follow the Op. 1088A20 Engine cooling system - wash inside . Follow the Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Follow the Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r . Follow the Op. 5050B38 Windscreen wiper assembly - r+r or repair . Follow the Op. 7055A18 Windscreen base trim - r+r . PA5106/00 06/1998 O REPAIR PROCEDURES Air conditioner box and components Follow the Op. S010B21 Climate control unit compartment - r r . Follow the Op. 5040C10 Air conditioner box - 5040 1b r+r . Follow the Op. 5040C52 Air conditioner heater radiator - r+r with fan unit disconnected . 3 Installation 1a Complete with Op. 5040C52 Air conditioner heater radiator - r+r with fan unit disconnected . Complete with Op. 5040C10 Air conditioner - W\ ■3 box - r+r . Complete with Op. 5010B21 Climate control unit compartment - r r . Complete with Op. 7055A18 Windscreen base trim - r+r . Complete with Op. 5050B38 Windscreen wiper assembly - r+r or repair . Complete with Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r . Complete with Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Supply the engine cooling system with the recommended fluid. i Type Component Description Liquid Engine cooling circuit Alfa Romeo Climafluid Super Perma¬ nent -40°C Removal m f Follow the Op. 1088A20 Engine cooling system - wash inside . I.Undo the bolts (1a) and remove the duct (1b). 2. Disconnect the coolant inlet and outlet pipes from the air conditioning heater radiator. 3. Remove the heater radiator. \ 5ÿ yP\f } i '7 ft'MjHt / / * jb V Q.ty. 5040C52 - AIR CONDITIONER HEATER RADIATOR - R + R WITH FAN UNIT DISCON¬ NECTED r MM Installation - - Fit the heater radiator. Connect the coolant inlet and outlet pipes to the air conditioning heater radiator. Apply sealant to the surface where the duct matches with the distributor unit. Fit the duct and fix it using the bolts. Supply the engine cooling system with the recommended fluid. m Type Component Description Liquid Engine cooling circuit Alfa Romeo Climafluid Super Perma¬ nent -40°C Q.ty. 5040C64 - A/C EVAPORATOR R+R - Removal - Follow the Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Follow the Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r . Follow the Op. 5050B38 Windscreen wiper assembly - r+r or repair . Follow the Op. 7055A18 Windscreen base trim - r+r . Follow the Op. 5010B21 Climate control unit compartment - r r . Follow the Op. 5040C10 Air conditioner box - r+r . Follow the Op. 5040C66 Air conditioner evap¬ orator - r+r with air conditioner box removed . PA5106/00 06/1998 31 REPAIR PROCEDURES I— I Air conditioner box and components 5040 tolslal I Installation Complete with Op. 5040C66 Air conditioner r+r with air conditioner box evaporator Air conditioner box - r+r . Complete with Op. 5010B21 Climate control unit compartment - r r . Complete with Op. 7055A18 Windscreen base trim - r+r . Complete with Op. 5050B38 Windscreen wiper assembly - r+r or repair . Complete with Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r . Complete with Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Complete with Op. 5040C10 2 o 1a / 4 111 !! Ho fo so Removal I.Undo the bolts (1a) and separate the fan unit (1b) from the air conditioning unit (1c). 2. Undo the bolts (2a) and remove the pollen filter filter element (2b). 3. Undo the bolts (3a) and remove the bracket (3b). JL 1b n 1c 3 Installation 2a - - 3b 2b - - lb b thk 5 5040C66 - AIR CONDITIONER EVAPORATOR - R + R WITH AIR CONDITIONER BOX REMOVED 3a-=§ES2T? a 3 removed . m,rz 1a Place the air conditioning evaporator back in the upper half of the casing without damaging the seal. Place the condensation drainage partition back in its housing. Join the two halves of the casing, with the seal in place and fix it using the bolts. Connect the evaporator inlet and outlet pipes, complete with expansion valve, and fix it tight¬ ening the connectors to the recommended torque. U Mounting Component Connector INLET PIPE TO EVAPORATOR 0 Evapo¬ rator side- 1c U 1a I.Undo the connectors (1a) and disconnect the evaporator inlet and outlet pipes (1b) complete with expansion valve (1c). 2. Undo the bolts fixing the air conditioning unit half casing. 3. Cut the seal, then separate the two halves of the Value (daNm) Mounting Component Connector OUTLET PIPE FROM EVAPO¬ RATOR 0 Value (daNm) Evapo¬ rator side- Fit the bracket on the air conditioning unit and fix it using the bolts. Fit the pollen filter filter element and fix it using the bolts. Join the fan unit to the air conditioning unit and fix it using the bolts. air conditioning casing. 4. Remove the condensation drainage partition. 5. Cut the sael and remove the air conditioning evaporator from the upper half of the casing. 32 PA5106/00 06/1998 REPAIR PROCEDURES Air conditioner box and components 5040 Follow the Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload . Follow the Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r . Follow the Op. 5050B38 Windscreen wiper assembly - r+r or repair . Follow the Op. 7055A18 Windscreen base trim 5040C80 - AIR INTAKE AND RECIRCULATION FLAP - R R WITH AIR CONDITIONING HOUSING DISCONNECTED - r+r . Removal Follow the Op. 5010B21 Climate control unit compartment - r r . Follow the Op. 5040C10 Air conditioner box - I.Undo the bolts (1a) and remove the intake/ recirculation air flap actuator (1b). 2. Remove the intake/recirculation air flap control linkage. 3. Remove the hinge pin (3a) and remove the intake/recirculation air flap (3b). r+r . 1. Undo the bolts (1a) and remove the duct (1b). 1a 3b \\ y&3'3 & 3a I I! 2 *y ffCi (\y» A' 1 ■C=>j -rS« I A /. ; ■ / Ref. Description Cmp 1 Windscreen and headlamp washer reservoir 5050A 2 Windscreen wash/wipe 5050B PA5106/00 06/1998 1 REPAIR PROCEDURES liliil Screen washers and headlamp wash/wipe 5050 JgJoJcj 5050A - Windscreen and headlamp washer reservoir VIEW OF ASSEMBLY 2 1 , S' V ■c=> \ / (f V ■ \ w*’ is 0 0. Ref. Description 1 WINDSCREEN WASHER RESERVOIR IN ENG BAY 2 WINDSCREEN WASHER RESERVOIR PLUG Operations index Code Operation Validity 5050A10 Windscreen washer fluid reservoir (in engine bay) - r+r 5050A14 Reservoir plug (in engine bay) or windscreen washer _ fluid level sensor - check and top up if necessary OPERATIONS Note: 5050A10 - WINDSCREEN WASHER FLUID RESERVOIR (IN ENGINE BAY) - R + R E3 1a Recover the windscreen washer fluid in a suitable container. Description Code Blade 1.823.015.000 Removal - 2 Place the vehicle on a ramp. Follow the Op. 7055B42 Supplementary wheel arch (one) - r+r . Follow the Op. 7055B43 Rear supplementary wheel arch (one) - r+r . Follow the Op. 7055A41 Front grille(one) - r r . Follow the Op. 7055B10 Front bumpers - r+r 1. Using the tool (1a), remove the windscreen washer pump (1b) from the reservoir. r*\ PA5106/00 06/1998 REPAIR PROCEDURES Screen washers and headlamp wash/wipe J / 5050 2a r Ja ] % >7 2a U-X! □1a 1b 3= V 2b' v \ I.Undo the bolts fixing the fuel vapour filter mounting bracket. 2. Remove the bracket and move the fuel vapour filter aside. 3. Undo the bolts and the nut fixing the reinforce¬ ment 2a bracket. 4. Remove the reinforcement bracket. Installation - \v - 3 - 4 4 - rs r+r . kas> \l T 3 Complete with Op. 7055A41 Front grille(one) rr. Complete with Op. 7055B43 Rear supplemen¬ tary wheel arch (one) - r+r Complete with Op. 7055B42 Supplementary wheel arch (one) - r+r . . c Refill the windscreen washer system. Remove the vehicle from the ramp. 2 1. Release the breather pipe from the fixings. 2. Undo the bolts (2a) and remove the windscreen washer fluid reservoir (2b). Fit the windscreen washer fluid reservoir and fix it using the bolts. Fix the breather pipe to the fixings. Fit the reinforcement bracket and fix it using the bolts and the nuts. Place the fuel vapour filter back in its housing. Fit the fuel vapour filter securing bracket and check that the bracket retaining tab is correctly inserted, then fix it using the bolt. Place the windscreen washer fluid pump back in its housing in the reservoir. Complete with Op. 7055B10 Front bumpers - 5050A14 - RESERVOIR PLUG (IN ENGINE BAY) OR WIND¬ SCREEN WASHER FLUID LEVEL SENSOR - CHECK AND TOP UP IF NECESSARY Removal Follow the Op. 7040D12 Engine front side cover (one) Ih or rh - r r (right). 1. Remove the windscreen washer fluid reservoir - PA5106/00 06/1998 cap. Check the level of the windscreen washer fluid and, if necessary, top it up. 3 REPAIR PROCEDURES 5050 Screen washers and headlamp wash/wipe |H1| iBl 1 id .dii Installation - 4 Fit the windscreen washer fluid reservoir cap. Complete with Op. 7040D12 Engine front side cover (one) Ih or rh - r r (right). PA5106/00 06/1998 REPAIR PROCEDURES Screen washers and headlamp wash/wipe 5050 5050B - Windscreen wash/wipe VIEW OF ASSEMBLY 4 3 1 <=>, f ! w ' \ ffi X ms \\C 2 Installation - Place the windscreen wiper motor in the rest position. Connect the left auxiliary arm lever (for the left - wiper arm only), then position the windscreen wiper arms in a horizontal position and fix them using the nuts without tightening them. Check that the wiper arms are working properly. - PA5106/00 06/1998 m >ÿ2 4S 3 7 REPAIR PROCEDURES Screen washers and headlamp wash/wipe 5050 r*\ Installation Connect the electrical connections to the motor. Place the front windscreen wiper assembly back in its housing and fix it using the bolts and the - 1 nut. Check that the motor is working properly. Place the motor in the rest position. 1.!n order to ensure that the travel of the wind¬ screen wiper arms is correct, the idler arm (1 a) must be fixed to the motor bearing, with the opening (1b) in the linkage aligned with the bearing (1c) and the bolt (Id). 5E 1a <1 XI 2 o o \NvJd 1c Installation - Clb - Since the action of tightening the nut causes the partial rotation of the linkage. before fitting the wiper arms, check that the motor is in the rest position. Complete with Op. 7055A18 Windscreen base trim - r+r . Complete with Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r Note: . 5050B42 - WINDSCREEN WIPER MOTOR - R + R Check that the motor is not damaged and test the electrical operation. Fit the front windscreen wiper motor and fix it tightening the bolts to the recommended torque. U Mounting Component 0 Screw FRONT WIDSCREEN M8 Value (daNm) 2.4 WIPER MOTOR Complete with Op. 5050B38 Windscreen wiper assembly - r+r or repair . Complete with Op. 7055A18 Windscreen base trim - r+r . Complete with Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r . Removal Follow the Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r . Follow the Op. 7055A18 Windscreen base trim - r+r . Follow the Op. 5050B38 Windscreen wiper assembly - r+r or repair . I.Undo the bolts fixing the front windscreen wiper motor to the mounting bracket. 2. Remove the front windscreen wiper motor. 8 PA5106/00 06/1998 REPAIR PROCEDURES Screen washers and headlamp wash/wipe 5050 5050D - Headlamp wash/wipe Operations index Code Validity Operation 5050D20 Headlamp washer pump - r+r OPERATIONS Complete with Op. 7055B39 Front additional wheel arch half (one), Ih or rh, front element - r 5050D20 - HEADLAMP WASHER PUMP - R + R Complete with Op. 4450B10 r (right). Front or rear wheel (one) - r+r (right). Refill the headlamp washer system. Remove the vehicle from the ramp. Removal Place the vehicle on a ramp. Follow the Op. 4450B10 Front or rear wheel (one) - r+r (right). Follow the Op. 7055B39 Front additional wheel arch half (one), Ih or rh, front element - r r (right). 1. Remove the electric headlamp washer pump from the reservoir. Note: Recover the windscreen washer fluid in a suitable container. 2. Disconnect the electrical connection from the electric headlamp washer pump. - IDescription 2 Connector Headlamp washer pump motor N25 3. Disconnect the pipe from the electric headlamp washer pump and remove it. AY Vv\ \ ) .c=7 i V h \ Q, -S %l i. \ /1 0 ° un 1 ir 0 0 3 1 2 ffef. Description 1 JUNCTION UNIT 2 MULTI-FUNCTION CONTROL UNIT 3 Data not yet available Operations index Code Operation Validity 5505A10 Electrical junction unit - r+r 5505A13 Supplementary junction control unit in engine bay - r r 5505A18 Multi-function control unit - r r 2 PA5106/00 06/1998 REPAIR PROCEDURES Instrument/guage electrical wiring OPERATIONS 5505A10 - ELECTRICAL JUNC¬ TION UNIT - R+R Follow the Op. 7040D12 Engine front side cover (one) Ih or rh - r r (left). Follow the Op. 7040D14 Engine bay rear side cover (one) Ih or rh - r r (left). 1 2.0 TB Removal - BM~I Vacuum air circuit Follow the Op. 1048A28 resonator pipe - r+r . Follow the Op. 5505A18 Multi-function control unit - r r . I.Undo the bolt (1a) and push back the junction unit as far as necessary to disconnect the elec¬ trical connections (1b). Note: For precise identification of the electrical connections, Wiring Diagrams see Section. 2. Remove the junction unit. 5505 Upper resonator Follow the Op. 1048A56 device - r r . 1. Undo the nuts (1a) and withdraw the additional junction unit from its seating as far as necessary to disconnect the electrical connections (1b). Note: For precise identification of the electrical connections, Wiring Diagrams see Section. 1a A v\ / \ a \ XllSÿ si \ / X 1a 11, A V A ft 1b & x ElTi I I' A 1b YX 1b 1a 1. Remove the additional junction unit. 1 JgSj 2 O Installation - - Fit the junction unit, connect the electrical connections and secure with its bolt. Complete with Op. 5505A18 Multi -function control unit - r r . Test the electrical system. \ // [ / 5505A13 - SUPPLEMENTARY JUNCTION CONTROL UNIT IN ENGINE BAY - R R \ A f/A X Removal - 0 \ Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). v> /"A Installation \Description Data not yet available PA5106/00 06/1998 Connector A01B - Refit the additional junction unit in its seating. Connect the electrical connections to the addi¬ tional junction unit. Fix the additional junction unit with its nuts. 3 REPAIR PROCEDURES Instrument/guage electrical wiring 5505 & I2.4jros>il Complete with Op. 1048A56 Upper resonator device - r r . 1 2.0 TB SMI "V // Complete with Op. 1048A28 Vacuum air circuit resonator pipe |g.oTs ila.s - r+r . HA v\ vslia.o V6 6M ua.QTB miia.4 jmeMi Complete with Op. 7040D12 Engine front side cover (one) Ih or rh r r (left). Complete with Op. 7040D14 Engine bay rear side cover (one) Ih or rh - r r (left). Connect the negative (-) battery terminal. \ - - - \ 1b 1a Installation - 4 Connector Connector Connector Connector Data not yet available \Description 2g seating and secure with its bolt. Close the fuse access cover and secure using the appropriate bolt. Connect the negative (-) battery terminal. Data not yet available IDescription 2f Connect the electrical connections to the inte¬ grated multiservices unit, then refit it in its Data not yet available IDescription 2e 2dD Data not yet available \Description 2d 2a D2' U A01B 2c H2g Connector 1. Unscrew bolt (1a) and open fuse access cover (1b). 2. Undo the bolt (2a) and remove the integrated multiservices unit (2b) after having discon¬ nected the electrical connections (2c), (2d), (2e), (2f) and (2g). lOescription 2b ! Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). Data not yet available 2c / Removal IDescription „ÿ / 5505A18 - MULTI-FUNCTION CONTROL UNIT - R R - a Connector Data not yet available PA5106/00 06/1998 REPAIR PROCEDURES Instrument/guage electrical wiring di i 5505 5505B - Door,boot and bonnet wiring. VIEW OF ASSEMBLY 3 *)L///Q) I 0 / I I J up AS i LX O i ' I! 2 1 Ref. Description 1 FRONT DOOR WIRING LEAD/S 2 REAR DOOR WIRING LEAD/S 3 LUGGAGE COMPARTMENT BOOT LID WIRING LEAD Operations index Code Validity Operation 5505B10 Front door wiring - r r Front door wiring - r r 5505B11 5505B20 Rear door wiring - r r 5505B21 Rear door wiring - r r 5505B50 Boot wiring - r r 5505B51 Boot wiring - r r OPERATIONS 5505B10 - FRONT DOOR WIRING - R R Removal - Follow the Op. 7005D24 Front door window rear guide - r r . 1. Disconnect the electrical connections for the door mirror. / IDescription 1 Left door mirror PA5106/00 06/1998 / IDescription Right door mirror 2 Connector P61 2. Disconnect the electrical connections (2a) of the door lock and electrical connection (2b) of the electric window motor. / 2a IDescription Left front door lock geared motor Connector N50 Connector P60 5 REPAIR PROCEDURES Instrument/guage electrical wiring 5505 IDescription 2a Connector Right front door lock geared motor N51 \Description 2b 2b Connect the electrical connections for the door mirror and fit the covers. Connect the main electrical connection and secure with the retainer. Secure the electrical wiring bands. Tighten the bolts securing the door check strap to the pillar. Fit the rubber protection on the door check Front left electric window motor Connector strap. N60 Complete with Op. 7005D24 window rear guide - r r . {Description Connector Front right electric window motor N61 5505B11 - FRONT DOOR WIRING - R R Removal 3. Remove the retainer (3a) and disconnect the electrical connection (3b). 3b {Description Connector Front left door connection D30 IDescription 3b - Connector Front right door connection D31 4. Release the electrical wiring bands from the door. 5. Remove the rubber protection and undo the bolts (5a) of the door check strap (5b). 6. Remove the weatherstrip from the door and withdraw the front door integrated wiring from the main electrical connection compartment. - 5b aw cwg -o /j >a 2a Of 3a 3b 4 6 Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r . Follow the Op. 7005E38 Front side door interior handle-r r . Follow the Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r . Follow the Op. 5570T90 Front speaker - r r . Follow the Op. 7005C44 Interior handle panel rr. Follow the Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed . Follow the Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed . Follow the Op. 7005D24 Front door window rear guide - r r . Follow the Op. 7040E24 Lower courtesy light indoor panel - r+r . Follow the Op. 5505B10 Front door wiring - r r . Installation - lo Front door Complete with Op. 5505B10 Front door wiring - rr . Complete with Op. 7040E24 Lower courtesy light indoor panel - r+r . Complete with Op. 7005D24 Front door window rear guide - r r . Complete with Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed . Complete with Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed . Complete with Op. 7005C44 Interior handle panel - r r . Complete with Op. 5570T90 Front speaker - r r . Complete with Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r . Complete with Op. 7005E38 Front side door interior handle-r r . Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r . \ imniroHivu-to/ . «... Installation - - 6 Refit the front door integrated wiring in its seating. Fit the weatherstrip on the door. Connect the electrical connection for the elec¬ tric window motor. Connect the door lock electrical connections. PA5106/00 06/1998 m REPAIR PROCEDURES Instrument/guage electrical wiring 5505 5505B20 - REAR DOOR WIRING - R R Removal - Rear side door Follow the Op. 7010D22 descending window glass guide (one) - r r with door panel (and support frame) removed . 1. Disconnect the electrical connection (1a) for the door lock, the main electrical connection (1b) and the electrical connection (1c) for the 3 ,o 1b II electric window motor. IDescription 1a Left rear door lock geared motor i Connector N55 *2 III 1a IDescription 1a Right rear door lock geared motor Connector 2 N56 1c Installation \Description 1b Rear left door connection IDescription 1b Rear right door connection IDescription 1c Rear left electric window motor Connector D35 Connector - - D36 Connector N65 Refit the rear door integral wiring in its seating and the main electrical connection in its seating in the door. Connect the main electrical wiring. Connect the electrical connections for the door lock and electric window motor. Secure the electrical wiring bands to the door. Complete with Op. 7010D22 Rear side door descending window glass guide (one) - r r with door panel (and support frame) removed . 5505B21 - R R - REAR DOOR WIRING Removal \Description 1c Rear right electric window motor Connector N66 2. Release the electrical wiring bands from the door. 3. Remove the weatherstrip from the door and withdraw the rear door integral wiring through the main electrical wiring compartment. Follow the Op. 7010C44 Interior handle panel rr. Follow the Op. 7010D38 Rear side door manual window mechanism handle/ring-nut r r . Follow the Op. 7010E38 Rear side door interior handle-r r . Follow the Op. 7040E26 Lower courtesy light in rear panel - r r . Follow the Op. 7010EU Lh or rh rear door inner panel r+r with fouling parts removed . Follow the Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed . Follow the Op. 7010D22 Rear side door descending window glass guide (one) - r r with door panel (and support frame) removed . Follow the Op. 5505B20 Rear door wiring - r r . - - Installation Complete with Op. 5505B20 Rear door wiring - r r. Complete with Op. 7010D22 Rear side door descending window glass guide (one) - r r with door panel (and support frame) removed . Complete with Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed . Complete with Op. 7010E11 Lh or rh rear door inner panel - r+r with fouling parts removed . /— V PA5106/00 06/1998 7 REPAIR PROCEDURES 5505 Instrument/guage electrical wiring r*\ Complete with Op. 7040E26 Lower courtesy light in rear panel - r r . Complete with Op. 7010E38 Rear side door interior handle-r r . Complete with Op. 7010D38 Rear side door manual window mechanism handle/ring-nut r r Complete with Op. 7010C44 panel r r . - l1a - rs'/ S* Z R R 3a, Removal Follow the Op. 7050A20 One-piece rear seat cushion - r r . Follow the Op. 7050A19 Rear seat squab - r r . - Follow the Op. 7040H42 Rear pillar trim r r . Follow the Op. 7040H84 Parcel rack plus speaker - r r . 1. Disconnect the electrical connections (1a), (1b), (1c), (1d) and (1e). 2 Right rear light cluster (moving part on boot lid) Connector F35 (4 _1 2 t JIL - 1a lie 1d 1b interior handle 5505B50 - BOOT WIRING IDescription_ & <5? 3b 1e Installation - Refit the boot lid integrated wiring in its seating. - Connect the electrical connections. - Fit the cable pass and secure the wiring to its bands. IDescription 1b Data not yet available IDescription 1c Complete with Op. 7040H84 Parcel rack plus speaker - r r . Complete with Op. 7040H42 Rear pillar trim - r Connector Data not yet available r. Complete with Op. 7050A19 Rear seat squab r r. Complete with Op. 7050A20 One-piece rear seat cushion - r r . Connector L11 5505B51 - BOOT WIRING Removal IDescription 1d 1e Connector Data not yet available N36 \Description Connector Data not yet available - - R R . Follow the Op. 7025B18 Boot lid lining - r+r Follow the Op. 7050A20 One-piece rear seat cushion - r r . Follow the Op. 7050A19 Rear seat squab - r r . Follow the Op. 7040H42 Rear pillar trim - r r . Parcel rack plus Follow the Op. 7040H84 speaker - r r . Follow the Op. 5505B50 Boot wiring - r r . Installation 2. Release the electrical wiring bands from the boot lid. 3. Remove the cable pass and withdraw the wiring (3b). 4. Remove the boot lid integrated wiring. Complete with Op. 5505B50 Boot wiring - r r . Complete with Op. 7040H84 Parcel rack plus speaker r r . Complete with Op. 7040H42 Rear pillar trim - r - r . Complete with Op. 7050A19 Rear seat squab r r. Complete with Op. 7050A20 One-piece rear seat cushion - r r . Complete with Op. 7025B18 Boot lid lining - r+r . 8 PA5106100 06/1998 REPAIR PROCEDURES Engine ignition 5510 Sub-group index - SUB-GROUP GRAPHIC INDEX Assembly drawings index Validity Cmp Description 5510C Coil, ecu, sensors 5510D Spark plugs and lead SUB-GROUP GRAPHIC INDEX 1 2 1 a jV iV 1 n Ik © y ' so mmSIt mr* Jf © u o 1 Ref. Description Cmp 1 Coil, ecu, sensors 551OC 2 Spark plugs and lead 5510D PA5106/00 06/1998 1 REPAIR PROCEDURES Engine ignition 5510 IV 5510C - Coil, ecu, sensors VIEW OF ASSEMBLY 2 1 0 ■i\' '\ : /*\ & W/ \ // aI J jer 5 'tW, 4 II r>rH WO*- /?ef. Description 1 IGNITION COIL/REEL 2 ENGINE RPM SENSOR 3 ENGINE TIMING SENSOR 4 FLYWHEEL SIDE KNOCK SENSOR 5 TIMING SIDE KNOCK SENSOR I . Installation I.Undo the remaining fixing bolts (1a) and remove the ignition coils (1b). 13-ii VEirSToVBGM I Right hand cylinder head ignition coil - r+r . Complete with Op. 1072B50 Sleeves connecting air capacity box to inlet manifold is Complete with Op. 5510C18 - \ \ r+r . Complete with Op. 1048A48 Throttle heater sleeve - r r . Complete with Op. 5510C16 Left hand cylinder head ignition coil - r+r . Complete with Op. 1016A42 Left hand cylinder head ignition coil cover - r+r . JP 1a ® 5510C16 - LEFT HAND CYLINDER HEAD IGNITION COIL - R + R \ 13 1aÿ \\ Removal Installation 12.5 VB|f3.0 VB 6M I 12.5 VB 113.0 VS SM I Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). {Description Connector Data not yet available A01B Follow the Op. 1016A42 Left hand cylinder head ignition coil cover - r+r . 1. Disconnect the electrical connections from the ignition coils. IDescription Connector Ignition coil A30 I.Undo the bolts (1a) and remove the electrical wiring securing brackets (1b). Move the electrical wiring to the side. PA5106/00 06/1998 o 1a 1 2.5 VB l fiTb VS BM I 1 \ $ m 'Alb - - - Fit the ignition coils and fix them using the bolts. Place the electrical wiring back in its housing. Fit the electrical wiring securing brackets and fix them using the bolts. Connect the electrical connections to the igni¬ tion coils. Complete with Op. 1016A42 Left hand cylinder head ignition coil cover - r+r . Connect the negative (-) battery terminal. la.5V6ir3T0VB8M i 5510C18 - RIGHT HAND CYLINDER HEAD IGNITION COIL - R+R Removal la.S VB ifTn V6 6M I Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). 5 REPAIR PROCEDURES Engine ignition 5510 * Installation I Description Data not yet Connector available Fit the ignition coils and fix them using the bolts. Place the electrical wiring back in its housing. Connect the electrical connections to the igni¬ tion coils. Complete with Op. 1072B50 Sleeves connecting air capacity box to inlet manifold is - r+r . Complete with Op. 1048A48 Throttle heater sleeve - r r . Connect the negative (-) battery terminal. A01B Follow the Op. 1048A48 Throttle heater sleeve -rr Follow the Op. 1072B50 Sleeves connecting air capacity box to inlet manifold is - r+r . 1. Disconnect the electrical connections from the ignition coils. . 1 IDescription Connector Ignition coil A30 r\ la.QTSl 2. Undo the bolts (2a) and remove the electrical wiring securing brackets (2b). Move the electrical wiring to the side. 5510C34 - RPM AND TIMING SENSOR (SINGLE) - R + R Removal I 2.0 T5 I T in, 1 Place the vehicle on a ramp. Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). c IPescription Connector A01B Data not yet available 1. Disconnect the electrical connection for the rpm and timing sensor. wr@ Oi o. o 1 o I Description Connector Rpm sensor K46 i? \\ V I.Undo the remaining fixing bolts (1a) and remove the ignition coils (1b). t. I / 1 H \V Vvft 1a v \ la (?) W // <_ u ■; X \ 6 4ÿ f// PA5106/00 06/1998 n REPAIR PROCEDURES Engine ignition li 5510 Follow the Op. 7055B54 Under-engine guard r r. I.Undo the bolt (1a) and remove the engine rpm and timing sensor (1b). 1b 1a w urn 1 I n 1 2.0 TB Installation Fit the engine rpm and timing sensor and fix it using the bolt to the cylinder block/crankcase. Complete with Op. 7055B54 Under-engine guard - r r Connect the electrical connection for the engine rpm and timing sensor. Connect the negative (-) battery terminal. Remove the vehicle from the ramp. IIS.5 V6inT0 V6 6M 1b 0 . 6M VB 11 3.0 VB BMI NJ I a.o TS I 1 2.0 TB 6M 11 2.5 1. Undo the bolts (1a) and remove the engine rpm and timing sensor (1b) from its housing. Release the engine rpm and timing sensor elec¬ trical wiring from the fixings. I 1C >0 5510C34 - RPM AND TIMING SENSOR (SINGLE) - R+R 1a' Removal % j 1 2.0 TB 6M lfg.B VB II3.D VB~5T1 - Place the vehicle on a ramp. Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). 1 2.S VB 11 3-P VB BM I IDescription Data not yet available Connector A01B Follow the Op. 7055B54 Under-engine guard rr. Follow the Op. 1076B52 Exhaust pipe (one) leaving l/h or r/h exhaust manifold -r + r (left). I.Undo the bolts (1a) and remove the engine flywheel lower protection (1b). PA5106/00 0611998 1. Disconnect the electrical connection for the rpm and timing sensor then remove it. IDescription 1 Rpm sensor Connector K46 7 REPAIR PROCEDURES Engine ignition 5510 & Connect the negative (-) battery terminal. Remove the vehicle from the ramp. ,r Me 0 la.QTsi 5510C42 - KNOCK SENSOR R +R - Removal / Place the vehicle on a ramp. Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). / /7/2.7 IDescription 1. Disconnect the electrical connection for the rpm and timing sensor then remove it. \Description Connector Rpm sensor 1 o 0 o i L Ss \\\ \V\7 Follow the Op. 7055B54 Under-engine guard Connector K50 Knock sensor 1 I, 2. Undo the bolt (2a) and remove the knock sensor (2b). «r A>; 1 1 I a G ;© / o A) un¬ - rr. Follow the Op. 1076B50 Exhaust pipe attach¬ ment to engine - r + r . \Description V ./ A01B 1. Disconnect the electrical connection for the knock sensor. K46 AN i 'D Connector Data not yet available 6M~1 1 2.0 TB pi i /./. B m j / V, installation Place the engine rpm and timing sensor back in its housing and connect the electrical connec¬ 2b tion. Tighten the bolts fixing the engine rpm and timing sensor. Fix the engine rpm and timing sensor electrical wiring to the bands. Fit the lower engine flywheel protection and fix it using the bolts. Complete with Op. 1076B52 Exhaust pipe (one) leaving l/h or r/h exhaust manifold - r + r (left). Complete with Op. 7055B54 Under-engine guard - r r . 8 o mj i 2a r 15 U I © Installation l a.o TS I Fit the knock sensor and fix it tightening the bolt to the recommended torque. PA5106/00 06/1998 REPAIR PROCEDURES m u Engine ignition 5510 "\ Value (daNm) Mounting Component 0 Screw KNOCK SENSOR M8 Crankcase 1 \ M- CM z'* 5510C46 - FLYWHEEL SIDE KNOCK SENSOR - R+R Removal la.QTC BMlla.svBl[37ovB6Ml \ 'o V 1 2.0 TB Data not yet available Connector A01B Follow the Op. 7055B54 Under-engine guard rr. Follow the Op. 7040D12 Engine front side cover (one) Ih or rh - r r (left). Follow the Op. 7040D14 Engine bay rear side cover (one) Ih or rh - r r (left). Follow the Op. 1048B44 Heat exchanger/mani¬ fold pipe - r r . Follow the Op. 1088C40 Thermostat- r + r . Follow the Op. 1088C36 Thermostat support r + r. Follow the Op. 7055B39 Front additional wheel arch half (one), Ih or rh, front element - r r . Follow the Op. 1088D26 Rigid intake pipe to water pump - r+r for versions with a/c . I.Undo the bolt (1a) and remove the flywheel side knock sensor (1b). 6M 1 1 2.5 VBII3.QVB SM Fit the flywheel side knock sensor and fix it tightening the bolt to the recommended torque. u Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). IDescription O. c /6] Installation BM - O C; side 1.95 2.05 Connect the electrical connection for the knock sensor. Complete with Op. 1076B50 Exhaust pipe attachment to engine - r + r . Complete with Op. 7055B54 Under-engine guard - r r . Connect the negative (-) battery terminal. Remove the vehicle from the ramp. J '\ Value (daNm) Mounting Component 0 Screw FLYWHEEL SIDE KNOCK SENSOR M8 1.95 2.05 Complete with Op. 1088D26 Rigid intake pipe to water pump - r+r for versions with a/c . Complete with Op. 7055B39 Front additional wheel arch half (one), Ih or rh, front element - r r. Complete with Op. 1088C36 Thermostat support - r + r . Complete with Op. 1088C40 Thermostat- r + r . Complete with Op. 1048B44 Heat exchanger/ manifold pipe - r r . Complete with Op. 7040D14 Engine bay rear side cover (one) Ih or rh - r r (left). Complete with Op. 7040D12 Engine front side cover (one) Ih or rh - r r (left). Complete with Op. 7055B54 Under-engine guard - r r . Connect the negative (-) battery terminal. 12.0 TB 6MM2.5 VBl iToWeMl 5510C48 - TIMING SIDE KNOCK SENSOR - R+R Removal ia.0 TB OM 112.5 VB I[3.0 VB BM Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). IDescription Data not yet available Connector A01B Follow the Op. 7055B54 Under-engine guard r r. PA5106/00 06/1998 9 REPAIR PROCEDURES Engine ignition 5510 Follow the Op. 7040D12 Engine front side cover (one) Ih or rh - r r (left). Follow the Op. 7040D14 Engine bay rear side cover (one) Ih or rh - r r (left). Follow the Op. 1048B44 Heat exchanger/mani¬ fold pipe - r r . Follow the Op. 1088C40 Thermostat- r + r . Follow the Op. 1088C36 Thermostat support r +r. Follow the Op. 7055B39 Front additional wheel arch half (one), Ih or rh, front element - r r . Follow the Op. 1088D26 Rigid intake pipe to water pump - r+r for versions with a/c . Follow the Op. 1072B42 Left hand or right hand inlet manifold (one) - r+r . Follow the Op. 1072B12 Intake manifold (one) Ih or rh - r r and replace gasket (right). I.Undo the bolt (1a) and remove the timing side knock sensor (1b). * Complete with Op. 7055B54 Under-engine guard - r r . Connect the negative (-) battery terminal. r*\ ft ft v\ op \ PA (< r r Installation Ig.OTB - mllg.S V/SIfTO VB ttM I Fit the timing side knock sensor and fix it tight¬ ening the bolt to the recommended torque. u Mounting Component 0 Screw TIMING SIDE KNOCK SENSOR M8 Value (daNm) 1.952.05 Complete with Op. 1072B12 Intake manifold (one) Ih or rh - r r and replace gasket (right). Complete with Op. 1072B42 Left hand or right hand inlet manifold (one) - r+r . Complete with Op. 1088D26 Rigid intake pipe to water pump - r+r for versions with a/c . Complete with Op. 7055B39 Front additional wheel arch half (one), Ih or rh, front element - r r. Complete with Op. 1088C36 Thermostat - r +r. Complete with Op. 1088C40 Thermostat- r + r . Complete with Op. 1048B44 Heat exchanger/ manifold pipe - r r Complete with Op. 7040D14 Engine bay rear side cover (one) Ih or rh - r r (left). Complete with Op. 7040D12 Engine front side cover (one) Ih or rh - r r (left). support . 10 PA5106/00 06/1998 REPAIR PROCEDURES Engine ignition 5510 5510D - Spark plugs and lead VIEW OF ASSEMBLY & 1 m Q 2 ms ( ■JO Ref. Description 1 SPARK PLUGS 2 IGNITION HIGH TENSION LEADS Operations index Code Validity Operation 5510D10 Spark plugs - r+r 1 2.0 TS I a.O TB 6M~ IS.5 V6II3.0V6BM I 5510D14 Spark plug cable lead bundle - r+r OPERATIONS I 2.0 TS i 5510D10 - SPARK PLUGS - R + R Removal Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). \Description Data not yet available PA5106/00 06/1998 |g.0TSII3.0TB BMl Follow the Op. 1016A40 Ignition coil cover on cylinder head- r+r . Follow the Op. 5510C14 Ignition coil/s - r+r . Blow through with compressed air in spark plug openings and remove any impurities or traces of dirt. I.With the engine cold, remove the small side spark plugs (1a) and the large centre spark plugs (1b). Connector A01B 11 REPAIR PROCEDURES Engine ignition 5510 i Follow the Op. 1016A30 Left cam cover - r + r and replace gasket . Disconnect the spark plug high tension leads. Note: Use the tool to disconnect the high tension leads from the left cylinder head spark plugs. l I 1a i xK ,+N MW ES S-1 K~i I I 1b i 1i Description Code Pliers 1 .820.636.000 Blow through with compressed air in spark plug openings and remove any impurities or traces of j Check the condition of the spark plugs and, when necessary, replace them. Note: Using different spark plugs from those recommended can cause damage to the engine and alter the exhaust emission levels. Installation Fit the large centre spark plugs and the small side ones tightening them to the recommended dirt. With the engine cold, remove the spark plugs. Check the condition of the spark plugs and, when necessary, replace them. Note: Using different spark plugs from those recommended can cause damage to the engine and alter the exhaust emission levels. Installation SM~ 1 2.0 TB Fit the spark plugs and tighten them to the recommended torque. u Value Mounting torque. U u Mounting Mounting Value (daNm) Component 0 SIDE IGNI¬ TION SPARK PLUG M10 Cylinder head side 1.0 - 1.3 Value (daNm) Component 0 CENTRAL IGNITION SPARK PLUG M14 Cylinder head side 2.3 - 2.8 Complete with Op. 5510C14 Ignition r+r . coil/s - Complete with Op. 1016A40 ignition coil cover on cylinder head- r+r . Connect the negative (-) battery terminal. 1 2.0 TB BM! 5510D10 - SPARK PLUGS - R+R Removal Ig.OTB - CMI Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). IDescription Data not yet available 12 Connector A01B (daNm) Component 0 SPARKPLUGS M14 Cylinder head side 2.1 - 2.6 Connect the high tension leads to the spark plugs. Complete with Op. 1016A30 Left cam cover - r + r and replace gasket . Connect the negative (-) battery terminal. 1 2.5 VB InTb VB 6M I 5510D10 - SPARK PLUGS - R+R Removal Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). \Description Connector Data not yet available A01B Follow the Op. 1016A42 Left hand cylinder head ignition coil cover - r+r . Follow the Op. 5510C16 Left hand cylinder head ignition coil - r+r . Follow the Op. 1048A48 Throttle heater sleeve - rr. Follow the Op. 1072B50 Sleeves connecting air capacity box to inlet manifold is - r+r . Follow the Op. 5510C18 Right hand cylinder head ignition coil - r+r . Blow through with compressed air in spark plug openings and remove any impurities or traces of dirt. PA5106/00 06/1998 r REPAIR PROCEDURES Engine ignition li With the engine cold, remove the spark plugs. Check the condition of the spark plugs and, when necessary, replace them. Using different spark plugs to those Note: recommended can cause damage to the engine and alter the exhaust emission levels. - Installation - Fit the spark plugs and tighten them to the recommended torque. u Mounting Installation la.OTSlfFOTB SM I - - - - la.B VB'inro VB 6M I 5510 - Place the spark plug leads band back in its housing and fix it. Connect the spark plug leads to the spark plugs. Connect the spark plug leads to the ignition coil. Fit the left cylinder head spark plugs cover and secure it using the bolts. Fit the engine oil filler cap. Connect the negative (-) battery terminal. Value (daNm) Component 0 SPARK PLUGS M14 Cylinder head side 2.7 - 3.4 Right hand cylinder head ignition coil - r+r . Complete with Op. 1072B50 Sleeves connecting air capacity box to inlet manifold is Complete with Op. 5510C18 - r+r . Complete with Op. 1048A48 sleeve - r r. Throttle heater Complete with Op. 5510C16 Left hand cylinder head ignition coil - r+r . Complete with Op. 1016A42 Left hand cylinder head ignition coil cover - r+r . Connect the negative (-) battery terminal. I a.o TS l fa.o TB BM i 5510D14 - SPARK PLUG CABLE LEAD BUNDLE - R + R Removal Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. S530B10 Battery - r+r ). \Description Data not yet available Connector A01B Remove the engine oil filler cap. Undo the bolts and remove the left cylinder head spark plugs cover. - Disconnect the spark plug leads from the igni¬ tion coil. - Disconnect the spark plug leads from the igni¬ tion coil. Note: Use the toot to disconnect the spark plug leads from the left cylinder head spark plugs. - - H Description Code Pliers 1.820.636.000 Release the spark plug leads band from the fixings and remove it. PA5106/00 06/1998 13 REPAIR PROCEDURES 5510 Engine ignition r\ r r 14 PA5106/00 06/1998 REPAIR PROCEDURES Engine ignition 5520 Sub-group index - SUB-GROUP GRAPHIC INDEX Assembly drawings index Validity Cmp Description 5520A Ignition switch 5520B Starter motor and components 5520C Cold starting system (diesel engines) SUB-GROUP GRAPHIC INDEX 1 3 c=>, ' W3 a 7l Q. Qj 2 Ref. Description Cmp 1 Ignition switch 5520A 2 Starter motor and components 5520B 3 Cold starting system (diesel engines) 5520C PA5106/00 06/1998 1 REPAIR PROCEDURES Engine ignition 5520 * 5520A - Ignition switch VIEW OF ASSEMBLY c rs x a f\ ' r\ 1 0. < V 2 Ref. Description 1 STARTER SWITCH ASSEMBLY 2 IGNITION KEY BARREL Operations index Code Operation Validity 5520A12 Ignition switch assembly - r r for versions with air bag 5520A14 Ignition key block - r+r OPERATIONS 5520A12 - IGNITION SWITCH ASSEMBLY - R R FOR VERSIONS WITH AIR BAG Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). IDescription Data not yet available Connector A01B Follow the Op. 5580018 Air bag module - r+r . 2 Follow the Op. 7040A26 Steering column trim - r+r . Removal - Closely observe the safety regulations established for this operation. Follow the Op. 4110A11 Steering wheel - r+r for replacement or check for versions with air bag . Follow the Op. 5550A12 Complete stalk unit r+r for versions with air bag . 1. Release the aerial for the electronic key from the ignition switch. 2. Release the electrical wiring from the fixing band and disconnect the electrical connection for the ignition switch. PA5106/00 06/1998 REPAIR PROCEDURES Engine ignition 5520 Complete with Op. 7040A26 Steering column \Description 2 trim - r+r . Complete with Op. 5580C18 Air bag module Connector Data not yet available - r+r . H01 Connect the negative (-) battery terminal. 5520A14 - IGNITION KEY BLOCK - R+R \ □ D \ % 9§a a code. When ordering barrels, observe the special procedure set out in 5580E - Special acces¬ sories. Removal Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op.5530B10 Battery - r+r ). 2 <£> It is not possible to order a single lock barrel or to order barrels simply by using a part n \ Description Connector Data not yet available A01B Follow the Op. 7040A26 Steering column trim 1 1. Undo the fixing bolt (1a) using a suitable punch and remove the complete ignition switch (1b). - - r+r . Release the aerial for the electronic key from the ignition lock barrel. 1. Insert the ignition key and turn it to the ON position. 2. Using a screwdriver, press on the spring clip and remove the ignition lock barrel. // & 1a // "V A r I * \ B ! v\ / Si 1b <£> - Fit the complete ignition switch and fix it using the bolt. Connect the electrical connection for the igni¬ tion switch and fix the electrical wiring with the band. Place the aerial for the electronic key back in the ignition switch. Complete with Op. 5550A12 Complete stalk unit - r+r for versions with air bag . Complete with Op. 4110A11 Steering wheel r+r for replacement or check for versions with air bag . PA5106/00 06/1998 [©J A01B IDescription Connector Starter' motor 1b A20 2. Release the electrical wiring from the band on the starter motor. oA la O 2 (6 p & °////_ \ Installation iA Fit the starter motor and fix it tightening the bolts to the recommended torque. u O r Mounting Component 0 Screw STARTER MOTOR M8 I Value (daNm) 'll Gearbox side 2.32.8 18.0 TB Connect the electrical connections to the starter motor and fix the wiring using the band. Close the protective cover for the electrical connections. PA5106/00 06/1998 m / 6M~1 the bolts (1a) and remove the starter bracket (1c). 2. Remove the spacer. I.Undo motor (1b), complete with 5 REPAIR PROCEDURES Engine ignition 5520 o ic \\ T ©.% IDescription Connector A01B Data not yet available 1. Disconnect the oil vapour recirculation pipe from the separator. 2. Undo the nuts (2a) and move the oil vapour separator (2b) away from the air chamber. 3. Recover the bracket. l l l 2b 3 'A 2 v\N 1a 1c 1b 2a v\ V Installation 1 la.OTB BM i - Fit the starter motor, complete with spacer and bracket, and fix it tightening the bolts to the recommended torque. u Value Mounting Component 0 Screw STARTER MOTOR M8 - Fix (daNm) Gearbox side 1.82.2 the electrical wiring to the band on the starter motor. - Connect the electrical connections to the starter and fix them using the nuts. Complete with Op. 1072C34 R/h exhaust mani¬ fold - r + r and replace seal . Complete with Op. 1064A44 Left hand or right hand sleeve (one) joining left hand or right hand cylinder head to turbocharger - r+r (right). Complete with Op. 1076B70 Exhaust pipe between pre-catalytic converter and catalytic converter - r r . Complete with Op. 7055B54 Under-engine guard - r r . Connect the negative (-) battery terminal. motor - m ia.4jTP8»«1 Undo the upper two starter motor fixing bolts. Follow the Op. 7055B54 Under-engine guard rr. Follow the Op. 1084A16 Oil dip stick pipe - r r . Follow the Op. 1076B50 Exhaust pipe attach¬ ment to engine - r + r . 1. Disconnect the electrical connections from the starter motor. IPescription 1 Starter' motor Connector A20 2. Undo the lower fixing bolt (2a) and remove the starter motor (2b). IS.4 JTDBMI 5520B12 - STARTER MOTOR R + R FOR VERSIONS WITH A/C Removal 18.4 JTPSMI - Place the vehicle on a ramp. Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). r*\ 6 PA5106/00 06/1998 REPAIR PROCEDURES Engine ignition ± }Dÿ <8> © 5520 12.5 V6|[X0V6BM I 5520B12 - STARTER MOTOR R+R FOR VERSIONS WITH A/C Removal © ig.svBilaoveeMi [rlS - Place the vehicle on a ramp. Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op.5530B10 Battery - r+r ). 1 mg tV-cci i IDescription Connector Data not yet available D 'sr (c- 2a 2b Installation ia.4 JTDBMI Fit the starter motor and fix it tightening the lower bolt to the recommended torque. u Value (daNm) Mounting Component 0 Screw STARTER MOTOR M8 Gearbox side 2.32.8 Connect the electrical connections to the starter motor. Complete with Op. 1076B50 Exhaust pipe attachment to engine - r + r . Complete with Op. 1084A16 Oil dip stick pipe - r r. Follow the Op. 7055B54 Under-engine guard r r. Follow the Op. 1076B52 Exhaust pipe (one) leaving l/h or r/h exhaust manifold -r + r (right and left). Follow the Op. 1084B30 Cartridge engine oil filter support - r + r . Follow the Op. 4450B10 Front or rear wheel (one) - r+r (right). Follow the Op. 7055B42 Supplementary wheel arch (one) - r+r (right). Follow the Op. 1092G10 Single engine belt r r . Follow the Op. 1092G20 Engine component single belt fixed tensioner - one - r + r . Follow the Op. 5530A14 Alternator - r+r for versions with air conditioner . Follow the Op. 1072C34 R/h exhaust manifold -r + r and replace seal . Release the electrical wiring from the starter motor rear mounting bracket. Undo the fixings and remove the starter motor rear mounting bracket. I.Undo the nuts (1a) and disconnect the elec¬ trical connections (1b) from the stater motor. Under-engine Complete with Op. 7055B54 guard - r r . IDescription Tighten the upper two bolts fixing the starter motor to the recommended torque. u A01B Mounting Component 0 Screw STARTER MOTOR M8 1b Value (daNm) Gearbox side 2.32.8 Place the vapour separator, complete with bracket, back in its housing and fix it to the air chamber. Connect the oil vapour recirculation pipe to the Connector Starter’ motor A20 2. Release the electrical wiring from the band on the starter motor. 2 MM#o <6 A \ r IU/ O separator. Connect the negative (-) battery terminal. Remove the vehicle from the ramp. % liS> I Vh PA5106/00 06/1998 I WrawHiKfiOW _ etflatAip 7 REPAIR PROCEDURES Engine ignition 5520 to IB.5 VBII3.QVB BM I the bolts (1a) and remove the starter I.Undo motor (1b), complete with bracket (1c). 2. Remove the spacer. o T & ©% A> i i © i \ tyfR v\ '1c 2 1a 1b Installation la.svBiia.otfBBMi - Fit the starter motor, complete with spacer and bracket, and fix it tightening the bolts to the recommended torque. u Mounting Component 0 Screw STARTER MOTOR M8 Value (daNm) Gearbox side 1 .8 2.2 Fix the electrical wiring to the band on the starter motor. Connect the electrical connections to the starter motor and fix them using the nuts. Fit the starter motor rear mounting bracket. Fix the electrical wiring to the starter motor rear mounting bracket. Complete with Op. 1072C34 R/h exhaust mani¬ fold - r + r and replace seal . Complete with Op. 5530A14 Alternator - r+r for versions with air conditioner . Complete with Op. 1092G20 Engine compo¬ nent single belt fixed tensioner - one - r + r . Complete with Op. 1092G10 Single engine belt rr. Complete with Op. 7055B42 Supplementary wheel arch (one) - r+r (right). Complete with Op. 4450B10 Front or rear wheel (one) - r+r (right). Complete with Op. 1084B30 Cartridge engine oil filter support - r + r . Complete with Op. 1076B52 Exhaust pipe (one) leaving l/h or r/h exhaust manifold - r + r (right and left). Complete with Op. 7055B54 Under-engine guard - r r . Connect the negative (-) battery terminal. 8 o PA5106/00 06/1998 REPAIR PROCEDURES Engine ignition & 5520 5520C - Cold starting system (diesel engines) VIEW OF ASSEMBLY \ \ 1 II vQ te \ o .© \0. Ref. Description 1 GLOW PLUGS Operations index Code Validity Operation 5520C10 Glow plugs - r+r I2.4 JTDflMl OPERATIONS 4. Disconnect the electrical leads from the heater plugs. ia.4 JTDBMI 5520C10 - GLOW PLUGS - R + R IDescription 4 Removal |g.4JTP6Ml Heater plugs Connector A40 5. Undo and remove the heater plugs. Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). \Description Data not yet available Connector A01B 1. Undo the nuts (1a) and move the fuel filter (1b) away from the air chamber. 2. Undo the nuts (2a) and move the oil vapour separator (2b) away from the air chamber. 3. Undo the bolts (3a) and move the fuel return manifold pipe (3b) aside. PA5106/00 06/1998 9 REPAIR PROCEDURES Engine ignition 5520 1b 1a & 2a ".5 *ZS 3a w(I K- 'll" 2b > Co 3b \ i \ Installation 18.4 JTOBMI Fit the heater plugs and tighten them to the recommended torque. u Mounting Value (daNm) Component 0 GLOW PLUGS M12 1.3 - 1.6 Connect the electrical connections to the heater plugs. Place the fuel return manifold pipe back in its housing and fix it to the air chamber using the bolts. Place the oil vapour separator back in its housing and fix it to the air chamber using the nuts. Place the fuel filter back in its housing and fix it to the air chamber using the nuts. 10 PA5106/00 06/1998 REPAIR PROCEDURES Current generation lighting if 5530 Sub-group index - SUB-GROUP GRAPHIC INDEX Assembly drawings index Validity Cmp Description 5530A Alternator and components 5530B Battery and leads SUB-GROUP GRAPHIC INDEX 2 1 % 4 £ i\ % e. CD, \ Q <2, r*\ Ref. Description Cmp 1 Alternator and components 5530A 2 Battery and leads 5530B PA5106/00 06/1998 1 REPAIR PROCEDURES Current generation lighting 5530 5530A - Alternator and components VIEW OF ASSEMBLY □ i 3 QQ Q r*\ / <07 , a T'T' -C] 7Sc A0 // k. £5 1 mm [A 2 k\ rfciemwii'M.t;/ Ref. Description 1 ALTERNATOR ASSEMBLY 2 ALTERNATOR BRACKETS 3 ALTERNATOR SUPPORT Operations index Code Operation 5530A14 Alternator - r+r for versions with air conditioner Validity 1 2.0 TS I l a.4 JTDBMI 1 5.0 TB BMlia.5V6ir3ÿV6 6M I 5530A40 Alternator brackets/mount/spacer - r r 2 la.5VSll3.0VBBM I PA5106/00 06/1998 REPAIR PROCEDURES Current generation lighting /ÿ—s OPERATIONS U 1 2.0 TS I 5530A14 - ALTERNATOR - R + R FOR VERSIONS WITH AIR CONDITIONER 5530 Value (daNm) Mounting Component 0 Bolt ALTERNATOR ASSEMBLY M12 Mountin g bracket side 7.79.5 Removal Connect the electrical connections to the alter¬ nator and fix them using the nuts. Complete with Op. 1092G10 Single engine belt r r. Complete with Op. 7055B42 Supplementary Place the vehicle on a ramp. Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). \Description wheel arch (one) - r+r (right). Complete with Op. 4450B10 Front or rear wheel (one) - r+r (right). Complete with Op. 7040D14 Engine bay rear side cover (one) Ih or rh - r r (right). Complete with Op. 7040D12 Engine front side cover (one) Ih or rh - r r (right). Connect the negative (-) battery terminal. Remove the vehicle from the ramp. Connector Data not yet available A01B Follow the Op. 7040D12 Engine front side cover (one) Ih or rh - r r (right). Follow the Op. 7040D14 Engine bay rear side cover (one) Ih or rh - r r (right). Follow the Op. 4450B10 Front or rear wheel (one) - r+r (right). Follow the Op. 7055B42 Supplementary wheel arch (one) - r+r (right). Follow the Op. 1092G10 Single engine belt r r . Disconnect the electrical connections from the alternator. I.Undo the bolts (1a) and remove the alternator (1b). - i a.4 JTDBMI 5530A14 - ALTERNATOR - R + R FOR VERSIONS WITH AIR CONDITIONER Removal 1 2.4 JTPSMI - \. Place the vehicle on a ramp. Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op.5530B10 Battery - r+r ). O 1a © ,0 / iDescription m Data not yet available N '&& m&i c. (5n„ .all v1b V/ Installation Fit the alternator and fix it tightening the bolts to the recommended torque. u Mounting Component 0 Bolt ALTERNATOR ASSEMBLY M10 Value (daNm) Mountin 9 bracket side 6.07.4 PA5106/00 06! 1998 Connector A01B Follow the Op. 7040D12 Engine front side cover (one) Ih or rh - r r (right). Follow the Op. 7040D14 Engine bay rear side cover (one) Ih or rh - r r (right). Follow the Op. 7055B54 Under-engine guard rr. Follow the Op. 1084A16 Oil dip stick pipe - r r . Follow the Op. 4450BIO Front or rear wheel (one) - r+r (right). Follow the Op. 7055B42 Supplementary wheel arch (one) - r+r (right). Follow the Op. 1092G10 Single engine belt r r . I.Open the plastic protection, undo the nuts (1a) and disconnect the electrical connections (1b) and (1c). IDescription 1b Alternator Connector A10A 3 REPAIR PROCEDURES Current generation lighting 5530 . IDescription 1c Complete with Op. 1092G10 Single engine belt rr Complete with Op. 7055B42 Supplementary wheel arch (one) - r+r (right). Complete with Op. 4450B10 Front or rear wheel (one) - r+r (right). Complete with Op. 1084A16 Oil dip stick pipe rr. Complete with Op. 7055B54 Under-engine guard - r r . Complete with Op. 7040D14 Engine bay rear side cover (one) Ih or rh - r r (right). Complete with Op. 7040D12 Engine front side cover (one) Ih or rh - r r (right). Connect the negative (-) battery terminal. Remove the vehicle from the ramp. Connector Alternator A10B 2. Undo the lower alternator fixing bolt. 3. Undo the bolt (3a) and remove the lower alter¬ nator mounting bracket (3b). 4. Undo the upper alternator fixing bolt. 5. Undo the bolt (5a) and remove the upper alter¬ nator mounting bracket (5b). 6. Remove the alternator. H1b 4 • - \ 5b 5a \ $4ÿ sj I 1®< la.OTB 0M ||2.5 V6inro V6 BM I 5530A14 - ALTERNATOR - R + R FOR VERSIONS WITH AIR CONDITIONER Removal vj la.OTB 8mHZ.5VBII3.0'/BbmI 5? Place the vehicle on a ramp. Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). - 3a - 2 \ i LA!i i \Dascription 3b 1c Installation 1 2.4 JTPSMI Place the alternator back in its housing. Fit the upper alternator mounting bracket and fix it using the bolt. Fit the lower alternator mounting bracket and fix it using the bolt. Tighten the alternator fixing bolts to the recom¬ mended torque. u U Value (daNm) Mounting Component 0 Bolt ALTERNATOR ASSEMBLY M10 Mountin 9 bracket side 4.35.3 Data not yet available Connector A01B Follow the Op. 7055B54 Under-engine guard rr. Follow the Op. 1084B30 Cartridge engine oil filter support - r + r . Follow the Op. 4450B10 Front or rear wheel (one) - r+r (right). Follow the Op. 7055B42 Supplementary wheel arch (one) - r+r (right). Follow the Op. 1092G10 Single engine belt r r . Follow the Op. 1092G20 Engine component single belt fixed tensioner - one - r + r . I.Undo the nut (1a) and disconnect the right power steering box rod (1b) from the front vertical link using the tool (1c). n 1c Description Code Extractor 1.821.169.000 Value (daNm) Mounting Component 0 Bolt ALTERNATOR ASSEMBLY M12 Mountin g bracket side 6.07.4 Connect the electrical connections to the alter¬ fix them using the nuts. nator and 4 PA5106/00 06/1998 REPAIR PROCEDURES Current generation lighting IV l \ i /I 1b 5530 Description Connector Alternator A10A 1b / IDescription — // J3§ a \ m Q a SB 6M I Connector A10B Alternator 1c 2. Undo the bolts (2a) and remove the alternator (2b). 0 a 1a d1c la.OTB ( / 1b / 1c II 1 12.5 VSireÿVB BM I 1. Release the A.B.S. sensor cable from the mounting bracket. 2. Undo the bolt (2a) and remove the A.B.S. cable mounting bracket (2b). 3. Undo the nut (3a) and move the front right anti-roll bar joint (3b) aside. §1ÿ *3 (Q \\ 2a ,Vjl 3TTTT ,«> 4 utinctit I8.0TB 8Mllg.SV6ir370V6wl 1. Fit the alternator (1a) and fix it tightening the bolts (1b) to the recommended torque. %04 Y •)IMounting / 1b 0 Q Q Q 1* ss a \ _ (' no'/H« 3a la.otB r*,niiniruvn-t>u Installation & 3b 2b ft 2a //2b m O' Q \\ Q Bolt Value Component 0 ALTERNATOR ASSEMBLY M8 (daNm) Mountin g bracket side 1 .9 2.3 <9; k 2. Connect the electrical connections (2a) to the alternator and fix them using the nuts (2b). Fit the plastic protection. naoonn/>MYt4"iu A ut went BMlla.s VBIIB.O VB BM I 1. Remove the plastic protection, undo the nuts (1a), then disconnect the electrical connections (1b) and (1c) from the alternator. PA5 106/00 06/1998 5 REPAIR PROCEDURES Current generation lighting 5530 X o >5 // 3 2bZ/2a A 2a l % o o /, ( [JJM Q jHS £ Sift y' /£ÿJ\ V O' O' Q l( e fws » B1b Wl/Zic \ 1a vfi a I8.0TB 8Ml|g.5VBirÿOV6 6Ml 1. Place the right front anti-roll bar joint (1a) back in its housing and fix it tightening the nut (1b) to the recommended torque. B 1b Value (daNm) Mounting Component 0 Nut FRONT ANTI¬ ROLL BAR JOINTS M10 Shock absorber fork side 3.8 - 4.7 2. Fit the A.B.S. cable mounting bracket (2a) and fix it using the bolt (2b). 3. Fix the A.B.S. sensor cable to the mounting bracket. 1a { §riibB la.OTB SMllg.5 VEinTOVE BM I Connect the right power steering box rod to the front vertical link and fix it tightening the nut to the recommended torque. B Value (daNm) Mounting Component 0 Nut ADJUSTABLE STEERING LINKS M10 Front wheel steering knuckle side 4.3 4.7 Complete with Op. 1092G20 Engine compo¬ nent single belt fixed tensioner - one - r + r . Complete with Op. 1092G10 Single engine belt r r. Complete with Op. 7055B42 Supplementary wheel arch (one) - r+r (right). Complete with Op. 4450B10 Front or rear wheel (one) - r+r (right). Complete with Op. 1084B30 Cartridge engine oil filter support - r + r . Complete with Op. 7055B54 Under-engine guard - r r . Connect the negative (-) battery terminal. Remove the vehicle from the ramp. 6 PA5106/00 06/1998 REPAIR PROCEDURES Current generation lighting & 5530 1 5.5 VB inn! V6 BM I 12.5 VBirsToVBBM 1. Undo the bolts (1a) and remove the alternator mounting (1b). 5530A40 - ALTERNATOR BRACKETS/MOUNT/SPACER - R R // Removal Follow the Op. 7055B54 Under-engine guard rr. Follow the Op. 1084B30 Cartridge engine oil filter support - r + r . Follow the Op. 4450B10 Front or rear wheel (one) - r+r (right). Follow the Op. 7055B42 Supplementary wheel arch (one) - r+r (right). Follow the Op. 1092G10 Single engine belt r r . Follow the Op. 1092G20 Engine component single belt fixed tensioner - one - r + r . Follow the Op. 5530A14 Alternator - r+r for versions with air conditioner . Undo the bolts fixing the timing belt cover to the alternator bracket/spacer. I.Undo the bolts (1a) and remove the alternator bracket/spacer (1b). 0 o' / U W/ a L u 0 1b m U r HR a Q Q Q Q r. ‘tc; Q Q O' \\ QJ K 1a Fit the alternator mounting and fix it using the bolts. Fit the alternator bracket/spacer and fix it using the bolts. Tighten the bolts fixing the timing belt cover to the alternator bracket/spacer. Complete with Op. 5530A14 Alternator - r+r for versions with air conditioner . Complete with Op. 1092G20 Engine compo¬ nent single belt fixed tensioner - one - r + r . Complete with Op. 1092G10 Single engine belt rr. Q 1b ), la.5VBinT0VB6Ml // 0 ) o Installation X Jl o' 1a PA5106/00 06/1998 w Q Q Q r ,‘AC Q —Qy N Gy K 7 Complete with Op. 705SB42 Supplementary wheel arch (one) - r+r (right). Complete with Op. 4450B10 Front or rear wheel (one) - r+r (right). Complete with Op. 1084B30 Cartridge engine oil filter support - r + r . Complete with Op. 7055B54 Under-engine guard - r r . 7 REPAIR PROCEDURES Current generation lighting 5530 & 5530B - Battery and leads VIEW OF ASSEMBLY 1 3 l- xT' \ \ ) o 2 \\ \ I u ,/ a 2 Ref. Description 1 BATTERY 2 BATTERY SUPPORT/CAGE 3 BATTERY COVER r*\ Operations index Code Validity Operation 5530B10 Battery - r+r 5530B52 Battery cradle - r r 5530B54 Battery cover - r+r OPERATIONS 1. Disconnect the battery negative and positive terminals. 5530B10 - BATTERY - R + R \Description Removal - 8 Follow the Op. 5530B54 Battery cover - r+r . Make sure that the ignition key is in the OFF position. 1 Data not yet available Connector A01B PA5106/00 06/1998 REPAIR PROCEDURES Current generation lighting $ 5530 ■ I.Undo the bolts (1a) and remove the battery cage (1b). IDescription 1 Connector Data not yet available A01 A 1b 2. Undo the bolt (2a) fixing the battery retaining bracket (2b). 3. Remove the battery. H1, -1a jTfC*) 1a 3 2a \ 2b Installation - - Fit the battery cage and fix it using the bolts. Fit the battery fluid collection reservoir. Complete with Op. 5530B10 Battery - r+r . Complete with Op. 5530B54 Battery cover - r+r Installation 5530B54 - BATTERY COVER R +R - Removal - Place the battery back in its housing. Fix the battery with the bracket and tighten the fixing bolt. Connect the negative and positive terminals to the battery. Complete with Op. 5530B54 Battery cover - r+r 1. Working in the luggage compartment, undo the knob for the battery cover. 2. Remove the battery cover. o' 5530B52 - BATTERY CRADLE R R Removal Follow the Op. 5530B54 Battery cover - r+r . Follow the Op. 5530B10 Battery - r+r . 1 2 1. Remove the battery fluid collection reservoir. c CsD 1 Installation - PA5106/00 06/1998 Fit the battery cover and fix it using the knob. 9 REPAIR PROCEDURES 5530 Current generation lighting A r*s r 10 PA5106/00 06/1998 REPAIR PROCEDURES Exterior lighting li Wi 5540 Sub-group index - SUB-GROUP GRAPHIC INDEX Assembly drawings index Validity Cmp Description 5540A Lighting 5540B Headlamps 5540C Headlamp/light cluster alignment correction devices 5540D Fog lamps SUB-GROUP GRAPHIC INDEX 1 3 >1 ) I n•I 0 L V i ■3 3 3 3 1 < 2 4 Ref. Description Cmp 1 Lighting 5540A 2 Headlamps 5540B 3 Headlamp/light cluster alignment correction devices 5540C 4 Fog lamps 5540D PA5106/00 06/1998 1 REPAIR PROCEDURES Exterior lighting 5540 t 1V I Wi 5540A - Lighting VIEW OF ASSEMBLY 9 8 fm JpMgsQ V \VS 6 5 7 i ) 0 \ 8i -v, ii a \ U I i 10 1 3 2 4 v !*ÿ/!// Ref. Description 1 EXTERNAL LIGHT SWITCH 2 OUTER TAIL-LIGHT 3 OUTER TAIL-LIGHT 5 REAR FOG LAMP BULB 6 REAR SIDELIGHT BULB 7 REVERSING LIGHT BULB 8 REAR SIDELIGHT BULB 9 BRAKE LIGHT BULB 10 NUMBER PATE LIGHT Operations index Code Operation 5540A22 Exterior lighting control switch - r+r 2 Validity [C=3) PA5106/00 06/1998 r __ Code REPAIR PROCEDURES Exterior lighting 5540 Validity Operation 5540A56 Dipped/main beam electrical wiring - check compo¬ nent operation, line continuity and repair contacts includes relay replacement if necessary _ 5540A58 Outer tail lights with integral turns signal unit (1) Ih or rh - r r 5540A68 L/h or r/h interior tail light (one) - r+r 5540A74 Bulb of a sidelight or fog lamp or reversing light in a _ tail-light. Ih or rh r r _ 5540A80 Rear exterior lightbulb 5540A94 -rr L/h or r/h number plate light (one) - r+r OPERATIONS 5540A22 - EXTERIOR LIGHTING CONTROL SWITCH - R+R Removal - "V // j> Ensure that the ignition key is in stop position, then disconnect the battery negative terminal & Ml / \Description Data not yet available Connector A1B \ I.Undo the bolt (1b) and open the fuse access cover (1b). 2. Remove the complete exterior light switch (2a) from its housing using the tool (2b). Note: Exert pressure inside the exterior lights switch to facilitate its removal. n BBJDescription 2b Blade 3a 1a Connector - IDescription 3c Connector - Data not yet available At the bench, remove the headlamp alignment switch and the instrument panel light dimmer. Installation - Place the instrument panel light dimmer and the 3b M 1.823.014.000 Data not yet available \Description 'r Code 3. Disconnect the electrical connections (3a), (3b) and (3c) and remove the exterior lights switch (3d). IDescription > S- 1b B |2b/7 headlamp alignment switch back in their hous¬ ings. Connect the electrical connections, then place the complete exterior lights switch back in its housing. Close the fuse access cover and secure using the appropriate bolt. Connect the negative (-) battery terminal. Connector Data not yet available PA5106/00 06/1998 3 REPAIR PROCEDURES Exterior lighting 5540 & 5540A56 - DIPPED/MAIN BEAM ELECTRICAL WIRING - CHECK COMPONENT OPERATION, LINE CONTINUITY AND REPAIR CONTACTS - INCLUDES RELAY REPLACEMENT IF NECESSARY / 2a ,2b ) Removal - Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). IDescription UES Connector Data not yet available 2a A01B 1 I.Undo the knob (1b) and open the protective cover (1a). r*\ Installation - o ? 1b Place the outer rear light cluster back in its housing and fix it using the nuts. Connect the electrical connections to the outer rear light cluster. Close the protective cover and fix it using the - knob. Connect the negative (-) battery terminal. 5540A58 - OUTER TAIL LIGHTS WITH INTEGRAL TURNS SIGNAL UNIT (1) LH OR RH - R R 1a Refer to op.. 5540A56 Dipped/main beam elec¬ trical wiring - check component operation, line continuity and repair contacts - includes relay replacement if necessary . 1. Disconnect the electrical connections from the rear light cluster. \Description 1 Rear left light cluster Connector F30 5540A68 - L/H OR R/H INTE¬ RIOR TAIL LIGHT (ONE) - R + R Removal IDescription 1 Rear right light cluster Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). Connector F31 2. Undo the nuts (2a) and remove the outer rear light cluster (2b). IDescription Connector Data not yet available A01B 1. Undo the fixing knob (1b) and open the access cover (1a) . 2. Disconnect the electrical connection from the inner rear light cluster. IDescription 2 4 Connector Right rear light cluster (moving part on boot lid) F35 PA5106/00 06/1998 REPAIR PROCEDURES Exterior lighting & r*\ 2 IPascription Connector Right rear light cluster (moving part on boot lid) F36 5540 3. Replace the rear fog lamps bulb (3a) or the reversing lights bulb (3b) or the side lights bulb (3c). 3a 3b 3. Undo the nuts (3a) and remove the inner rear light cluster (3b). □i O 1 3c 1b 1a Q 2b o 2a 2 3bx\ Installation - - - 5540A80 - REAR EXTERIOR LIGHTBULB - R R 3a Removal - Installation - Place the bulb holder back in its housing and fix it using the retaining tabs. Close the access cover and fix it using the knob. Connect the negative (-) battery terminal. Place the inner rear light cluster back in its housing and fix it using the nuts. Connect the electrical connection to the inner rear light cluster. Close the access cover and fix it using the knob. Connect the negative (-) battery terminal. 5540A74 - BULB OF A SIDE¬ LIGHT OR FOG LAMP OR REVERSING LIGHT IN A TAILLIGHT, LH OR RH R R Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). {Description Connector Data not yet available A01B I.Open the protective cover (1a) after having undone the fixing knob (1b). Removal - Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). {Description Connector Data not yet available A01B I.Open the access cover after having undone the fixing knob. 2. Release the retaining tabs (2a) and extract the bulb holder (2b) from its housing. PA5106/00 06/1998 ? D 1b 1a \ 1. Disconnect the electrical connection (1a) and remove the bulb holder (1b). 5 REPAIR PROCEDURES Exterior lighting 5540 IDescription 1a 1a & Connector IDescription Rear left light cluster F30 Left number plate light \Description Connector Rear right light cluster 2 Connector Connector \Description F31 Right number plate light 2 F50 F51 2. Replace the side/brake lights bulb. 1aQ 1b mam ®B f <& \ ¥ u 2 1b 1.To replace the bulb, rotate the bulb holder (1a) in an anti-clockwise direction, take it out and remove the bulb (1b) which is a press fit. Installation Place the bulb holder back in its housing. Connect the electrical connection. Close the protective cover and secure it using the knob. Connect the negative (-) battery terminal. - - - a 5540A94 - L/H OR R/H NUMBER PLATE LIGHT (ONE) - R + R 1b 1a Removal - Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). Installation - IDescription Data not yet available - Connector A01B Fit the bulb complete with bulb holder. Connect the electrical connection to the number plate light and place it back in its housing. Connect the negative (-) battery terminal. 1. Using the tool (1a), remove the complete number plate light (1b). 1a Description Code Blade 1.823.014.000 2. Disconnect the electrical connection remove the number plate light. 6 and PA5106/00 06/1998 o REPAIR PROCEDURES Exterior lighting 5540 5540B - Headlamps VIEW OF ASSEMBLY 3 1 <\ & m 4 —9W* Q. 5 2 Ref. Description 1 LIGHT CLUSTER 2 LIGHT CLUSTER LENS 3 HEADLAMP/ LIGHT CLUSTER BULB 4 HEAD LAMP/ LIGHT CLUSTER SIDELIGHT BULB 5 HDLMP/LIGHT CLUSTER SIDELIGHT BLB HOLDER Operations index Code Operation 5540B16 Front headlight unit with turn signal (1), Ih or rh - r r 5540B22 L/h or r/h headlamp/light cluster bulb (one) - r+r Validity 5540B26 Bulb (one) for side lights of one headlamp/light _cluster, l/h or r/h - r+r _ 5540B38 Headlamp/light cluster light beam - position PA5106/00 06/1998 7 REPAIR PROCEDURES Exterior lighting 5540 * OPERATIONS 5540B16 - FRONT HEADLIGHT UNIT WITH TURN SIGNAL (1 ), LH OR RH - R R Removal - IDescription Connector Data not yet available N30 3a Place the vehicle on a ramp. Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). IDescription Connector Data not yet available 3a N31 IDescription \Description Connector Data not yet available A01B 3b Follow the Op. 7055B42 Supplementary wheel arch (one) - r+r . Follow the Op. 7055A43 Central front grille - r r. Follow the Op. 7055A41 Front grille(one) - r r I.Undo the lower bolts fixing the bumper to the lower radiator crossmember. 2. Unscrew the bolts retaining the bumper to the body. 3. Unscrew the upper bolts securing the bumper to the body. . Connector Left headlamp F10 IDescription Connector Right headlamp F11 3b rs 4. Remove the front light cluster with the direction indicator. 3a A', Jt 3 \ am JL 3b a — 7 / D N / fU /II 2i 1 I 1. Move the front bumper aside, as necessary, to gain access to the light cluster bolts. 2. Undo the bolt and the nuts and move the light cluster aside, as necessary. 3. Disconnect the electrical connections (3a) and (3b). 8 2 y 2 4 <~S 2 1 *ÿ etmtvei* Installation - - Place the front light cluster with the direction indicator back in its housing, align it with the wing and fix it using the nuts and the bolt. Connect the electrical connections. Place the front bumper back in its housing and fix it using the bolts. Complete with Op. 7055A41 Front grille (one) rr. Complete with Op. 7055A43 Central front grille - r r. Complete with Op. 7055B42 Supplementary wheel arch (one) - r+r . Connect the negative (-) battery terminal. Remove the vehicle from the ramp. PA5106/00 06/1998 REPAIR PROCEDURES m Exterior lighting 5540B22 - L/H OR R/H HEAD¬ LAMP/LIGHT CLUSTER BULB (ONE) - R+R Removal Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). - \ Description Connector Data not yet available A01B 1. Release the spring clip (1a) and remove the protective cover (1b). 2. Disconnect the electrical connection from the lamp. Place the lamp back in its housing so that the references on the actual lamp line up with those on the bulb holder. Attach the lamp spring clip. Connect the electrical connection to the lamp. Fit the protective cover and fix it using the spring clip. - 5540B26 - BULB (ONE) FOR SIDE LIGHTS OF ONE HEAD¬ LAMP/LIGHT CLUSTER, L/H OR R/H - R + R Removal Make sure that the ignition is in the OFF posi¬ - tion, then disconnect the negative battery terminal (refer to op.5530B10 Battery - r+r ). tDescription F10 Left headlamp IDescription 2 Installation Connector tDescription 2 5540 Data not yet available Connector Right headlamp F11 Connector A01B 1 . Rotate the bulb holder (1 a) in an anti-clockwise direction until it is released from the light cluster (1b). 2. Disconnect the electrical connection (2a) and take out the bulb holder. 3. Release the spring clip (3a) and remove the lamp (3b) from the light cluster. Note: If the lamp is working properly, avoid touching the bulb with your hands.lf this does happen, dean the bulb with alcohol. tDescription 2 IDescription f 2 1ÿ 1b 3 1a Right headlamp AJ Left headlamp Connector F11 Connector F10 3. Separate the lamp from the bulb holder (press fit). Note: if the lamp is working properly, avoid touching the bulb with your hands.lf this does happen, dean the bulb with alcohol. -3a 3b 1a □2 1b PA5106/00 06/1998 9 REPAIR PROCEDURES m Exterior lighting 5540 hiJ 3 S' HC 1b J m/t C r, B \r=5 h \ Prepare the vehicle complete with spare wheel, tools, fluids, fuel reserve. Check that the tyre inflation pressure is correct. Set the headlamp alignment switch in position "0". Position the vehicle on a flat surface, perpendic¬ ular to a screen with an opaque surface, 10 metres away, which contains the following - c \ 2 m O D 5540B38 - HEADLAMP/LIGHT CLUSTER LIGHT BEAM - POSI¬ TION - AC 15V \ 2 Fit the lamp in the bulb holder. Connect the electrical connection to the bulb holder. Place the bulb holder back in its housing and rotate in an anti-clockwise direction until it is fixed in the light cluster. Connect the negative (-) battery terminal. - L2 'll Installation - / 3 1a HC 15V 2 \ - 'JO. AC_ //////////////z z/ÿZ&ffiz/zX// V////////////Z 4 % 5 c Switch on the dipped headlamps. 1. Vertical alignment. Adjust the light cluster's vertical adjustment screw so that the horizontal section of the demarcation line between the area which is dark and the area which is lit up by the light beam coincides with the line AC - AC on the screen. 2. Horizontal alignment. Adjust the light cluster's horizontal adjustment screw so that the point where the two horizontal and inclined demarcation lines intersect coincides with the point where lines C - C and AC - AC inter¬ sect on the screen. - 2 1 v, V, © lines. 1 . V - V: vertical line corresponding to the trace of the plane of symmetry of the vehicle. 2.C - C: traces of the vertical planes passing through the reference centres of the light clus¬ ters. 3. HC - HC: horizontal line corresponding to the height from the ground of the reference centres for the light clusters. 4. AC - AC: horizontal line 11 cm below the HC HC line. 5. Lines inclined at 15° as illustrated in the El % diagram. 10 PA5106/00 06/1998 REPAIR PROCEDURES Exterior lighting * 5540 5540C - Headlamp/light cluster alignment correction devices VIEW OF ASSEMBLY 1 f/ 2 r J. m I T $ $ V I Ref. Description 1 HDLMP/LIGHT CLUSTER RIDE SWITCH 2 HDLMP/LIGHT CLUSTER RIDE MOTOR Operations index r*\ Code Validity Operation 5540C18 Headlamp/light cluster alignment correction motor switch - r+r 5540C24 Motor (one) for l/h or r/h headlamp/light cluster align¬ ment correction - r+r OPERATIONS 5540C18 - HEADLAMP/LIGHT CLUSTER ALIGNMENT CORRECTION MOTOR SWITCH - R+R Removal - Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op.5530B10 Battery - r+r ). PA5106/00 06/1998 {Description Data not yet available - Connector A01B Open the fuse carrier compartment flap. 1. Using the tool (1a) and pushing the fuse carrier compartment, remove the surround (1b) complete with switches. □ 1a Description Code Blade 1.823.014.000 11 REPAIR PROCEDURES 5540 2. Disconnect the electrical connections (2a), (2b) and (2c) and remove the surround complete with switches. IDescription 2a Connector Data not yet available H10 \Description 2b Connector Data not yet available Fit the surround, complete with switches, in the housing. Close the fuse carrier compartment flap. Connect the negative (-) battery terminal. Removal H10 \Description Connector Data not yet available H10 Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op.5530B10 Battery - r+r ). \Description Connector A01B Data not yet available um 1. Disconnect the electrical connection from the headlamp alignment adjustment motor. 2b 2c \Description 1 □ 1a 2a Connector N30 Data not yet available IDescription 1 Connector N31 Data not yet available 2. For the left light cluster alignment motor only, open the spring clip (2a) and remove the main beam headlamp bulb protective cover (2b). 3. Rotate the light cluster alignment motor in a clockwise direction and remove it. 1b uuiftiMrwai/ *ÿ . ciatoteip 1. Remove the light cluster alignment motor switch, releasing the fixing tabs. Q •1a //) & \ 2b 2a 1 3 1b Q A Installation - 12 /—N 5540C24 - MOTOR (ONE) FOR L/H OR R/H HEADLAMP/LIGHT CLUSTER ALIGNMENT CORRECTION - R+R - 2c m Exterior lighting Fit the light cluster alignment motor switch in the housing in the surround. Connect the electrical connections. $ K \ PA5106/00 06/1998 r\ r-*\ m REPAIR PROCEDURES Exterior lighting 5540 Installation - - - Place the light cluster alignment motor in its housing, check that the pin is correctly attached to the parabola, then rotate the motor in an anti¬ clockwise direction to secure it. For the left light cluster alignment motor, fit the main beam headlamp bulb protective cover and fix it using the spring clip. Connect the negative (-) terminal to the battery. PA5106/00 06/1998 13 REPAIR PROCEDURES 5540 m Exterior lighting 5540D - Fog lamps VIEW OF ASSEMBLY ' aa % Ref. Description 1 FOG LAMP 1 Operations index Code Operation Validity 5540D10 L/h or r/h fog lamp (one) - r+r OPERATIONS 5540D10 - L/H OR R/H FOG LAMP (ONE) - R + R Removal - - Follow the Op. 7055B39 Front additional wheel arch half (one), Ih or rh, front element - r r . Follow the Op. 7055A43 Central front grille - r r - Complete with Op. 7055A41 Front grille(one) rr. Complete with Op. 7055A43 Central front grille rr. Complete with Op. 7055B39 Front additional wheel arch half (one), Ih or rh, front element - r r. . Follow the Op. 7055A41 Front grille(one) - r r . Follow the Op. 7055B10 Front bumpers - r+r . At the bench, undo the bolts and remove the fog lamp after having released the headlamp washer system pipes from the fixings. Installation - Fit the fog lamp and fix it to the front bumper using the bolts. Fix the headlamp washer system pipes. Complete with Op. 7055B10 Front bumpers - r+r . 14 PA5106/00 06! 1998 REPAIR PROCEDURES Warning and manoeuvring indicators 5550 Sub-group index - SUB-GROUP GRAPHIC INDEX Assembly drawings index Cmp Description 5550A Stalk unit 5550B Horns 5550C Turn signal/hazard warning lights 5550D Brake and reversing lights Validity SUB-GROUP GRAPHIC INDEX 1 2 4 'f m{6 i ii i <0 & o St* v> ~~oy • 3 ~f K> I I / i ! /?ef. Description Cmp 1 Stalk unit 5550A 2 Horns 5550B 3 Turn signal/hazard warning lights 5550C 4 Brake and reversing lights 5550D PA5106/00 06/1998 u 1 REPAIR PROCEDURES Warning and manoeuvring indicators 5550 5550A - Stalk unit VIEW OF ASSEMBLY 1 m \ Jj n I v, \ : \ ii $ k) Ref. Description 1 STORK UNIT CASE ASSEMBLY Operations index Code Operation Validity 5550A12 Complete stalk unit - r+r for versions with air bag OPERATIONS 5550A12 - COMPLETE STALK UNIT - R+R FOR VERSIONS WITH AIR BAG 1c Removal Follow the Op. 5580C18 Air bag module - r+r . m Connector Stalk unit H5A \Description 1d Stalk unit Connector H5B Closely observe the safety regulations established for this operation. Follow the Op. 7040A26 Steering column trim - r+r . Follow the Op. 4110A11 Steering wheel - r+r for replacement or check for versions with air bag . I.Undo the bolts (1a) and remove the complete steering column switch unit (1b) after having disconnected the electrical connections (1c), (1d), (1e) and (1f). 2 \ Description \Description 1e Stalk unit IDescription 1f Stalk unit Connector H5C Connector H5D PA5106/00 06/1998 REPAIR PROCEDURES Warning and manoeuvring indicators * 5550 1b & \J )j A JD MM C JJJ c 1f flic idD H Installation - Connect the electrical connections to the complete steering column switch unit, place it back in its housing and fix it using the bolts. Complete with Op. 4110A11 Steering wheel r+r for replacement or check for versions with air bag . Complete with Op. 7040A26 Steering column trim - r+r . Complete with Op. 5580C18 Air bag module - r+r . PA5106/00 06/1998 3 REPAIR PROCEDURES 5550 Warning and manoeuvring indicators to 5550B - Horns VIEW OF ASSEMBLY WA I a?, 1 ■C=>) m SSir r \ i 1 flef. Description 1 HORN Operations index Code Validity Operation 5550B30 L/h or r/h horn (one) - r+r 5550B34 Horn tone - adjust OPERATIONS 5550B30 - L/H OR R/H HORN (ONE) - R+R IDescription 1a High-tone horn Connector P10A Removal - - Place the vehicle on a ramp. Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). IDescription Data not yet available {Description 1b Connector A01B 1c High-tone horn Connector P10B IDescription Connector Low-tone horn P11 A 1. Disconnect the electrical connections (1a), (1b) and/or (1c), (1d) from the horns. IDescription 1d 4 Low-tone horn Connector P11B PA5106/00 06/1998 r REPAIR PROCEDURES Warning and manoeuvring indicators 5550 2. Undo the nut (2a) and remove the horn (2b) concerned. Note: To remove the inner horn, the outer one has to be removed first. O 11a 2a \ 1c lib id /ÿs f 2b >\ Installation - - Fit the horn and fix to the mounting bracket using the nut. Connect the electrical connections. Connect the negative (-) battery terminal. Remove the vehicle from the ramp. 5550B34 - HORN TONE ADJUST Removal Follow the Op. 5550B30 - r+r . L/h or r/h horn (one) I.Act on the special adjustment screw and adjust the tone connecting the horn to a suitable supply unit. 1 Q Installation Complete with Op. 5550B30 (one) - r+r . PA5106/00 06/1998 L/h or r/h horn 5 REPAIR PROCEDURES m Warning and manoeuvring indicators 5550 5550C - Turn signal/hazard warning lights VIEW OF ASSEMBLY 4 iUT '-g|t r CEcemj'c) 3 '/• \ / T '1 I /) o W'l \ I '/ $ i* 7 4 1 2 l Ref. Description 1 FRONT TURN SIGNAL BULB 2 FRONT TURN SIGNAL BULB HOLDER 3 SIDE REPEATER UNIT 4 INT.COMBINED LIGHTS REV./FRONT FOG/REAR FOG lot HU* Operations index Code Operation 5550C16 Hazard warning light/fog lamp/reversing light combined switch - r r 5550C18 Bulb of one front turn signal, l/h or r/h - r+r Validity 5550C22 L/h or r/h side flasher (one) - r+r 5550C40 Rear turn signal control unit - r r 6 PA5106/00 06/1998 REPAIR PROCEDURES Warning and manoeuvring indicators & 5550 OPERATIONS IDescription 5550C16 - HAZARD WARNING Data not LIGHT/FOG LAMP/REVERSING LIGHT COMBINED SWITCH - R R yet Connector available F11A 2. Rotate the bulb holder in an anti-clockwise direction and extract it. 3. Remove the bulb for the front direction indicator from the bulb holder (bayonet fitting). Removal Follow the Op. 5580M10 On-board navigator panel unit - r r . 1.At the bench, remove the combined hazard lights/front fog lamps/rear fog lamps switch by releasing from the retaining lugs and with¬ drawing it from its guide rails. ) © nmi (t j\ ■f 1 3 0 D Installation - Fit the combined hazard lights/front fog lamps/ rear fog lamps switch on its guide rails until the retaining lugs click into place. Complete with Op. 5580M10 On-board navi¬ gator panel unit - r r . 5550C18 - BULB OF ONE FRONT TURN SIGNAL, L/H OR R/H - R+R Removal Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). 2 Installation - - Data not yet available Connector A01B 1. Disconnect the electrical connection from the front direction indicator bulb. iDescription 1 Left headlamp Connector F10A Fit the bulb for the front direction indicator in the bulb holder. Connect the electrical connection, then fit it in its housing in the bulb holder and rotate it in a clockwise direction. Connect the negative (-) battery terminal. 5550C22 - L/H OR R/H SIDE FLASHER (ONE) - R+R Removal \Description t Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). \Description Data not yet available Note: Connector A01B Protect the panel surrounding the side repeater using paper tape to prevent the paintwork from being damaged. 1. Remove the side repeater (1a) using the tool (1b). PA5106/00 06/1998 7 REPAIR PROCEDURES Warning and manoeuvring indicators 5550 n 1b // Description Code Blade 1.823.014.000 v 2. Disconnect the electrical connection from the side repeater and remove it. / 2 IV \Description s\ Connector \\ Mil) ) \ / \Description 2 f * 1 1a 1b V 1. Disconnect the electrical connection from the rear direction indicators control unit. 1b / 1 2 rfek M F21 3. Rotate the bulb holder (3a) in an anti-clockwise direction and extract it, then remove the bulb (3b) which is a press fit. / © \ Connector Right side repeater ) 1b TN=: F20 Left side repeater // 1a Description Connector Data not yet available 2. Undo the attachments and remove the rear direction indicators control unit. 2 77 ,o A m. 3a 3b ManslE Cn intHl* Installation - Fit the bulb in the bulb holder. - Connect the electrical connection and place the side repeater back in its housing. - Connect the negative (-) battery terminal. 5550C40 - REAR TURN SIGNAL CONTROL UNIT - R R 1 tMotnirKvH.cs/ Installation - Removal - Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). /I Description Connector Data not yet available A01B t/> - Fit the rear direction indicators control unit and secure it. Connect the electrical connection to the rear direction indicators control unit. Fit the right and left trims and secure using the relevant bolts. Connect the negative (-) battery terminal. I.Undo the bolts (1a) and remove the right and left trims (1b). 8 PA5106/00 06/1998 REPAIR PROCEDURES Warning and manoeuvring indicators if Wi 5550 5550D - Brake and reversing lights VIEW OF ASSEMBLY o X 3 % 1 ■'I EXgcv I O X/%y) \ / \ V/? $ Ref. Description 1 THIRD BRAKE LIGHT 2 THIRD BRAKE LIGHT BULB 3 HANDBRAKE ON SWITCH 2 Operations index r> Code Validity Operation 5550D16 Third stop light - r+r 5550D17 Third brake light - r r 5550D18 Handbrake on warning light switch - r+r OPERATIONS 5550D16 - THIRD STOP LIGHT R+R 1. Remove the caps (1a) and undo the bolts (1b) fixing the third brake light to the rear parcel shelf. 2. Disconnect the electrical connection (2a) and remove the third brake light (2b). Removal - Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). IDescription Data not yet available PA5106/00 06/1998 \Description 2a Data not yet Connector available Connector A01B 9 REPAIR PROCEDURES Warning and manoeuvring indicators 5550 1a & 1a 1b — 2b 1b r i i 2a\ n Remove the anti-tamper protection on the screw shown by the arrow. 1. Undo the fixing bolts. 2. Separate the bulb holder and remove the bulbs for the third brake light (press fit). Installation - Connect the electrical connection to the third brake light, then place it back in its housing in the rear parcel shelf. Tighten the fixing bolts and fit the caps. Connect the negative (-) battery terminal. - 5550D17 - R R - THIRD BRAKE LIGHT 1 Removal - Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). I Description Connector Data not yet available A01B r 1 Follow the Op. 5550D16 Third stop light - r+r . 1. Undo the bolts (1a) and remove the bulb holder (1b). * 2 Installation - Fit the bulbs for the third brake light. Close the bulb holder and fix it using the bolts. Fit the bulb holder on the cover and fix it using the bolts. Connect the negative (-) battery terminal. 5550D18 - HANDBRAKE ON WARNING LIGHT SWITCH R +R Removal - 10 Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). PA5106/00 06/1998 REPAIR PROCEDURES Warning and manoeuvring indicators ft IDescription 5550 Connector Data not yet available A01B Follow the Op. 7040L20 Tunnel trim - r r 1. Undo the nut (1a) and disconnect the earth lead (1b). IDescription 1b Connector Data not yet available 2. Disconnect the electrical connection from the handbrake warning light switch. IDescription 2 Connector Handbrake "on" switch I40 3. Undo the nut (3a) and remove the handbrake warning light switch (3b). \ 2 'M 6 & 3b 1a 1bQ 3a Installation - - Fit the handbrake warning light switch and fix it using the nut. Connect the electrical connection to the hand¬ brake warning light switch. Connect the earth lead and fix it using the nut. Check the operation of the handbrake warning light switch. Complete with Op. 7040L20 Tunnel trim - r r Connect the negative (-) battery terminal. PA5106/00 06/1998 11 REPAIR PROCEDURES 5550 Warning and manoeuvring indicators o 12 PA5106/00 06/1998 REPAIR PROCEDURES a Instruments 5560 Sub-group index - SUB-GROUP GRAPHIC INDEX Assembly drawings index Cmp Description 5560B Analogue control panel Validity SUB-GROUP GRAPHIC INDEX 1 €SM \< m i ±3 f l i H \ o \ S) ( i \ \ ! 3 i I I Ref. Description Cmp 1 Analogue control panel 5560B PA5106/00 06/1998 1 REPAIR PROCEDURES Instruments 5560 5560B - Analogue control panel VIEW OF ASSEMBLY 1 O, C3, mtf/, 2 few Kl \ \ a A Ref. Description 1 CONTROL AND INSTRUMENT BULB/S 2 CONTROL + INSTRUMENT LIGHTING DIMMER ■D "5 TO Operations index Code Operation Validity 5560B06 Instrument lightbulb/s - r+r - includes instrument r+r 5560B11 Analogue control panel - r+r or replace 5560B12 Instrument lighting dimmer - r+r OPERATIONS 5560B06 - INSTRUMENT LIGHTBULB/S - R + R INCLUDES INSTRUMENT R+R 53 53j Removal Follow the Op. 5560B11 Analogue control panel - r+r or replace . 1- At the bench, remove the bulbs from the panel using suitable pliers. Cff (£ (® (Q 1 2 PA5106/00 06/1998 REPAIR PROCEDURES Instruments Installation Fit the bulbs in the panel. Complete with Op. 5560B11 Analogue control panel - r+r or replace . Note: Before fitting the panel in its housing. make sure that the bulbs are working. - 5560B11 - ANALOGUE CONTROL PANEL - R+R OR REPLACE Removal - Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). \Description Connector Data not yet available H1? 1b 7/A / r M c I (( 'N \ 1a \ 1. Disconnect the electrical connections (1a), (1b) and (1c), then remove the analogue panel (1d). A01B Lower the steering wheel and move it back. 1-Undo the bolts (1a) and remove the upper half casing for the steering column (1b). IDescription 1a 1b Connector Instrument panel E50A iDescription Connector Instrument panel E50C 1b // IDescription f? /MV A ft \ E \ K \\ 1a I.Undo the bolts (1a) and remove the analogue panel (1b) from its housing using the tool (1c). E9 Instrument panel E50B D1,b orVf/V/1cD mm / hi III A 1c Connector - \ /5 1c 5560 Description Code Blade 1.823.014.000 r 1d 'll! & Qla 0 y j \ \ PA5106/00 06/1998 V \ 3 REPAIR PROCEDURES Instruments 5560 & Installation - Connect the electrical connections to the analogue panel, then place it back in its housing and fix it using the bolts. Fit the upper half casing for the steering column and fix it using the bolts. Place the steering wheel in the correct position. Connect the negative (-) battery terminal. - - um 5560B12- INSTRUMENT LIGHTING DIMMER - R + R - □ 1a * 2a Removal Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). 1b \Description Connector Data not yet available A01B Open the fuse carrier compartment flap. 1. Using the tool (1a) and pushing the fuse carrier compartment, remove the surround (1b) complete with switches. E9 1a Description Code Blade 1.823.014.000 1. Remove the instrument panel light dimmer, releasing it from the fixing tabs. 1 m 2. Disconnect the elelectrical connections (2a), (2b) and (2c) and remove the surround complete with switches. {Description 2a Data not yet Yi Connector available IDescription 2b To % Data not yet available H10 Connector H10 Installation - IDescription 2c 4 Data not yet available 1= Connector H10 - Fit the instrument panel light dimmer in its housing in the frame. Connect the electrical connections. Fit the surround, complete with switches, in the housing. Close the fuse carrier compartment flap. Connect the negative (-) battery terminal. PA5106/00 06/1998 r\ REPAIR PROCEDURES Accessories # 5570 Sub-group index - SUB-GROUP GRAPHIC INDEX Assembly drawings index Cmp Description 5570T Car radio and car telephone Validity SUB-GROUP GRAPHIC INDEX '/ Z I i I o tv W $ 1 1 Ref. Description Cmp 1 Car radio and car telephone 5570T PA5106/00 06/1998 1 REPAIR PROCEDURES Accessories 5570 Si 5570T - Car radio and car telephone VIEW OF ASSEMBLY ©s 11 ' rS ■ t> JC3}\ y \y v I 3 : \ 0 © 2 5 6 1 /?ef. Description 1 FRONT SPEAKER 2 FRONT TWEETER 3 REAR SPEAKER 4 ECU FOR RADIO AERIAL IN REAR WINDOW 5 SPEAKER AMPLIFIER 6 CD/AUDIO PLAYER/LOADER Operations index Code Operation 5570T28 Ecu for car radio aerial in rear window heater element 5570T36 - r+r Amplifier for speaker system - r+r 5570T85 Cd/audio player loader - r r 5570T90 Front speaker - r r 2 Validity PA5106/00 06/1998 REPAIR PROCEDURES iv Accessories i Code Operation 5570T92 Front tweeter - r r 5570T98 Rear speaker - r r Validity OPERATIONS 5570T28 - ECU FOR CAR RADIO AERIAL IN REAR WINDOW HEATER ELEMENT - R + R 5570T36 - AMPLIFIER FOR SPEAKER SYSTEM - R + R Removal - Undo the wing bolts and remove the boot left side trim. Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). - Removal - Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). / \Description / Connector Battery A1 S 3b x O % 'Q 3a A1 \ \ i t . . - 1b r 1 1 \ ff 1b 2 \ Installation - c> I.Undo the bolts (1a), disconnect the electrical connections and remove the loudspeakers' amplifier (1b). I A> I ui A in - : JWTffc5 I! \. A Battery 1a is / Connector __ \\ r \Description I.Undo the bolts (1a) and remove the embellish¬ ment (1b). Follow the Op. 7050A20 One-piece rear seat cushion - r r . Follow the Op. 7050A19 Rear seat squab - r r . Follow the Op. 7050A42 Rear squab catch device (one) - r+r (left). 1. Disconnect the electrical connections from the radio aerial control unit in the heated rear window. 2. Disconnect the aerial cable from the radio aerial control unit in the heated rear window. 3. Undo the nuts (3a) and remove the radio aerial control unit in the heated rear window (3b). ) 5570 Fit the radio aerial control unit in the heated rear window and secure it with its nuts. Connect the aerial cable to the radio aerial control unit in the heated rear window. Connect the electrical connections to the radio aerial control unit in the heated rear window. Complete with Op. 7050A42 Rear squab catch device (one) - r+r (left). Complete with Op. 7050A19 Rear seat squab rr. Complete with Op. 7050A20 One-piece rear seat cushion - r r . Connect the negative (-) battery terminal. PA5106/00 06/1998 \ \ ■ 1a o i o V. AQ ninvK.ii// Installation - IBfliral the loudspeakers' amplifier and electrical connections. Refit the loudspeakers' amplifier in its housing and secure it with its screws. Position connect its 3 REPAIR PROCEDURES Accessories 5570 Fit the embellishment and secure it with its screws. Connect the negative (-) battery terminal. Fit the boot left side trim and secure it with its wing bolts. \Description 2 5570T85 - CD/AUDIO PLAYER LOADER - R R Connector P36 Speaker in right front door 3. Remove the front speaker. & Removal Follow the Op. 5580M50 Mount for on-board navigator component in boot - r r . 1.At the bench, undo the bolts (1a) and remove the CD/Audio player/changer (1b). 3 >/ cT / fa P? © \ 2 1 Installation - \ \ (7 - 1b 1a Installation - Fit the CD/Audio player/changer on its mounting and secure it with its screws. Complete with Op. 5580M50 Mount for on¬ board navigator component in boot - r r . 5570T90 - FRONT SPEAKER R - R - Connect the electrical connection to the front speaker. Place the front speaker back in its housing and fix it using the bolts. Complete with Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r . Connect the negative (-) battery terminal. 5570T92 - FRONT TWEETER - R R Removal - Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). Removal - Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). IDescription Battery Connector A1 \Description Battery Connector A1 Follow the Op. 7005C44 Interior handle panel rr. 1. Rotate and remove the front tweeter (1a), releasing the clips (1b). Follow the Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r . 1-Undo the fixing bolts. 2. Disconnect the electrical connection. 2 4 [Description Speaker in left front door Connector P35 PA5106/00 06/1998 REPAIR PROCEDURES m Accessories 5570 4. Remove the speaker. E91,a 1c 1b 1a 1b W 4 r e B /ÿN Installation - - 2 Place the front tweeter back in its housing in the handle escutcheon and rotate it to secure the Installation clips. Complete with Op. 7005C44 Interior handle panel - r r . Connect the negative (-) battery terminal. - 5570T98 - REAR SPEAKER - R R - - - Connect the electrical connection to the rear speaker and place it back in its housing. Check the operation of the speaker. Tighten the bolts fixing the speaker to the rear parcel shelf. Fit the rear speaker protective grille. Connect the negative (-) battery terminal. Removal Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). - \Description Battery r*\ Connector A1 1. Using the tool (1a), release the attachments (1b) and remove the rear speaker protective grille (1c). E9 1a Description Code Blade 1.823.014.000 2. Undo the bolts fixing the rear speaker to the rear parcel shelf. 3. Disconnect the electrical connection from the rear speaker. IDescription 3 3 Connector Rear left loudspeaker (on parcel shelf) P30 IDescription Connector Rear right speaker (on parcel shelf) P31 PA5106/00 06/1998 5 REPAIR PROCEDURES 5570 Accessories r\ r*\ 6 PA5106/00 06/1998 REPAIR PROCEDURES Special accessories & 5580 Sub-group index - SUB-GROUP GRAPHIC INDEX Assembly drawings index Validity Cmp Description 5580C Air bag system 5580E Anti-theft device 5580M Om-board navigator SUB-GROUP GRAPHIC INDEX Z 1 : i7 P C "'X X ) "C5 ccS / L2 m )) 3«» (( la Jo 3 A C / \V \ // \\v JL \ % \ Ref. Description Cmp 1 Air bag system 5580C 2 Anti -theft device 5580E 3 Om-board navigator 5580M PA5106/00 06/1998 1 REPAIR PROCEDURES Special accessories 5580 jV 5580C - Air bag system VIEW OF ASSEMBLY 5 4 h w r?L j i ~x l i I x X fx / // ✓j -/X XX X $ l 2 * 6 Ref. Description 1 DEVICE WITH COILED LEAD FOR AIR BAG 2 AIR BAG CONTROL UNIT 3 AIR BAG ASSEMBLY MODULE 4 AIR BAG COMPLETE MODULE 5 PASSENGER AIR BAG DEATIVATION SWITCH 6 AIR BAG E.C.U. CABLE/S Operations index Code Operation Validity 5580C12 Air bag clocks spring lead - r r 5580C14 Air bag ecu - r+r 5580C18 Air bag module - r+r 5580C22 Air bag module (passenger side) -r + r 5580C26 2 Passenger air bag switch - r r PA5106/00 06/1998 REPAIR PROCEDURES Special accessories Code Operation 5580C81 Airbag and pretensioner system wiring harness - r r or replace 5580 Validity 5580C83 Airbag and pretensioner system wiring harness - r r or _replace with facia removed _ SAFETY INSTRUC¬ TIONS TO BE OBSERVED FOR INTER¬ VENTIONS ON VEHI¬ CLES FITTED WITH AIR BAG SYSTEM □ IT IS MANDATORY for the following instructions to be observed during any interventions on vehicles fitted with safety system with Air Bags. Preliminary instructions □ Remember that Air Bag modules must be handled with caution. The use, transport and storage of these components are governed by following procedures concerning their handling. (because they are faulty, their expiry date has been reached or for other reasons) must be returned to the special centre by means of the following proce¬ dure. □ Components of the safety system must be fitted and removed ONLY by skilled and authorized technical staff. The failure to observe the instructions below could lead to the accidental activa¬ tion of the system, personal injury or unnec¬ essary repairs on the system. IT IS STRICTLY PROHIBITED TO DISMANTLE THE AIR BAG MODULES INTO THEIR COMPO¬ NENTS. All the system's components have been designed specially for a specific make and model of car, so the Air Bags cannot be adapted, reused or installed on cars other than those for which they have been designed and manufactured. rfl Any attempt to reuse, adapt or install the Air Pii Bags on a different type of car could cause serious or fatal injury to the occupants of the car in the event of a crash. Interventions on the system's Before commencing bodywork repairs, welding jobs or tasks for which the Air Bag modules or control unit need to be removed, it is necessary to: - Remove the ignition key from the ignition switch. - Always disconnect the battery, i.e. disconnect the two leads and insulate them carefully with - /ÿS tape. Wait at least 10 minutes after disconnecting the battery, then disconnect the control unit elec¬ trical connection. Place the devices with the cover facing upwards in a locked metal cupboard. This cupboard, allocated exclusively to this purpose, must not, under any circumstances, be used for storing other kinds of materials, especially if flammable. The cupboard must meet the requirements for housing pyro¬ technic charges (impact-resistant metal cupboard with grille to allow natural internal ventilation), and must have the signs stipulated by current legal regulations (DANGER EXPLOSIVES - DO NOT USE NAKED FLAMES - NOT TO BE OPENED BY UNAUTHORIZED PERSONS). All the connectors used and wired on the Air Bag modules contain a short circuit clip. Unless the Air Bag modules are connected to a power source of suitable characteristics, there is no possibility of the units being activated accidentally. A component of the system which has not been activated in a crash should be considered still to be "active". Unexploded components components which have to be removed from the vehicle PA5106/00 06/1998 components At the end of any intervention on the system, the be checked with the EXAMINER or other diagnostic instruments. REPLACEMENT OF AIR BAG MODULES (BECAUSE OF A FAULT OR EXPIRY OF THE GUARANTEE PERIOD) system must If an Air Bag module is replaced because of a fault or expiry of the guarantee period, it is necessary to: - Detach the removable part of the adhesive label from the new module and put it in a specific file recording the vehicle details (model, registration data, chassis no.) and the serial no. of the old control unit. This file should be kept for future checks. - A new label is supplied with the module, to be stuck onto the label already present on the driver's door pillar. However, it should first be perforated to indicate the month and 10 years after the year when the module is fitted (e.g. 2007 will correspond to 1997). 3 REPAIR PROCEDURES Special accessories 5580 ''AIRS AO 8 2 ATTENZIONE: consultare il libretto di manutenzione. sostituire la carica entro il CAUTION: 8 see owner s manual. replace gas generator by S 2 ATTENTION: consulter la notice d'entretien. remplacer la charge avant le 3 8 ACHTUNG: Bedienungsanleitungen nachsehen. Ladung ersetzen vor £ CM S 8 5 I* Some components of the system should be inspected both if the system has been activated and if it has NOT been activated. These components are: - steering column - steering column mountings attachment area for electronic control unit and modules - clock spring - dashboard (in the area of the passenger's Air Bag module). Components must be replaced if they are twisted, broken or bent. CRASHES WITH ACTIVATION OF THE AIR BAGS Some components of the system must be replaced if the vehicle has sustained a front-end crash involving the total or partial activation of the system. REPLACING CONTROL UNIT The electronic control unit MUST ALWAYS be replaced in the event of a crash which leads to the activation of the complete system (Air Bags and pretensioners). Even if the control unit is replaced, the removable part of the adhesive label should be detached and put in the file described above. REPLACING CLOCK SPRING The clock spring for connecting the driver's Air Bag comprises a device which automatically prevents its rotation when the steering wheel is removed. This is to stop the top plate, no longer attached to the steering wheel, from rotating freely and so accidentally winding or unwinding the cables, which might then break. In the case of partial activation (pretensioners only), these components are: - Pre-tensioners - Electronic control unit (only after the third acti¬ vation of the pretensioners) In the case of total activation (Air Bags and preten¬ sioners), these components are: - Air Bag modules - Pre-tensioners - Electronic control unit The wiring and connectors should be inspected for signs of burning, melting of the outer insulation or damage caused by excessive heat. If there are any signs of damage on the clock spring or in the area of attachment of the electronic control unit and Air Bag modules, the damaged compo¬ nents must be replaced. The device is automatically unlocked when the steering wheel is refitted. - If the clock spring is removed and refitted, it must be refitted on the stalk unit in the position it was in prior to removal. - If for any reason the clock spring's top plate rotates in relation to the bottom plate and its original position prior to removal can no longer be identified, it is essential to REPLACE the clock spring. - In the case of replacement, if the new clock spring is supplied separately from the stalk unit, it must be installed with the vehicle's wheels straight, as this is the position for the new device. The new device has a safety tab which keeps it locked. This tab must be removed when the steering wheel is installed, in order to allow the system to rotate correctly. There are no special safety provisions to be observed for paint jobs followed by oven drying, as the modules in particular are designed not to suffer damage if the external surfaces of the vehicle are heated up by normal paint drying systems. Do not use naked flames near the modules. However, all the electronic control units (including the Air Bag control unit) should be removed if their temperature in certain environments could reach or exceed 85°C. Interventions after a crash handling activated Air Bag modules are as 4 follows: M Paint jobs Health risks w The precautions to be observed when - □ If any component of the safety system is damaged following a crash, it MUST be replaced. Do not attempt to repair the control unit, dock spring or Air Bag modules. - wear polyethylene protective gloves and safety goggles: after touching primed Air Bas, wash your hands and exposed parts of your body with soap and water. EFFECTS OF OVER-EXPOSURE CRASHES WITH OR WITHOUT ACTIVATION OF THE AIR BAGS 4 There is no potential risk of exposure to the propel¬ lents, as the system is fully sealed. PA5106/00 0611998 REPAIR PROCEDURES & Special accessories The propellent mixture is in the solid state, so inha¬ lation is impossible even if the gas generator cartridge breaks. If the gas leaks out, there is no risk to human health. Nevertheless avoid contact with the skin and do not swallow the propellent. In case of: - Contact with the skin: wash immediately with soap and water. - Contact with the eyes:rinse the eyes immediately in running water for at least 15 minutes. - lnhalation:bring the victim out into the open air - immediately. lngestion:induce vomiting if the person is conscious. PM Always seek medical advice in all these M conditions. SAFETY REGULATIONS CONCERNING THE HANDLING OF AIR BAG MODULES Under normal conditions, the driver's and passenger's Air Bags are activated by the action of the electronic ignition command during a crash. The gases which develop under these conditions are not toxic. It is mandatory for staff who are carrying out inter¬ ventions on a device fitted to a vehicle to observe the safety instructions listed below. Staff intervening on the devices must be properly trained and must observe the following precautions: - During removal and replacement of open (exploded) Air Bags, handle only one module at a time and wear gloves and goggles during removal. - Always rest the Air Bag module with the opening flap and pre-cut break groove facing upwards. Never put anything on top of the flap. - At the end of operations, wash your hands thor¬ oughly in soap and water, and if the residual powders of the device come into contact with your eyes, rinse immediately with plenty of running water. - On all versions fitted with Air Bags, operators must not work from the front seats without first rendering the system inoperative by discon¬ necting the two battery leads and waiting 10 minutes. - The metal components of an Air Bag which has just exploded are very hot. Avoid touching these components for 20 minutes after activation of the Air Bag. - Do not carry out repairs on Air Bag modules. Return all faulty modules to the supplier. Do not subject the Air Bag module to heat, for example drilling, hammering, welding, dudring machining, etc. - Never install in a vehicle Air Bags which have been dropped or which show signs of any kind of damage. PA5106/00 06/1998 5580 - It is not permitted to store Air Bag modules together with flammable or combustible material. - The gas generators must not come into contact with acids, greases or heavy metals; contact with such substances can cause poisonous or harmful gases or explosive compounds to form. If stored, replacement parts must be kept in their original packaging and their temporary storage must follow the same procedure as for a non-activated Air Bag module removed from the vehicle, i.e. a specifically-allocated locked metal cupboard must be used (metal impact-resistant cupboard with grille to allow natural internal ventilation). The cupboard must have specific warning signs (DANGER EXPLOSIVES - DO NOT USE NAKED FLAMES - NOT TO BE OPENED BY UNAUTHOR¬ IZED PERSONS) . SCRAPPING AIR BAG MODULES The Air Bag modules fitted to the vehicle must not be demolished with the car, but should first be removed. The Air Bag units must not be scrapped unless they have already been activated. If the Air Bag module has not been activated during an accident, the device must still be considered to be charged. Any unexploded material MUST NOT BE ACTIVATED, but must be sent to a specialist centre (for Italy, GECMA in Chivasso), with the following wording on the delivery note: "AIR BAG DEVICE CONTAINING PYRO¬ TECHNIC CHARGE TO BE DEACTIVATED". For FOREIGN MARKETS, current regulations must be observed. The devices must, without fail, be shipped in the same packaging in which the replacement parts are received, and if it is not available, the packaging alone may be ordered from PARTS. Obviously if Air Bags are replaced, the original packaging should be kept undamaged, ready for shipping the non -activated device. rfl If these procedures are not observed, the Air be activated accidentally and M Bags may personal injury. Non-activated Air cause Bags must NOT be disposed of through the usual waste disposal channels. Non-activated Air Bags contain substances which are harmful to health and can cause personal injury if the sealed container containing them is damaged during disposal. Relevant current laws may be violated if Air Bags are not disposed of in accordance with this procedure. ORDERING PROCE¬ DURE The devices should be ordered as and when required from the Volvera Parts-After Sales Depart¬ ment, but only for specific repairs as the Network must not keep these parts in stock. At all events, for internal handling purposes, an in -out register 5 REPAIR PROCEDURES Special accessories 5580 should be kept, recording the identification numbers of the modules and the vehicle details (chassis number, registration date, model, etc.). OPERATIONS Closely observe the safety regulations established for this operation. Follow the Op. 7040A26 Steering column trim - r+r Follow the Op. 4110A11 Steering wheel - r+r for replacement or check for versions with air bag . 1. Disconnect the electrical connection for the horn. IDescription Connector High-tone horn P10 2. Remove the protection, slipping it out of its housing. 3. Undo the bolts (3a) and remove the clock spring for the Air Bag system (3b). □ f°r anV reason, the upper plate for the lower one in such position is no longer known, then the clock spring must be replaced. Place the steering wheel in the centred position with the wheels straight. Follow the Op. 5580C18 Air bag module - r+r . 1 Check that the wheels are straight as the parts available as spares are designed to be fitted in this condition. ppj Removal - - in relation to the ril clock spring shouldarotate way that the relative 5580C12 - AIR BAG CLOCKS SPRING LEAD - R R - Installation The dock spring is fitted with a device which automatically stops its rotation when it is removed from the steering wheel.Avoid forcing its rotation. - Place the clock spring for the Air Bag system back in its housing and fix it using the bolts. Note: if a new dock spring is being fitted, remove the safety tab. Fit the protection in the housing. Connect the electrical connection for the horn. Complete with Op. 4110A11 Steering wheel r+r for replacement or check for versions with air bag . Complete with Op. 7040A26 Steering column trim - r+r Complete with Op. 5580C18 Air bag module - r+r . Test the operation of the horns. Check the operation of the Air Bag system using the Examiner or other diagnostic equipment. 5580C14 - AIR BAG ECU - R+R Before removing and refitting the control unit, carry out the following preliminary operations: place the ignition key in the OFF position and extract it; disconnect and insulate the battery leads; wait for 10 minutes before continuing. Follow the safety instructions (see 5080C Warnings ). 3a 3b L ki ML £) o m 2 // / it u tWMltU* r-\ 6 PA5106/00 06/1998 REPAIR PROCEDURES Special accessories * 5580 Removal 1. Unscrew bolts (1a) and remove right and left trims (1b). / // v PM Follow these precautions: never strike or shake the control unit; M mmM do not connect the electrical connection to the control unit before having fixed the control unit correctly; make sure that the battery is disconnected. / \ □ % -=OJ £ ) \ I © i checks. ©; 1. Fit the Air Bag control unit (1a) and fix it tight¬ ening the nuts (1b) to the recommended torque. Note: Make sure that the arrow on the upper surface of the control unit is facing the direction of travel. % 1a 1b 1. Undo the bolts (1a) and move the relay mounting bracket (1b). 2. Rotate the safety bracket and disconnect the electrical connection from the Air Bag control unit. \Description U 1b Component 0 Nut AIR BAG CONTROL UNIT M6 M60 v\ 3. Undo the nuts (3a) and remove the Air Bag control unit (3b). r // Vj 1b l £ i! 1a I Ml ) ] / 9 ) 1a } I 3a V / if 3b Installation 06/1998 D 2 Place the relay mounting bracket back in its housing and fix it using the bolts. Fit the right and left trims and secure using the relevant bolts. 5580C18 - AIR BAG MODULE R +R 9 'v Bodyshell side 0.8 - 0.9 1b vs? PA5106/00 Value (daNm) Mounting 2. Connect the electrical connection and secure it using the safety bracket. Connector AIR BAG control unit 2 if the control unit is being replaced, remove the removable part of the adhesive label from the new control unit and place it in a special file which contains the vehicle data (model, registration date, chassis number) and the serial number of the old control unitJhis file should be kept for future 2 Before removing and refitting the control unit, carry out the following preliminary operations: place the ignition key in the OFF position and extract it; wait for 10 minutes before continuing. 7 REPAIR PROCEDURES Special accessories 5580 Follow the safety instructions (see 5080C Warnings). & E 2b Mounting Component 0 Screw AIR BAG ASSEMBLY M6 Removal \\ Q09 / icil v\ 'M 1b 05 .. $ m A v rv Place the Air Bag module in the special cupboard, resting it on a free surface with the bag facing upwards. u ' / $ - .1/ K rv Connect the battery terminals. Check the operation of the system using the Examiner or the other diagnostic equipment. yif- C$2 1a - \ sj v\ n {-m w Q>5 \\ 1 (I 2a 1 Connector Data not yet available \ side 0.5 % IPescription ) Flywheel - 0.7 MODULE I.Undo the bolts (1a), move the Air Bag module (1b) as far back as necessary to disconnect the electrical connection (1c), then remove it. 1c Value (daNm) 5580C22 - AIR BAG MODULE (PASSENGER SIDE) - R + R Before removing and refitting the control unit, carry out the following preliminary operations: place the ignition key in the OFF position and extract it; disconnect and insulate the battery leads; wait for 10 minutes before continuing. Installation ff] Follow these precautions: handle the Air Bag module with extreme caution; make sure that the battery is disconnected. Follow the safety instructions (see 5080C Warnings). □ If the Air Bag module is being replaced. remove the removable part of the adhesive label from the new module and place it in a special file containing the vehicle details (model, registration date, chassis number) and the serial number of the old module.This file should be kept for future checks. A new adhesive label is supplied together with the Air Bag module to be stuck on top of the one present on the driver's door pillar. It must be perforated first by the month. 10 years after the year in which the module is fitted (e.g. for 1998, this will be 2008). 1. Connect the electrical connection to the Air Bag module. 2. Place the Air Bag module (2a) back in its housing and fix it tightening the bolts (2b) to the recommended torque. 8 Removal Follow the Op. 7040A67 Partition between passenger airbag and facia compartment - r r . Follow the Op. 7040A31 Flap assembly - r r . 1. Disconnect the electrical connection for the passenger Air Bag module after having releaed it from the anchorage devices. Connector \Description 1 Air Bag in dashboard (passenger side) Q1 1 2. Undo the bolts (2a) fixing the passenger Air Bag module (2b), then remove it after having released it from the two attachments. PA5106/00 06/1998 REPAIR PROCEDURES Special accessories & 5580 iN\ /A \\ // // o. \ 2b \ \ ■s? - J v<5 2a 1 Place the Air Bag module in the special cupboard, resting it on a free surface with the bag facing upwards. Installation Follow these precautions: handle the Air Bag module with extreme 1a \ J \ \ B1b 2 1. Place the passenger Air Bag module (1a) back in its housing, fixing it to the two attachments, then fix it tightening the bolts (1b) to recommended torque. E 1b Mounting Component 0 Screw AIR BAG COMPLETE MODULE M6 caution: make sure that the battery is disconnected. m If the Air Bag module is being replaced, ril remove the removable part of the adhesive ■a. I V \ T I \ r; Jl / "\ '1 Value (daNm) 0.6 - 0.8 2. Connect the electrical connection to the passenger Air Bag module and fix the wiring to the anchorage devices. label from the new module and place it in a special file containing the vehicle details (model, registration date, chassis number) and the serial number of the old module.This file should be kept for future checks. A new adhesive label is supplied together with the Air Bag module to be stuck on top of the one present on the driver's door pillar. It must be perforated first by the month, 10 years after the year in which the module is fitted (e.g. for 1998, this will be 2008). is // c\ fr \ \. Jl V/ T \ \ \ Bib \ 1a J A 2 Complete with Op. 7040A31 Flap assembly - r r. Complete with Op. 7040A67 Partition between passenger airbag and facia compartment - r r . Connect the battery terminals. Check the operation of the system using the Examiner or the other diagnostic equipment. PA5106/00 06/1998 9 REPAIR PROCEDURES Special accessories 5580 5580C26 - PASSENGER AIR BAG SWITCH - R R Removal Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). - 5580C81 - AIRBAG AND PRETENSIONER SYSTEM WIRING HARNESS - R R OR REPLACE Removal - {Description Connector Data not yet available A01B Follow the Op. 7040A45 Facia rh side cover - r r. 1. Remove the switch for deactivating the passenger Air Bag (1a) using the tool (1b) after having disconnected the electrical connection (1c). H 1b Description Code Blade 1.823.014.000 - - - {Description 1c Connector Passenger's Air Bag disablement H75 switch S' v\ / i o m X 1a IX '7 Complete with Op. 5580C83 Airbag and pretensioner system wiring harness - r r or replace with facia removed . - - IS Installation - Connect the electrical connection to the switch for deactivating the Air Bag, then place it back in its housing. Note: Check the operation of the switch before placing it back in its housing. - - Complete with Op. 7040A45 Facia rh side cover - r r . Connect the negative (-) battery terminal. - 10 r Installation /, xxa Refer to 7040A10 Instrument facia trim - r+r Follow the Op. 7045A10 L/h or r/h front seat (one) - r+r . Follow the Op. 7050A20 One-piece rear seat cushion - r r . Follow the Op. 7040L40 Front compartment scuff strip - r r . Follow the Op. 7050A20 One-piece rear seat cushion - r r . Follow the Op. 7040L44 Rear compartment scuff strip - r r . Follow the Op. 7040H36 Central trim lower element - r r . Follow the Op. 7040L20 Tunnel trim - r r . Follow the Op. 1056B79 Injection/ignition contro unit guard - r r . Follow the Op. 7040L50 Driver side foot rest rr. Follow the Op. 7040A65 Passenger compart¬ ment box lock , one , r r . Follow the Op. 7040L10 Cabin floor carpet - r r . Follow the Op. 7040H38 Central pillar upper element - r r . Follow the Op. 5580C14 Air bag ecu - r+r . Follow the Op. 5580C83 Airbag and preten¬ sioner system wiring harness - r r or replace with facia removed . Complete with Op. 5580C14 Air bag ecu - r+r . Complete with Op. 7040H38 Central pillar upper element - r r . Complete with Op. 7040L10 Cabin floor carpet - r r . Complete with Op. 7040A65 Passenger compartment box lock , one , r r . Complete with Op. 7040L50 Driver side foot rest - r r . Complete with Op. 1056B79 Injection/ignition contro unit guard - r r . Complete with Op. 7040L20 Tunnel trim - r r . Complete with Op. 7040H36 Central trim lower element - r r . Complete with Op. 7040L44 Rear compartment scuff strip - r r . Complete with Op. 7050A20 One-piece rear seat cushion - r r . Complete with Op. 7040L40 Front compart¬ ment scuff strip - r r . Complete with Op. 7050A20 One-piece rear seat cushion - r r . Complete with Op. 7045A10 L/h or r/h front seat (one) - r+r . Refer to 7040A10 Instrument facia trim - r+r . PA5106/00 06/1998 o REPAIR PROCEDURES Special accessories Ji 5580C83 - AIRBAG AND PRETENSIONER SYSTEM WIRING HARNESS - R R OR REPLACE WITH FACIA REMOVED 2 z I - IDescription 1 Os) MjsfT ? 1 Ml Installation - - Data not yet available - - Place the cable loom for the Air Bag system and pre-tensioners back in its housing and fix it using the bands. Connect the electrical connections to the front seat belt pre-tensioners. Complete with Op. 5580C14 Air bag ecu - r+r . Complete with Op. 7040H38 Central pillar upper element - r r . Complete with Op. 7040L10 Cabin floor carpet - rr. Complete with Op. 7040A65 Passenger compartment box lock , one , r r . Complete with Op. 7040L50 Driver side foot rest - r r . Complete with Op. 1056B79 Injection/ignition contro unit guard - r r . Complete with Op. 7040L20 Tunnel trim - r r . Complete with Op. 7040H36 Central trim lower element - r r . Complete with Op. 7040L44 Rear compartment scuff strip - r r . Complete with Op. 7050A20 seat cushion - r r . Complete with Op. 7040L40 ment scuff strip - r r . Complete with Op. 7050A20 seat cushion - r r . Complete with Op. 7045A10 seat (one) - r+r . PA5106/00 06/1998 k, 2 Connector 2. Release the cable loom for the Air Bag system and pre-tensioners from the fixings, then remove it. I ,11 Removal Follow the Op. 7045A10 L/h or r/h front seat (one) - r+r . - Follow the Op. 7050A20 One-piece rear seat cushion - r r . - Follow the Op. 7040L40 Front compartment scuff strip - r r . - Follow the Op. 7050A20 One-piece rear seat cushion - r r . - Follow the Op. 7040L44 Rear compartment scuff strip - r r . - Follow the Op. 7040H36 Central trim lower element - r r . Follow the Op. 7040L20 Tunnel trim - r r . Follow the Op. 1056B79 Injection/ignition contro unit guard - r r . - Follow the Op. 7040L50 Driver side foot rest rr. Follow the Op. 7040A65 Passenger compart¬ ment box lock , one , r r . Follow the Op. 7040L10 Cabin floor carpet - r r . Follow the Op. 7040H38 Central pillar upper element - r r . Follow the Op. 5580C14 Air bag ecu - r+r . 1. Disconnect the electrical connections from the front seat belt pre-tensioners.. 5580 One-piece rear Front compart¬ One-piece rear L/h or r/h front 11 REPAIR PROCEDURES Special accessories 5580 5580E - Anti -theft device VIEW OF ASSEMBLY r 5ÿ? 7 5 O O i®* Sr* 3 1 6 %L \ 0 V. 7£\o'ÿ I MW iTrx 2 r ( h tfS* :/ "V 1 1U3 I 7 vQÿ 4 © © /, v* /, flef. Description 1 ELECTRONIC IGNITION KEY AERIAL 2 IMMOBILISER DEVICE ECU 3 ANTI-THEFT ACTIVATION WARNING LIGHT 4 BOOT/TAILGATE OPEN SWITCH 5 BONNET LID OPEN SWITCH 6 CAR-ALARM REMOTE CONTROL RECEIVER 7 ANTI THEFT ECU/SIREN UNIT Operations index Code Operation 5580E08 Aerial for alpha code - r r 5580E12 Immobiliser device ecu - r+r following electric circuit check Anti-theft device w/l - r+r following electrical wiring check 5580E18 5580E26 Validity Boot/tailgate open alert switch - r+r following elec- _trical wiring check _ 5580E28 Bonnet lid open alert switch - r+r following electrical _ wiring check _ 5580E30 Receiver for car alarm remote control - r r 12 PA5106/00 06/1998 REPAIR PROCEDURES m Special accessories Code Operation 5580E46 Antitheft device ecu / siren unit r + r WARNINGS To avoid causing severe damage to the wiring, do the engine if the battery cable is loose. Never pull cables or wiring with force, as this could disconnect the cables from their connections or terminals. Disconnect all the control units and electronic devices before carrying out arc-welding operations on the bodywork. Before replacing a fuse, check that the protected circuit is not faulty. When replacing fuses, make sure that the new fuse is of the correct amp. rating. Do not use fuses with a higher or lower amp. rating. not attempt to turn PRECAUTIONS When working on electrical components, the following precautions must be strictly observed: - Remove rings, wrist watches or other metal objects. - DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical components, wiring etc.). - Be careful about electric arcs. Even if the voltage is 12V, the battery can cause high short circuit currents, inducing arcs or sparks which could constitute a risk to the operator or start a fire. - Be careful about high voltages. The electronic ignition system generates voltages of 20,000 V and higher which can be very dangerous. Take great care when working on or near the compo¬ nents. - Avoid fires. Do not smoke when working near the battery or components which warm up during operation (e.g. halogen lamps), or in the engine compartment area if the engine is still hot. Also take care to avoid scalding or damage to tools and components. MANAGEMENT OF CODE ALARM SYSTEM COMPONENTS When replacing and therefore ordering components of the CODE alarm system, follow the procedures described below. LOSS OF KEY(S) 1. Ask the customer for all the keys remaining in his possession. He should also prove that he owns the vehicle by showing the registration document and a valid identity document. 2. MEMORIZE THE REMAINING KEYS using the Examiner or another diagnostic instrument, working on the Code control unit, in this way keys which PA5106/00 06/1998 5580 Validity have not been presented will never be able to be used. A list of keys which are still valid will also be printed. 3. Only versions with alarm. MEMORIZE THE REMAINING REMOTE CONTROLS using the Examiner or another diagnostic instrument, working on the alarm control unit. In this way keys which have not been presented will no longer be able to be used. 2. Link up to FIAT RICAMBI, giving the vehicle chassis number and other details as requested. Place an order for one or several keys, for the vehicle in question. 5. By consulting the DATA BASE and on the basis of the chassis number, FIAT PARTS can make a key which has: the same shape (but indicates that it is a replace¬ - ment part). - transponder with new ID3 , but with secret code of the Code control unit of the vehicle in ques¬ tion - new mechanical code (metal insert) - new remote control TX3 (only versions with alarm). In addition, the DATA BASE is updated by the entry of the new ID3 . 6. FIAT PARTS must despatch the key to the Sen/ice Network point within 24-48 hours. 7. MEMORIZE THE KEYS using the Examiner or another diagnostic instsrument, working on the Code control unit, entering both the new key(s) and the previous key(s). 8. Only versions with alarm. MEMORIZE THE REMOTE CONTROLS using the Examiner or another diagnostic instrument, working on the alarm control unit, entering both the new key(s) and the previous key(s). Note: To do this, the receiver's PASSWORD must be entered. Ask FIAT PARTS for this PASSWORD, again stating the vehicle's chassis number. 9. Conduct a final check on both Code system and alarm system (if present) using the Examiner or another diagnostic instrument. REQUESTING A NEW KEY Proceed as described above, skipping step 2 which in this case is superfluous. REPLACING TRANSPONDER The transponder is moulded in the key shell. It is therefore not possible to replace it: this ensures greater security against transponder theft. REPLACING KEY LOCK BARRELS . 1 Ask the customer for all the keys remaining in his possession. He must also prove that he owns the vehicle by showing the registration document and a valid identity document. 13 REPAIR PROCEDURES 5580 Special accessories 2. CANCEL THE MEMORIZED KEYS using the Examiner or another diagnostic instrument, working on the Code control unit and not the alarm control unit. These keys will never be able to be used again. 3. Link up to FIAT PARTS, giving the vehicle's chassis number and other details as requested. Place an order for a complete key kit for the vehicle in question. ifI It is not possible to order only the lock barrel, or the kit. by giving only the mechanM mma ical code of the keys. 4. By consulting the DATA BASE and on the basis of the chassis number, FIAT PARTS can make a complete key kit which has: - the same shape (although indicating that it is a replacement part) - transponder with new ID3 , ID4 , but with secret code of the Code control unit of the vehicle in question - same mechanical code (metal insert) - new remote control codes TX3 , TX4 (only versions with alarm). A new Code Card, with the previous recovery code but a new mechanical code, is also supplied. In addition the DATA BASE is updated by the entry ofthenewlD3 and ID4 and the new mechanical code. 5. FIAT PARTS must despatch the key kit to the Service Network point within 24-28 hours. 6. MEMORIZE THE KEYS using the Examiner or another diagnostic instrument, working on the Code control unit, entering all the keys received. 7. Only versions with alarm. MEMORIZE THE REMOTE CONTROLS using the Examiner or other diagnostic instrument, working on the alarm control unit, entering all the keys received. Note: To do this, the receiver’s PASSWORD must be entered. Ask FIAT PARTS for this PASSWORD, again stating the vehicle's chassis number. 8. Conduct a final check on both the Code system and the alarm system (if present) using the Exam¬ iner or another diagnostic instrument. LOSS OF CODE CARD 1. Ask the customer for all the keys remaining in his possession. He must also prove that he owns the vehicle by showing the registration document and a valid identity document. 2. Link up to FIAT PARTS, giving the vehicle's chassis number and other details as requested. Also place an order for a Code Card for the vehicle in question. 3. By consulting the DATA BASE and on the basis of the chassis number, FIAT PARTS can made a new Code Card which is identical (emergency code and mechanical code) to the lost Card. The Card is then sent to the Service Network point. 4. Hand over the Card to the customer, informing him that it is simply a duplicate. Thus the old Card, if found, will still allow the vehicle to be started, in an emergency situation. 14 REPLACING CODE CONTROL UNIT A suspected fault in the Code control unit must always be confirmed by a thorough check carried out using the Examiner or another diagnostic instrument. 1. Ask the customer for all the keys remaining in his possession. He must also prove that he owns the car by showing the registration document and a valid identity document. 2. Link up to FIAT PARTS, giving the vehicle's chassis number and other details as requested. Place an order for a Code control unit for the vehicle in question. 3. By consulting the DATA BASE and on the basis of the chassis number, FIAT PARTS can make a control unit which has the same secret code and the same "FIX CODE" as the faulty unit. In addition, the DATA BASE is updated by the entry of the completed operation. 4. FIAT PARTS must despatch the control unit to the Service Network point within 24-48 hours. 5. Fit the new control unit in place of the faulty unit. 6. MEMORIZE THE KEYS using the Examiner or another diagnostic instrument, working on the Code control unit, entering all the keys enabled previously. 7. Conduct a final check on the Code system using the Examiner or another diagnostic instrument. REPLACING ENGINE MANAGE¬ MENT CONTROL UNIT A suspected fault in the electronic fuel injection control unit must always be confirmed by a thor¬ ough check carried out using the Examiner or another diagnostic instrument. 1. Ask the customer for all the keys remaining in his possession. He must also prove that he owns the vehicle by showing the registration document and a valid identity document. 2. Link up to FIAT PARTS, giving the vehicle's chassis number and other details as requested. In addition place an order for an engine management control unit for the vehicle in question. 3. FIAT PARTS must despatch a new, unpro¬ grammed control unit to the Service Network point within 24-48 hours. 4. Fit the new control unit in place of the faulty unit. 5. Turn the ignition on (MARCIA); this causes the new control unit to be initialized by the Code control unit, which transmits the "FIX CODE". 6. Conduct a final check on the engine manage¬ ment system using the Examiner or another diag¬ nostic instrument. PA5106/00 06/1998 REPAIR PROCEDURES /ÿN Special accessories * 5580 OPERATIONS IDescription 5580E08 - AERIAL FOR ALPHA CODE - R R Data not yet available Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). IDescription A01B 1. Unscrew bolt (1a) and open fuse access cover (1b). 2. Undo the nuts (2a) and remove the electronic key anti-theft control unit (2b) after having disconnected the electrical connections (2c) and (2d). Removal - Connector Connector Data not yet available IDescription A01B Follow the Op. 5580E12 Immobiliser device ecu - r+r following electric circuit check . Follow the Op. 7040A26 Steering column trim CODE control unit 2c - r+r . 1. Remove the aerial for the electronic key (1a) releasing it from the lock barrel and the retaining bands (1b). Connector M20B IDescription Connector CODE control unit 2d M20A // // // // P j* i, rvfi & H ) NS /' © E 2c C/i 1a I T X. ■ , 1b 1aÿ[ÿ: 1b Installation - - Fit the aerial for the electronic key in the lock barrel and fix the wiring using the bands. Complete with Op. 7040A26 Steering column trim - r+r . Complete with Op. 5580E12 Immobiliser device ecu - r+r following electric circuit check Connect the negative (-) battery terminal. Check the operation of the system using the Examiner or the other diagnostic equipment. . 5580E12 - IMMOBILISER DEVICE ECU - R + R FOLLOWING ELECTRIC CIRCUIT CHECK Removal - Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). PA5106/00 06/1998 \ m2b S' Installation - Connect the electrical connections to the elec¬ tronic key anti-theft control unit, then place it back in its housing and fix it using the nuts. Close the fuse access cover and secure using the appropriate bolt. Connect the negative (-) battery terminal. 5580E18 - ANTI-THEFT DEVICE W/L - R + R FOLLOWING ELEC¬ TRICAL WIRING CHECK Removal - Follow the Op. 5010C30 Central air outlet on fascia r+r . 1.At the bench, remove the anti-theft device on warning light from the centre air vent in the dashboard. - 15 REPAIR PROCEDURES m Special accessories 5580 1 A A w *&?/ H \ J S' 2a 1 Installation - Fit the anti-theft device on warning light in the centre air vent in the dashboard. Complete with Op. 5010C30 Central air outlet on fascia - r+r . Refer to op.. 7025A34 Bonnet lid lock (one) - - Removal - Ensure that the ignition key is in stop position, then disconnect the battery negative terminal Data not yet available Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). - Removal IDescription r+r . Connect the negative (-) battery terminal. - 5580E46 - ANTITHEFT DEVICE ECU / SIREN UNIT R + R 5580E30 - RECEIVER FOR CAR ALARM REMOTE CONTROL - R R - Connect the electrical connection to the anti¬ theft device remote control receiver. Place the anti-theft device remote control receiver back in its housing in the rear parcel shelf and fix it using the bolts. Complete with Op. 5550D16 Third stop light - - 5580E28 - BONNET LID OPEN ALERT SWITCH - R + R FOLLOWING ELECTRICAL WIRING CHECK Refer to op.. 7025A34 Bonnet lid lock (one) r+r or repair . Connector \ Description Data not yet available 16 Alarm remote control receiver A01B Follow the Op. 7040B13 Load compartment/ load platform right side trim - r r . I.Undo the bolt (1a) and the nut (1b) fixing the anti-theft device alarm/control unit. 2. Disconnect the electrical connections (2a) and (2b), then remove the anti-theft device alarm/ control unit (2c). IDescription 2a 2b 2b Connector A1B Follow the Op. 55S0D16 Third stop light - r+r . I.Undo the bolts fixing the anti-theft remote control receiver to the rear parcel shelf. 2. Remove the anti-theft device remote control receiver (2a) after having disconnected the electrical connection (2b). IDescription Q Installation 5580E26 - BOOT/TAILGATE OPEN ALERT SWITCH - R + R FOLLOWING ELECTRICAL WIRING CHECK r+r or repair . 2b Connector Alarm control unit M30 iDescription Connector Alarm control unit M30 Connector M35 PA5106/00 06/1998 REPAIR PROCEDURES M Special accessories 5580 !c i 2b; 1a ? l •Hi Installation - - Connect the electrical connections to the anti¬ theft device alarm/control unit. Place the anti-theft device alarm/control unit back in its housing and fix it using the bolt and the nut. Complete with Op. 7040B13 Load compart¬ ment/load platform right side trim - r r . Connect the negative (-) battery terminal. PA5106/00 06/1998 17 REPAIR PROCEDURES Special accessories 5580 & 5580M - Om-board navigator VIEW OF ASSEMBLY 3 /- '/• i 't SLL'/ /) O ‘VJ ' \ / I \ V; V ■ U NiS 1° r \ VS I o DDBB /c 2 4 pj >>Jl 5 \ c»l /?ef. Description 1 FULL ON-BOARD NAVIGATOR PANEL 2 Data not yet available 3 Data not yet available 4 Data not yet available 5 Data not yet available ii Operations index Code Operation Validity 5580M10 On-board navigator panel unit - r r 5580M12 On-board navigator panel unit - r r for replacement 5580M16 On-board navigator panel trim plate - r r 5580M32 On-board navigator cd player/loader - r r 5580M50 Mount for on-board navigator component in boot - r r 5580M70 Aerial for on-board navigator - r r 18 PA5106/00 06/1998 REPAIR PROCEDURES Special accessories ±L r\ OPERATIONS 1. Disengage the two retaining clips using a screwdriver in the space between dashboard and complete on-board navigator panel. 2. Withdraw the complete on-board navigator panel as much as necessary to disconnect the electrical connections (2a), (2b), (2c), (2d), (2e) and (2f). 5580M10 - ON-BOARD NAVI¬ GATOR PANEL UNIT - R R Removal - Make sure that the ignition is in the OFF posi¬ tion, then disconnect the negative battery terminal (refer to op. 5530B10 Battery - r+r ). {Description 2a {Description 5580 Connector Data not yet available Connector Data not yet available A01B {Description 1. Prise off and move aside the embellishment for the switch holder, cigarette light and gear lever gaiter without disconnecting the electrical connections. ( V o «3o o Q 2b yj \ oj OK Connector Data not yet available Q m ! -N> IDescription 2c Connector Data not yet available SP. IDescription 2d y 1 Data not yet available IDescription 2e Connector Connector Data not yet available , /*,nl an, I.Undo the bolts (1a), disengage the gear lever surround (1b) from its attachment buttons and remove it. \ \ fa oa {Description 2f Connector Data not yet available 3. Remove the complete on-board navigator panel. o 10 03 (9 7j yÿ//i -ib PA5106/00 06/1998 19 REPAIR PROCEDURES Special accessories 5580 r*s \ .X 3 Op o Q C? a IW\ ,1 %r% \ O' a f4 \ TTf 1 2 1 3 Installation - - 101 13 2b m 2d - 2c Installation Position the complete on-board navigator panel and connect its electrical connections. Refit the complete on-board navigator panel in its housing until the two retaining clips click into place. Fit the gear lever surround and fix it with the buttons and bolts. Refit the embellishment for the switch holder, cigarette lighter and gear lever gaiter in its seating. Connect the negative (-) battery terminal. - - - 5580M12 - ON-BOARD NAVI¬ GATOR PANEL UNIT - R R FOR REPLACEMENT Removal - Follow the Op. 5580M10 On-board navigator panel unit - r r . 1.At the bench, remove the air conditioner push¬ button unit by releasing it from the retaining lugs and withdrawing it from the guide rails. 2. Remove the combined hazard lights/front fog lamps/rear fog lamps switch by releasing it from the retaining lugs and withdrawing it from the guide rails. 3. Manually release the embellishment from the on-board navigator panel. 20 Press fit the embellishment on the on-board navigator panel until the retaining lugs click into place. Fit the combined hazard lights/front fog lamps/ rear fog lamps on the guide rails until the retaining lugs click into place. Fit the air conditioner pushbutton unit on the guide rails until the retaining lugs click into place. Complete with Op. 5580M10 On-board navi¬ gator panel unit - r r . 5580M16 - ON-BOARD NAVI¬ GATOR PANEL TRIM PLATE - R R Removal 1. Prise off and move aside the embellishment for the switch holder, cigarette lighter and gear lever gaiter without disconnecting the electrical connections. I v O' O o £5 (Q o W\& t o£ 0 ■Ji y / y PA5106/00 06/1998 r\ REPAIR PROCEDURES m Special accessories I.Undo the bolts (1a), disengage the gear lever surround (1b) from its attachment buttons and remove it. \ \ ®T 3 \o Jk to (L o — 7 5580 5580M32 - ON-BOARD NAVI¬ GATOR CD PLAYER/LOADER R R Removal - I Follow the Op. 5580M50 Mount for on-board navigator component in boot r r . 1.At the bench, unto the screws (1a) and remove the CD player/changer (1b). - K (Q r* s uXXv7X ib 1a 1. Disengage the two retaining clips using a screwdriver in the space bewteen the dashboard and complete on-board navigator panel. 2. Withdraw the complete on-board navigator panel as much as necessary and remove the embellishment after manually releasing it from its attachments. \ \ © Installation 1 %j X\ 6 r/„, Fit the CD player/changer in its mounting and fix it with its screws. Complete with Op. 5580M50 Mount for on¬ board navigator component in boot - r r . 5580M50 - MOUNT FOR ON¬ BOARD NAVIGATOR COMPO¬ NENT IN BOOT - R R Removal -/ / Installation - £ '0, % / - o G i D - - 0 o h JWS X □ The removal of the damaged elements is the repair operation during which the poten¬ tially most dangerous equipment is used. Before carrying out any sort of operation. read the instruction manuals, the safety instructions and the manufacturer's warn¬ ings which come with the equipment very carefully and follow all the accident preven¬ tion and safety instructions to the tetter. The use of the following is required for the removal of damaged body panels: - hack-sawing machines: - circular saws; PA5106/00 06/1998 REPAIR PROCEDURES Body r 2 2 1 . Panel to be removed 2. Box section panel preventing the use of a milling cutter. MILLING CUTTER A milling cutter for removing weld spots should be used after cutting the panel to be replaced in order to allow the removal of the panel offcuts remaining on the edges of the bodyshell. The milling cutter acts on the panel which consti¬ tutes the offcut, cutting it as far as the panel under¬ neath and thereby isolating the spot weld. After the reduction of all the spot welds, the offcut is removed using pliers. - To facilitate the operation, use a cutting speed of around 1 000 rpm. - Adjust the depth of the cutting using the special screw. \\ DOLLY BLOCKS AND LEVERS These instruments are used when panels need to be straightened by beating, in order to have a counter¬ action point to support the panel. Dolly blocks are shaped so that they can adapt to different shaped panels and, when the work area allows, they can replace the hammer. Levers are used in the same way as dolly blocks, however they are designed so that they can be introduced through restricted openings and spaces to get to areas which are difficult to reach. Dolly blocks and levers are also used to eliminate distortions from the edges of panels which are not removed thereby allowing correct matching with the replaced panels, avoiding weakening the struc¬ ture. Welding replacement elements □ if welding operations or work which could produce flames near the fuel system components illustrated in the diagram or other flammable parts of the vehicle need to be carried out, the parts involved must be removed from the vehicle and the free pipe connections sealed if the connectors are removed. Disconnect the electronic control units (i.E„ ABS. Air Bag, Air conditioning. Alarm, etc.) which could be damaged during the work. 6 PA5106/00 06/1998 REPAIR PROCEDURES Body rC 70 j Parts of the fuel system '1 Mi O, Welding bodywork elements should be carried out, according to requirements, using different methods: Spot welding; seam (MIG) welding; - Brazing. EQUIPMENT The following equipment is used for these opera¬ tions: weldinig guns; seam (MIG) welders; - oxy-acetylene torches (brazing). GENERAL INFORMATION ON ELECTRIC SPOT WELDING In electric spot welding a current is passed through the metal to provide the resistance required for the necessary heat to melt the metal. Spot welding is carried out to panels where the join edges overlap and the panel metal melts; no metal filler is therefore needed for this type of welding. In areas where three or more panels overlap, spot welding should be repeated for a second time. The type of join produced is not continuous; to create a join with good mechanical strength the spot welds must be correctly spaced following precise instructions (see tables below). SPOT WELDING In the case of spot welding, check:: - that the arms are correctly aligned; - that the diameter of the edges of the electrodes is correct; PA5106/00 06/1998 - the planarity and that the weld edges are correctly matched; - that the welding sequence is correct. electro-weldable galvanizing protective to the edges of the join to protect the box sections from corro¬ sion. ■na Before welding, apply 7 REPAIR PROCEDURES a Body 70 Spot welder, geometric characteristics of the elec¬ trode according to the thickness of the panel and the welding sequence. A / 150° yr D ≤ ? T 4 rs D = 2t + 3 (mm) 1 B 4 5 5 1 * 2 3 4 5 C A- Electro-weldable galvanizing protective B- Correct welding sequence C- Incorrect welding sequence D- Electrode dimension 8 PA5106/00 06/1998 tÿS REPAIR PROCEDURES 0 Body Table of reference values for carrying out spot A 70 welds e * A * e B e e * A. Table for determining the distance of the spot welds from the edges of the panels according to their thickness. B. Table of reference values for the correct spacing of the spot welds according to the thickness of the panel. Do not weld on angular shaped surfaces. Welding on this type of surface would create a concentration of tension which would result in breakage. Example of correct spot welding at corners A A- Area where welding should not be carried out SEAM (MIG) WELDING MIG welding should be used for parts where spot welding cannot be used. When carrying out seam (MIG) welding, check: - the speed - that the seam weld beads have been correctly made (alternating weld sections) In this welding system (automatic advance seam) a protective inert gas atmosphere is used (hence the name M.I.G. which stands for Metal Inert Gas). The continuous progress of the seam (which constitutes both the electrode and the filler metal), allows long welds to be made without interruption. PA5106I00 06/1998 B (t) mm ( e ) mm 0,6 11 0,8 12 1 18 1,2 20 1,6 27 1,8 31 ( t ) mm ( e ) mm 0,6 11 0,8 11 1 12 1,2 14 1,6 16 1,8 17 The flow of inert gas sent to the welding area elim¬ inates the surrounding air preventing the oxidation of the metal and therefore has the function of providing a protective layer for the weld. For these reasons, MIG welding differs from welding carried out with a covered electrode through the absence of dross on the welding bead; also there are no pores which can occur during normal arc welding. □ The use of MIG welding requires an extractor system to get rid of the fumes and harmful gases. OPERATING METHODS In order to weld two panels correctly using a MIG welder: grind or pickle the panel thoroughly, place the equipment in a sensible position so that whilst carrying out the welding the outer casing of the torch does not become twisted or assume positions which could hinder progress, wear protective clothing and a suitable mask with non-actinic glass (glass standard no. 8 for currents of 40/60A and no. 9 for currents of 80/200A). Make sure that there is good electrical contact. Regulate the flow of gas according to the instruc¬ tions of the equipment Manufacturer. Make two spot welds at the two edges of the join line and one at the centre, then carry out spot welds in the middle of the two sections defined in this way. The spot welds should be 25-30 mm apart. The diagram below illustrates correct welding. 9 REPAIR PROCEDURES 70 joining two matched panels. the correct gap is about 1 mm. Carrying out a weld using inert gas (MIG) for Note: /r> 1 2 4 6 1 2 5 7 3 1 3 It is not advisable to initially carry out a seam weld because, in addition to being difficult to do, it can cause distortion of the panel through the accumu¬ lation of heat involved. The difficulty in carrying out a single seam weld lies in the need to move the torch rather slowly in order to ensure good weld penetration, but sufficiently quickly not to risk "burning" the panel. Moving the torch too quickly also means that the weld seam will be poor because, after grinding the bead, an insufficient layer of filler material remains to guarantee the strength of the join. After the initial spot welding of the panel, the spot welds should be ground to the level of the panel using a rigid disc grinder. At this point the alignment of the panels should be checked and, if necessary, corrected using a hammer and steel dolly block. Then proceed with filling the gaps between the various spot welds carrying out alternating welding sections, keeping the torch at an angle of around 60°, (see diagram above). 1. Tacking the join. The tack welds are illustrated from the rear of the panel. Grinding join tack welds. 2. Carrying out the welding. 3. Two alternatives are illustrated for the correct sequence of welding to be carried out to avoid deformations of the panel. The fact that the weld has been carried out correctly is confirmed from the rear of the weld bead which should show a series of spherical bumps along the entire length of the join. The MIG welder can also be used for joining over¬ lapping panels where only one side is accessible. To carry out the welding, the panels must adhere perfectly and the torch should be kept perpendic¬ ular to the surface. In this way the action of the electrode melts the first panel initially, then the second producing a crater which is filled. 10 a Body 2 3 4 5 6 7 *TTT7*- In order to carry out this operation correctly, the welding machine must be adjusted to the correct current value for the thickness of the panels being worked on and pressure must be applied to the surface, with the torch resting on its supports, to faciliate the matching of the panels. Where the thickness of the panels is more than 1.5 - 2.5 mm, holes 0.6 mm in diameter must be made level with the weld spots. PA5106/00 06/1998 REPAIR PROCEDURES 0 Body Carrying out inert gas (MIG) welding to join over¬ 70 lapping panels 5 1} 4 3 1 2 1 . Area where panels are joined 2. Electrode 3. Weld spot 4. Torch 5. Hole (only for thick panels) GENERAL INSTRUCTIONS FOR EXPOSED WELDING Below are some important instructions not be underestimated: - incomplete penetration (p) should be 15-30% of the thickness of the panel (see diagram below point A incorrect welding, point B correct welding). - the height of the bead (a) should be 60% of the thinnest thickness (s), the clearance (g) between the panels before welding should be 20% of the thinnest thickness for at least two thirds of the length (I) of the bead, (see diagram below, point C and detail X). The diagram indicates the value of the convexity (c) of the bead according to the length (I) of the weld. - the shape of the bead section should have a convexity (e) which depends on the length of the actual bead (see diagram below, point D). PA5106/00 06/1998 11 REPAIR PROCEDURES a Body 70 Examples of welding B A % Y/Z//ZZZZZ?ÿJZZZ p % P x O c r % (s) — V -4 x (I) (2/3) g D V-1 C mm 2,2 c 2 c 1.8 1,6 1,4 1,2 1 I mm 34 BRAZING Brazing is only used if the panels being replaced have been welded by this method, with the welding only carried out at the points defined by the Manu¬ facturer. This type of welding does not guarantee mechan¬ ical characteristics which are comparable with the other systems described previously and therefore is not used for joining structural parts. When using oxy -acetylene torches for brazing, follow the safety instructions relating to their usage and be sure to work in a safe environment. The use of this welding system requires the use of an extractor system to get rid of the fumes and harmful gases. 5678 9 10 The filtration takes place in two stages; mechani¬ cally eliminating the largest particles of dust through wire gauze and then by subjecting the air flow to ionization which statically charges the parti¬ cles of dust which will then be eliminated through the electro-static process. The air flow is then purified by passing through active charcoal filters. In addition to their efficiency, handling and noise levels in these systems has been improved so that they never create a nuisance. The diagram below illustrates a possible conforma¬ tion decribed above. AIR FILTRATION AND PURIFICATION SYSTEM When carrying out operations which produce fumes, gases and dust which is dangerous to the operator, air filtration and purification systems must be used. These systems are adapted to suit the varying requirements and their size depends on the volume of air to be purified. These systems usually operate through the combined action of mechanical and electro-static filtration and purification through active charcoal. 72 PA5106/00 06/1998 r*s REPAIR PROCEDURES Body r*C 70 J Example of a portable air filtration and penetration system O PAINTING Introduction Painting the bodyshell has two fundamental objec¬ tives; protecting the surfaces of the panels from environmental attack and, from an aesthetic point of view, producing a shiny, bright colour. The large number of chemical products used in painting operations requires special care to be taken over their handling and usage. These painting operations involve the emission of paint fumes and solvent vapours which, if inhaled by the operators, can seriously affect their health and they should only be carried out in special spray booths. The operator should always wear a mask and protective clothing. These masks can be the filtration type for brief oper¬ ations and the total protection pressurized type for longer operations. EQUIPMENT The following equipment is used during painting operations: filtration masks and protective clothing masking materials and tape - spray booths and drying ovens - spray guns - infra-red lamps polishers PA5106/00 06/1998 PROTECTIVE CLOTHING When carrying out painting operations, suitable clothing should always be worn, so that the oper¬ ator is well protected from contact with harmful agents. It is also advisable to use a barrier cream applied to the most exposed uncovered areas (face, hands and arms) which should be removed at the end of the painting operations. FILTRATION MASK This type of mask only protects the operator's respi¬ ratory tracts and goggles and hair protection should also be used at the same time. Its use is recommended for small retouching opera¬ tions. Example of a filtration mask | lM 13 REPAIR PROCEDURES 70 Body PRESSURIZED MASK This mask guarantees all round protection of the face and hair, providing pure air by means of the compressed air system which operates the spray gun. The air is further purified with a degree of separa¬ tion approaching 1 00% by an active charcoal filter fitted to the operator's belt. The slight excess pressure created inside the helmet prevents the infiltration of paint vapours. The use of this mask is advisable for lengthy painting operations. Example of a pressurized mask HT J Special attention has been paid to the ease of adjustment which requires minimal, simple move¬ ments. This spray gun has an extremely high efficiency combined with a very fine atomization capacity for any product, even water soluble products, used at pressures equal to or below 0.7 g (10 PSI). Thanks to these capacities for exploiting the painting mate¬ rial, considerable savings are achieved in financial terms and the working environment is improved. The diagram below illustrates several possibilities for using spray guns. SPRAY BOOTH Painting and drying operations for prepared parts should be carried out in spray booths. If the extent of the damage repaired is medium to large, it is advisable to use a special spray booth and a hot air oven for drying the paint. The workplace must be equipped with an air conditoning system and filtered by purifiers, mainly consisting of renewable active charcoal filters. The optimum painting conditions which should be maintained in the booth during painting are as follows: - constant temperature of between 22 -25 °C - constant humidity of between 75-80% The workplace in question can be: a combined type spray booth and diying oven: - a separate type spray booth and drying oven. SPRAY GUNS The development of ergonomics and spraying tech¬ niques has led to the definition of a new type high air volume and low atomization pressure spray gun where the paint mist is considerably reduced. This type of spray gun is lighter with a grip designed to reduce tiredness and the onset of cramp and has a trigger which requires far less effort than traditional spray guns. The handling of the spray gun has also been made easier through the balance and the reduced visual restriction which allows greater control when working. The most interesting aspect of this spray gun is the supply system which allows painting in any direc¬ tion, even with the reservoir pointing downwards, also improving cleaning procedures with a consid¬ erable saving in time and materials. The possibility of painting from the top or from the bottom, in addition to avoiding the formation of areas which are too wet or too dry, facilitates access to areas of the bodywork which are difficult to reach. 14 PA5106/00 06/1998 REPAIR PROCEDURES a Body 70 Using a spray gun B A - "\ ■**> <±> C '[ A- Normal method of use B- Use from the bottom to the top C- Use from the top to the bottom PORTABLE INFRA-RED LAMPS If the operation only involves small retouches, the use of a drying oven is not advisable. In such cases drying the paint can be done using special infra-red lamps fitted on parabolic mirrors. The use of one or more lamps positioned in such a way that an even temperature is produced on the surface of the area retouched, allows the diying of the paint film and produces results which are comparable to those obtained in drying ovens. These types of lamps considerably reduce the drying times, also reducing energy consumption. The lamp should only be used when the paint has undergone a degree of drying so that it is "outside the powder" condition. PA5106/00 06/1998 15 REPAIR PROCEDURES Body 70 rC J Drying a retouched area using a portable infra-red lamp t l *' 0 i \\ & a fcGp) POLISHERS The operation of polishing the paint should only be carried out after drying the enamel and after the base has cooled down to ambient temperature. Polishing is also necessary if there are defects in the paintwork such as dust, paint fumes, drips, orange peel, small scratches. There are many products designed to eliminate these defects which should be applied either manu¬ ally or mechanically, using a polishing machine. The tool should be held parallel to the surface to be polished and should not be held at an angle, to avoid the paint overheating and the creation of circular, concentric grooves. The diagram below illustrates the correct way of holding the polisher. Correct use of a polisher / rM > If A iV \ K ft \ Painting cycles □ When using chemical products, follow the safety instructions from the supplier closely. The painting operations vary according to the type of operation. The sequence of operations is described in the paragraphs which follow. There is a special proce¬ dure for the colour "Nuvola (cloud) Light Blue". 16 PA5106/00 06/1998 REPAIR PROCEDURES Body rC j r\ PAINTING A REPLACED BODY PANEL (BOLTED) With the original part treated with cataphoresis on electro-galvanized panels. 1. Clean the replacement panel, to remove any traces of dust, grease, etc. using a "VOC" low volatile organic compound detergent product. 2. Carry out a slight "surface” dry sanding using P 220 - P 240 grade abrasive paper, using a power sander equipped with a suction system only on the panel being painted. 3. Suction the dust and clean with a low "VOC" detergent product or an anti-silicone product. 4. Apply a chrome-free passivating product (wash primer) in a single coat to the areas stripped following the instructions from the supplier. 5. Apply sealant by extrusion to visible panel joins/ matches following the supplier's instructions (for the subsequent application of the filler). 6. Apply the high/medium solid filler, prepared previously, following the supplier's instructions. 7. Finish off with P 320 - P 400 grade abrasive paper, dry sanding using power sanding machines fitted with a suction system and repeat operation 3. 8. Blow through the entire panel thoroughly. 9. Clean the surface with an anti-static cloth. 1 0.Apply the pastel/metallic/metallescent base tint, prepared previously, following the supplier's instructions. 1 1 .Apply the normal or high solid twin component acrylic clear coat, prepared previously, following the supplier's instructions. Note: Check the panel, if there is a slight dent, fill the part concerned then dry sand with P 320 - P 400 grade abrasive paper using a sanding machine fitted with a suction system. Repeat operation 3/4. A REPLACED BODY PANEL PAINTING (WELDED) With the original part treated with cataphoresis on electro-galvanized panels. 1 . Clean the (welded) replacement panel to elimi¬ nate any dust, grease, etc. using a low "VOC" detergent or an anti-silicone product. 2. Dry sand the areas involved in the welding with P 80 - P 100 grade abrasive paper using a sanding machine fitted with a suction system. 3. Carry out a slight "surface" sanding using P 220 - P 240 grade abrasive paper using a sanding machine fitted with a suction system only on the panel involved in the painting. 4. Suction the dust and clean with a low "VOC" detergent product or an anti-silicone product. 5. Apply a chrome-free passivating product (epoxide base coat) to the stripped areas following the supplier's instructions. 6. Fill the areas of the join affected by the welding using polyester filler, following the supplier's instructions. 7. Dry sand with P 100 - P 120 grade abrasive paper using a sanding machine fitted with a suction system and carry out operation 4/5. 8. Apply sealant through extrusion to visible panel joins/matches following the supplier's instruc¬ tions (for the subsequent application of the filler). PA5106/00 06/1998 70 9. Apply the high/medium solid filler, prepared previously, following the supplier's instructions. 10. Finish with P 320 - P 400 grade abrasive paper using a sanding machine fitted with a suction system and repeat operation 3. 11 .Clean the surface with an anti-static cloth. 1 2.Apply the pastel/metallic/metallescent base tint, prepared previously, following the supplier's instructions. 1 3.Apply the normal or high solid twin component acrylic clear coat, prepared previously, following the supplier's instructions. Note: Check the panel, if there is a slight dent. fill the part concerned then dry sand with P 320 - P 400 grade abrasive paper using a sanding machine fitted with a suction system. Repeat operation 4/5. PAINTING A (REPAIRED) BODY PANEL 1 . Dry sand the "repaired area" with P 80 - P 1 80 grade abrasive paper using a sanding machine fitted with a suction system. 2. Suction the dust and clean with a low "VOC" detergent product or an anti-silicone product. 3. Apply a chrome-free twin component passi¬ vating product (epoxide base coat) to the repaired area in a single coat, following the supplier's instructions. 4. Fill the areas with air drying twin component polyester filler. 5. Dry sand with P 100 - P 120 grade abrasive paper using a sanding machine fitted with a suction system and carry out operation 2/3. 6. Apply the high/medium solid filler by shading in the filled area prepared previously, following the supplier's instructions. 7. Dry sand with P 320 - P 400 grade abrasive paper using a sanding machine fitted with a suction system and carry out operation 2. 8. Blow through the entire panel thoroughly. 9. Clean the surface with an anti-static cloth. 10.Apply the pastel/metallic/metallescent base tint, prepared previously, following the supplier's instructions. 11 .Apply the normal or high solid twin component acrylic clear coat, prepared previously, following the supplier's instructions. Note: Check the panel, if there is a slight dent, fill the part concerned then dry sand with P 320 - P 400 grade abrasive paper using a sanding machine fitted with a suction system. Repeat operation 2/3. PAINTING (REPLACEMENT) BUMPERS 1. Clean the bumper ordered from the Parts Divi¬ sion to remove any traces of dust, grease, etc. using an anti-static product because it is protected by a special base coat for the subse¬ quent painting. 2. Rub down the surface to be painted, with P 360 - P 400 grade abrasive paper, using a sanding machine fitted with a suction system. 3. Suction the dust and clean using a low "VOC" anti-static product. 4. Blow through the entire panel thoroughly. 5. Clean the surface with an anti-static cloth. 17 REPAIR PROCEDURES Body 70 J 6. Apply the chrome-free twin component passi¬ vating product (plastic base coat) to all the stripped areas in a single coat, following the supplier's instructions. 7. Apply the pastel/metallic/metallescent base tint, prepared previously, following the supplier's instructions. 8. Apply the normal or high solid twin component acrylic clear coat, prepared previously, following the supplier's instructions. Add elasticized dear coat, following the supplier's instructions. PLASTIC (REPLACEMENT) PAINTING A ELEMENT (KMC COMPOUND MATERIAL) 1 . Clean the bolted (plastic) part ordered from the Parts Division to remove any traces of dust, grease, etc. using a low "VOC" detergent product or an anti-silicone product. 2. Carry out a slight "surface" dry sanding, only on the plastic involved with the painting, with P 220 - P 240 grade abrasive paper using a sanding machine fitted with a suction system. 3. Suction the dust and clean using a low "VOC" detergent product. 4. Apply high/medium solid filler, prepared previ¬ ously, following the supplier's instructions. 5. Finish off with P 320 - P 400 grade abrasive paper using a sanding machine fitted with a suction system. Repeat operation 3. 6. Blow through the entire panel thoroughly. 7. Clean the surface with an anti-static cloth. 8. Apply the pastel/metallic/metallescent base tint, prepared previously, following the supplier's Note: instructions. 9. Apply the normal or high solid twin component acrylic clear coat, prepared previously, following the supplier's instructions. Note: r£ Check the panel, if there is a slight dent, fill the part concerned then dry sand with P 320 - P 400 grade abrasive paper using a sanding machine fitted with a suction system. Repeat operation 3. PAINTING A NON REPLACED BODY PANEL/ PLASTIC (KMC) ELEMENT "COSMETIC CYCLE" 1. Dry sand the panel with the defect in the PV applied, with P 360 - P 400 grade abrasive paper, using a sanding machine fitted with a suction system. 2. Suction the dust and clean the panels with low "VOC" detergent or with an anti-silicone product, whilst a low "VOC" anti-static product should be used for plastics. 3. Blow through the entire panel thoroughly. 4. Clean the surface with an anti-static cloth. 5. Apply the pastel/metallic/metallescent base tint, prepared previously, following the supplier's instructions. 6. Apply the normal or high solid twin component acrylic clear coat, prepared previously, following the supplier's instructions. PAINTING REPLACEMENT OF REPAIRED PANELS USING SPECIAL "NUVOLA" MICALIZED ENAMEL "Nuvola" micalized enamel is a special colour with a CHANGING/PEARLESCENT appearance. The colouring changing effect is achieved through a special enamel containing particles of mica coated in iridescent colourings; this type of enamel is an almost transparent paint which adds a pearlescent appearance to the base colour which shows through and gives the tone. PAINTING A REPLACEMENT PANEL (WITH THE ORIGINAL PART TREATED WITH CATAPHORESIS) Operating cycle for micalized "Nuvola" enamel with iridescent colourings. 1. Clean the replacement panel to remove any traces of dust, grease, etc. using low "VOC" detergents. 2. (If there is accidental rust due to storage, grind the area until the panel is stripped). 3. Slightly dry sand the "surface" of only the part of the panel involved in the painting, using 220 grade abrasive paper using a sanding machine fitted with a suction system. 4. Clean the exposed part of the panel using a low "VOC" detergent. 5. Blow through the entire panel with compressed air. 6. Apply the chrome-free twin component passi¬ vating product by spraying in a single coat. (Film thickness from 5....10 micron). 7. Apply plastic sealants to the joins where applied originally (see specific cycle in Notes chapter). 8. Apply High Solid twin component filler, by spraying in two cross coats, with an interval of several minutes according to the desired thick¬ ness. 9. Wait for 10 - 15 minutes before starting the drying. 1 0.Dry the base coat in an oven at a temperature of 40°....60° C for 30 - 40 minutes. (Film thickness from 70....80 micron; hardness F-H). 11 .Dry sand the element sprayed with suction using 400 grade abrasive paper. Make sure that the element is at ambient temperature for this opera¬ tion. 12.Blow through with compressed air. 13.Clean with low "VOC" detergents and polish with an anti-static cloth. 1 4.Apply a cross coat of twin layer pastel enamel. 15.Dry for 10-15 minutes at ambient temperature (20°C) and then dry in an oven at a temperature of (60°C) for 40 minutes. 1 6.Dry sand the element sprayed with suction using 800 grade abrasive paper. Make sure that the element is at ambient temperature for this opera¬ tion. 17.Blow through with compressed air. 18.Clean with low "VOC" detergents and polish with an anti-static cloth. 19.Apply the "Nuvovla" base coat by spraying one light coat and four normal coats at intervals of several minutes then follow with a light, fadedin coat to even the paint (film thickness around 30 micron). 20.Drying for 15-20 minutes at a temperature of 20°C. 18 PA5106/00 06/1998 REPAIR PROCEDURES Body rC j 21 .Application of normal or high solid twin compo¬ nent acrylic clear coat. 22. For normal clear coat: spray a light coat followed by two coats at intervals of several minutes. 23.For High Solid clear coat: spray a light coat followed by a full coat with an interval of several ...... minutes. 20 minutes at ambient temperature for 15 (20°C) and then dry in an oven at a temperature of 60°C for 40 minutes (film thickness 40....50 24.Dry micron; hardness HB-F). 25. Possible mechanical or manual polishing of the retouch or the painted panel (or the adjacent area) with fine grade abrasive paste and/or polish. It is advisable to carry out this operation at least 24 hours after drying. PAINTING A REPAIRED - RETOUCHED PANEL (OPERATION ON BARE PANEL) Operating cycle for "Nuvola" micalized enamel with iridescent colourings. 1. Overhaul the area to be retouched with 150 ... 200 grade abrasive paper, taking care to level the surrounding area and eliminate any traces of corrosion on the exposed panel. 2. Clean the exposed part of the panel and the surrounding area overhauled with low "VOC" detergent. 3. Blow through with compressed air. 4. Apply the chrome-free twin component passi¬ vating product to the exposed areas of the panel by spraying in a single coat. (Film thickness from 5....10 micron). 5. Possible filling with air drying twin component polyester product. 6. Dry overhauling with suction of the filled area with 80 1 20 grade abrasive paper. 7. Blow through with compressed air. 8. Washing the sanded area with low "VOC" deter¬ ..... gents. 9. Further application of the twin component passi¬ vating product on the areas of the panel exposed during overhauling by spraying a single coat. 10.Appiication of High Solid twin component filler by spraying 2....4 cross coats, with intervals of several minutes according to the desired thick¬ ness. 11.Wait for 10....15 minutes before starting the drying. 12.Drying of base coat with infra-red lamps: 13.initial distance 50 60 cm. for a period of 5 minutes; then place the lamp 35....40 cm away for 15 minutes. (Film thickness 80...150 micron; hardness F-H). Alternatively, dry in an oven at a temperature of 60°C for 40 minutes. 14.Dry sand the element sprayed with suction using 400 grade abrasive paper. Make sure that the element is at ambient temperature for this opera¬ tion. 15.Blow through with compressed air. 1 6.Clean with low "VOC" detergent. 17.Polish with an anti-static cloth. 18.Carry out the cycle for replacement panels from point 1.1 2 to point 1.20. ..... PA5106/00 06/1998 70 THERMO-PLASTIC PAINTING MATERIAL COMPONENTS (OPERATIONS ON REPLACE¬ MENT PARTS) On the model in question, these parts are the: Bumper, Spoiler and . Miniskirts. Operating cycle for "Nuvola" micalized enamel with iridescent colourings. 1. Apply the adhesion promoter (primer) for thermo-plastic materials. 2. Carry out the cycle for replacement panels from point 1.12 to point 1.20. PAINTING THERMO-HARDENING MATERIAL COMPONENTS (OPERATIONS ON REPLACE¬ MENT PARTS) On the model in question, the part involved is the fuel filler. Operating cycle for "Nuvola" micalized enamel with iridescent colourings. 1. Carry out the cycle for replacement panels from point 1.7 to point 1 .20. All the spraying operations of the passi¬ vating product, the filler and the enamels, should be carried out in a spray booth after having masked the area surrounding the part to be painted. Base coats, filler, enamels and solvents should be handled and used in well ventilated areas. Special solvents with a maximum of 3% toluene and xylene should be used for cleaning the equipment. Before carrying out any polishing, make sure that the panel and he surrounding area are at ambient Note: temperature. Before spot welding the panels, apply electro-weld¬ able galvanizing protective (type PPG D 386 - 459632 or an equivalent product) to ground edges of the join area. Renew the anti-corrosion/ sound insulation/sealant treat¬ ments. The treatments to which the bodyshell is subjected to achieve the necessary resistance characteristics to corrosion, sound inslation and sealing can be damaged or destroyed by repair operations. They should therefore be renewed, as appropriate during the repair operations, so that the vehicle is restored to its original condition. EQUIPMENT The following equipment is used: power guns for sealant product extrusion - foam injection systems - wax based oil injection systems The internal anti-corrosion protection must be renewed in box sections which have been replaced or repaired by welding or overheating through: the application of rust converter in the over¬ heated or welded areas which require drying for at least 24 hours at ambient temperature (20 °C); - the application of wax based protection in the replaced or repaired box section (type PPG 853.764 or equivalent product); 19 REPAIR PROCEDURES Body 70 a Renew the rigid type expanded polyurethane foam in the box sections (e.g.: Schiuma - fix from BOSTON, Schiumal P.U.R. from TORGGLER - Merano or an equivalent product); - Where necessary, restore the sealing of the joins; - Carry out the sealing, following the instructions given below, in the flanges of the moving parts (tailgate, bonnet) supplied as spares: on replacement parts treated with cataphoresis, clean the areas concerned with heptane or anti¬ silicone/anti-static solvents; - apply a bead of SIKAFLEX 221 type poly¬ urethane sealant manufactured by SIKA (*) in the shape and position illustrated in the diagram. - leave the sealant to dry for 24 hours at ambient temperature (20 °C) or 40 minutes at 60 °C; - carry out the normal painting of the component. Apply sound-deadening paint on external parts which have been replaced or repaired, as required. (*) Alternatively, use a similar product manufac¬ tured by 3M or other equivalent products, following the supplier's instructions. Examples of application of sealant - .o A A - Sealant When using chemicals, closely follow the safety instructions given on the safety sheet which the supplier must give to the user (in Italy, in accordance with D.M. no. 47/ 1992). □ 20 PA5106/00 06/1998 REPAIR PROCEDURES Body 70 J Group index - GROUP GRAPHIC INDEX Sub-groups index Sbgrp. Description 7040 Body interior upholstery and trim 7090 Body panels Validity - replacement and repair GROUP GRAPHIC INDEX 10 4 8 5 0 6 3 3 a 7 0 Q 2 1 0 9 Ref. Description Sbgrp. 1 Passenger compartment front side door 7005 2 Passenger compartment rear side doors 7010 3 Compartment covers lids 7025 4 Sun roof and hood 7030 5 Body window glasses 7035 6 Body interior upholstery and trim 7040 7 Front seats 7045 8 Rear seats 7050 9 Mouldings on protections 7055 10 Safety belts and accessories 7065 Body panels - replacement and repair PA5106/03 10/1998 7090 1BB 1 REPAIR PROCEDURES 70 2 Body El PA5106/03 10/1998 REPAIR PROCEDURES Passenger compartment front side door rC J 7005 Sub-group index - SUB-GROUP GRAPHIC INDEX Assembly drawings index Cmp Description 7005A Front side door assembly 7005 B Front door mechanical locks 7005C Front lock controls 7005D Front side door window glasses 7005E Front side door trim 7005M Front electric windows 7005N Front door central locking system 7005R Front door mirrors Validity SUB-GROUP GRAPHIC INDEX 8 4 iQ 1 rs J) S\ D 3 [7 2 \ V 7 6 0 r*\ \ 5 Ref. Description Cmp 1 Front side door assembly 7005A PA5106/00 06/1998 1 REPAIR PROCEDURES 7005 Passenger compartment front side door rC J Ref. Description Cmp 2 Front door mechanical locks 7005B 3 Front lock controls 7005C 4 Front side door window glasses 7005D 5 Front side door trim 7005E 6 Front electric windows 7005M 7 Front door central locking system 7005N 8 Front door mirrors 7005R 2 PA5106/00 06/1998 o REPAIR PROCEDURES a Passenger compartment front side door 7005 7005A - Front side door assembly VIEW OF ASSEMBLY 5 ea 4 Q \\d£ 1 A vo ! w f 4 / [V 2 O 3 6 W. Ref. Description 1 FRONT DOOR 2 FRONT DOOR WATER GUARD PROTECTION 3 FRONT SIDE DOOR HINGES 4 FRONT DOOR OPENING LIMITER 5 FRONT SIDE DOOR FRAME SEAL 6 FRONT SIDE DOOR LOWER SEAL Operations index Code Validity Operation Front side door water guard protection - r r or replace panel removed _ with door 7005A05 Front side door water guard protection r r or arrange /ÿS 7005A04 _ 7005A10 Front side door - adjust striker and adapt seal in neces- _sary _ PA5106/00 06/1998 3 REPAIR PROCEDURES 7005 Code a Passenger compartment front side door Validity Operation 7005A14 Front side door - adjust centering and moulding includes adaptation of hinges and seals on door _compartment _ 7005A18 Front side door includes removing and refitting all _parts for vehicle with electrical appliances on door 7005A20 Front side door - adjust centring and moulding _includes adaptation of hinges _ 7005A24 Front side door r r 7005A28 Front side door hinges - repair or replace with door removed 7005A34 Front side door compartment seal r r 7005A46 Front side door lower seal r r 7005A48 Front side door lower seal support - r r WARNINGS ? Observe the following instructions when working on the front door assembly: - When working on the hinges, take care not to damage the paintwork. - If door adjustment requires the hinges to be moved, remove the door and touch up the paint¬ work in the hinge area. - After removing a door, lean the door against a stable support and avoid damage to the paint¬ work. \0 am 3a ml% A |QL /1/ t- / PRECAUTIONS // O’ DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). 1 2 OPERATIONS 7005A04 - FRONT SIDE DOOR WATER GUARD PROTECTION R R OR REPLACE WITH DOOR PANEL REMOVED Removal 1. Remove the door panel retaining bushes. 2. Take off the adhesive water guard. Installation - - - Remove the protective film from the upper part of the water guard. Position the water guard using the panel retaining holes as a reference. Bond the sealant strip at the upper and lower corners of the door. Press the sealant strip evenly around the outside of the guard. Do up the studs fastening the guard to the door. 7005A05 - FRONT SIDE DOOR WATER GUARD PROTECTION R R OR ARRANGE Removal Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r Follow the Op. 7005E38 Front side door interior handle-r r Follow the Op. 5570T90 Front speaker - r r 4 PA5106/00 06/1998 REPAIR PROCEDURES a Passenger compartment front side door 7005 Follow the Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Follow the Op. 7005C44 Interior handle panel rr Follow the Op. 7040E24 Lower courtesy light indoor panel - r+r Follow the Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Follow the Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed L 3 Installation door panel radio grille (one) - r+r Complete with Op. 7005E38 Front side door interior handle-r r Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r 7005A10 - FRONT SIDE DOOR ADJUST STRIKER AND ADAPT SEAL IN NECESSARY Before altering the position of the door striker, ensure the door is properly aligned. 1. Loosen the striker retaining screws. 2. Use the locating holes to move striker (2a) into the correct position. Fit shims (2b) if necessary in order to adjust the striker accurately. 3. Permitted adjustment movements are indicated by arrows. - Following adjustment, tighten the lock striker screws to the specified torque. \ 2a \\/ 2b <1 1 Mounting Component 0 Screw STRIKER ON FRONTSIDE DOOR PILLAR M8 Value (daNm) 2.4 \ 7005A14 - FRONT SIDE DOOR ADJUST CENTERING AND MOULDING - INCLUDES ADAP¬ TATION OF HINGES AND SEALS ON DOOR COMPART¬ MENT - U \ / Complete with Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed Complete with Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Complete with Op. 7040E24 Lower courtesy light indoor panel - r+r Complete with Op. 7005C44 Interior handle panel - r r Complete with Op. 5570T90 Front speaker - r r Complete with Op. 7005E22 L/h or r/h front Look to ensure the gap between door and front wing and between front and rear door is even. it is advisable to work on one hinge at a time. Removal Follow the Op. 7005B14 Front side door catch striker r r 1. Loosen the nuts retaining the hinges to the door. 2. Move the door in the directions arrowed in the figure. Fit shims between hinges and door if necessary to ensure the door is adjusted properly - Following adjustment, tighten the nuts retaining the hinges to the door to the specified torque. u 1 Value Mounting Component 0 Nut FRONT SIDE M8 (daNm) 3.6 DOOR HINGES PA5106/00 06/1998 5 REPAIR PROCEDURES 7005 Passenger compartment front side door Follow the Op. 7005D15 Front side door descending window glass r r Follow the Op. 7005D18 Front side door descending window glass channel r r Follow the Op. 7005D21 Front door window front guide - r r Follow the Op. 7005D24 Front door window rear guide - r r Follow the Op. 7005D25 Front door window rear guide - r r Follow the Op. 7005D26 Front side descending window glass scraper (outer) r r Follow the Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r Follow the Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Follow the Op. 7005E38 Front side door interior handle-r r Follow the Op. 7005E50 Front side door pillar trim (one) Ih or rh - r r Follow the Op. 7005M21 Front side door elec¬ trically operated window - r r Follow the Op. 7005N21 Front side door lock motor- lock assembley-r r Follow the Op. 7005R30 Electrically controlled door mirror (one) - r+r Follow the Op. 7040E24 Lower courtesy light indoor panel - r+r 2 1 2 c 1 Installation - Touch up the affected door hinge area with paint. 7005A18 - FRONT SIDE DOOR INCLUDES REMOVING AND REFITTING ALL PARTS FOR VEHICLE WITH ELECTRICAL APPLIANCES ON DOOR Installation - Removal Follow the Op. 5570T90 Front speaker - r r Follow the Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed Follow the Op. 7005A10 Front side door adjust striker and adapt seal in necessary Follow the Op. 7005A20 Front side door adjust centring and moulding - includes adapta¬ tion of hinges Follow the Op. 7005A28 Front side door hinges - repair or replace with door removed Follow the Op. 7005A46 Front side door lower seal r r Follow the Op. 7005A48 Front side door lower seal support - r r Follow the Op. 7005B14 Front side door catch striker r r Follow the Op. 7005C11 Front side door outside handle r r Follow the Op. 7005C43 Link connecting front side door barrels/catch - r+r Follow the Op. 7005C44 Interior handle panel rr Follow the Op. 7005C51 Front side door inner catch device - r+r for repair or replacement Follow the Op. 7005C53 Interior opening handle - r r Follow the Op. 7005C62 Front side door safety catch knob and seal r r Follow the Op. 7005C67 Front side door safety catch link r r 6 El - - Check that the door and the various parts are undamaged. Complete with Op. 7040E24 Lower courtesy light indoor panel - r+r Electrically Complete with Op. 7005R30 controlled door mirror (one) - r+r Complete with Op. 7005N21 Front side door lock motor- lock assembley-r r Complete with Op. 7005M21 Front side door electrically operated window - r r Complete with Op. 7005E50 Front side door pillar trim (one) Ih or rh - r r Complete with Op. 7005E38 Front side door interior handle-r r Complete with Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r Complete with Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Complete with Op. 7005D26 Front side descending window glass scraper (outer) r r Complete with Op. 7005D25 Front door window rear guide - r r Complete with Op. 7005D24 Front door window rear guide - r r Complete with Op. 7005D21 Front door window front guide - r r Complete with Op. 7005D18 Front side door descending window glass channel r r Complete with Op. 7005D15 Front side door descending window glass r r Complete with Op. 7005C67 Front side door safety catch link r r Complete with Op. 7005C62 Front side door safety catch knob and seal r r Complete with Op. 7005C53 Interior opening handle - r r PA5706/00 06/1998 a REPAIR PROCEDURES Passenger compartment front side door Complete with Op. 7005C51 Front side door inner catch device - r+r for repair or replacement Complete with Op. 7005C44 Interior handle panel - r r Complete with Op. 7005C11 Front side door outside handle r r Complete with Op. 7005B14 Front side door catch striker r r Complete with Op. 7005A48 Front side door lower seal support - r r Complete with Op. 7005A46 Front side door lower seal r r Complete with Op. 7005A28 Front side door hinges - repair or replace with door removed Complete with Op. 7005A20 Front side door adjust centring and moulding - includes adapta¬ tion of hinges Complete with Op. 7005A10 Front side door adjust striker and adapt seal in necessary Complete with Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed Complete with Op. 5570T90 Front speaker A 3 dgo] With the ignition key in the stop position, disconnect the battery negative terminal - Apply protective tape to the edge of the front wing. 1.Withdraw safety retaininer (1a) of the main door wiring connector and disconnect connector (1b). - \Description Front left door connection Connector D30 />S IDescription Front right door connection Connector D31 2. Pull away limiter rubber protection (2a), and unscrew door opening limiter retaining bolts (2b). 3. Unscrew the door hinge retaining bolts. 4. With the aid of a second operator, raise the door and withdraw the hinge pins. Remove the hinge and place it on a sheet of protective material. PA5106/00 06/1998 2b n V ■ am 2a 1a(C 3 Installation - - 1b \ Km - Removal 02* 1 -rr 7005A20 - FRONT SIDE DOOR ADJUST CENTRING AND MOULDING - INCLUDES ADAP¬ TATION OF HINGES 7005 With the aid of a second operator, raise the door and refit. Ensure the hinge pins are centred. Tighten the hinge retaining bolts Connect the main connector and position the safety retainer. Take out the limiter and extend it to the end of its travel. Tighten both bolts retaining the door opening limiter to the car and fit the plastic cover. Check the door and its electrical components are working properly. 7005A24 - FRONT SIDE DOOR R R Removal 1. Unscrew the nuts retaining the hinges to the door. 2. Remove hinge (2a) and recover any underlying shims (2b). 7 REPAIR PROCEDURES a Passenger compartment front side door 7005 3. Unscrew the bolts securing the limiter to the door. 4. Remove the door opening limiter. 2a 1 a g) 2b 1a e © / n 1 2a — •4' it 1b 2b 3 Installation Position the hinges and any shims removed previously. Take care to keep the pad pins moving freely through the centre of the hole. Screw in the nuts retaining the hinges to the door without tightening. Complete with Op. 7005A14 Front side door adjust centering and moulding - includes adap¬ tation of hinges and seals on door compartment - 7005A28 - FRONT SIDE DOOR HINGES - REPAIR OR REPLACE WITH DOOR REMOVED Removal Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r Follow the Op. 7005E38 Front side door interior handle-r r Follow the Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Follow the Op. 5570T90 Front speaker - r r Follow the Op. 7005C44 Interior handle panel rr Follow the Op. 7040E24 Lower courtesy light indoor panel - r+r Follow the Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Follow the Op. 7005A04 Front side door water guard protection - r r or replace with door panel - - removed I.Use tool (1a) to pull up plastic covers (1b) protecting the limiter fastenings on the door and car. E9 MDescription 1a Blade ~ 6 2 e Installation - - Check that the limiter is undamaged and lubri¬ cate with suitable grease. Position the limiter in the door compartment and fit the plastic protections. Tighten the bolts securing the limiter to the pillar and car. Check the limiter is working properly by opening the door partially. Position the plastic covers protecting the limiter fastenings. Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r Complete with Op. 7005E38 Front side door interior handle-r r Complete with Op. 5570T90 Front speaker - r r Complete with Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Complete with Op. 700SC44 interior handle panel - r r Complete with Op. 7040E24 Lower courtesy light indoor panel - r+r Complete with Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Complete with Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed 7005A34 - FRONT SIDE DOOR COMPARTMENT SEAL R R Removal Code 1.823.014.000 Follow the Op. 7040L40 Front compartment scuff strip - r r 1. Prise up the seal from its seat, beginning from the joint shown in the figure. 2. Unscrew the bolts securing the limiter to the pillar. Unscrew the plastic covers from the limiter. 8 PA5106/00 06/1998 A REPAIR PROCEDURES s Passenger compartment front side door 7005 2 r), o o a 1b □ 1a Installation 1 Installation Check that the seal is in one piece and does not show signs of damage or deformation. Fit the seal in its seat. Position the heat-sealed joint near the central pillar. Complete with Op. 7040L40 Front compart¬ ment scuff strip - r r - - Check that the seal is undamaged. 1. Unscrew bolts (1a) retaining mount (1b) to the door and remove. 2. Fit the front section of the seal to the mount, then fit the mount together with the front seal section. - Tighten the seven bolts retaining the mount to the door. 3. Fit the lower seal section and fastening the retaining studs. - 7005A46 - FRONT SIDE DOOR LOWER SEAL R R Removal Follow the Op. 7005A20 Front side door adjust centring and moulding - includes adapta¬ tion of hinges 1. Use tool (1a) to remove studs (1b) securing the lower edge of the seal. ES 1a Description Code Blade 1.823.015.000 2. Prise up the lower seal edge from the plastic mount and remove the seal. PA5106/00 06/1998 9 REPAIR PROCEDURES Passenger compartment front side door 7005 Tighten the bolts retaining the mount to the door. Complete with Op. 7005A20 Front side door adjust centring and moulding - includes adapta¬ tion of hinges 1a 1b a 2 3 4 Complete with Op. 7005A20 Front side door adjust centring and moulding - includes adapta¬ tion of hinges 7005A48 - FRONT SIDE DOOR LOWER SEAL SUPPORT - R R Removal Follow the Op. 7005A20 Front side door adjust centring and moulding - includes adapta¬ tion of hinges 1. Prise up the front seal section from the plastic mount. 2. Unscrew the bolts retaining the mount to the door. 3. Remove the seal mount. \ 0, 0 o 1 Installation - 10 Fit the front seal section to the mount. Fit the mount together with the front seal section. PA5106/00 06/1998 REPAIR PROCEDURES 0 Passenger compartment front side door 7005 7005B - Front door mechanical locks VIEW OF ASSEMBLY L TL % - 1 7 i Ref. Description 1 STRIKER ON FRONT SIDE DOOR PILLAR Operations index Code Validity Operation 7005B14 Front side door catch striker r r OPERATIONS 7005B14 - FRONT SIDE DOOR CATCH STRIKER R R L ■/_ Removal 1. Unscrew the bolts retaining the striker to the door. 2. Remove striker (2a) together with any under¬ lying shims (2b). 1 \ tSPp- 2a \\/ 2b / PA5106/00 06/1998 l 11 REPAIR PROCEDURES 7005 Passenger compartment front side door a Installation - Fit the striker and any shims removed previously. Screw in both retaining bolts without tightening to torque. Complete with Op. 7005A10 Front side door adjust striker and adapt seal in necessary 12 PA5106/00 06/1998 REPAIR PROCEDURES Passenger compartment front side door rC 7005 j 7005C - Front lock controls VIEW OF ASSEMBLY 2 7 fy 4 6 B, c » A a i / 3 $ C3 8 la 5 >0T)>* V/!UV/ Ref. Description 1 FRONT DOOR EXTERIOR HANDLE 2 FRONT DOOR LOCK BARREL 3 BLOCK/LOCK CONNECTION LINK 4 FRONT DOOR RETURN HANDLE PLATE 5 FRONT DOOR OPENING RETURN LINK 6 FRONT SIDE DOOR RETURN HANDLE 7 FRONT SIDE DOOR SAFETY KNOB 8 FRONT DOOR SAFETY CATCH LINK «• (. LOt II III Operations index Code Operation Validity 7005C10 Front door outer handle - r r with door panel removed 7005C11 Front side door outside handle r r PA5106/00 06/1998 13 REPAIR PROCEDURES Passenger compartment front side door 7005 J Validity Code Operation 7005C14 Front side door lock barrel (in handle) r r with handle removed Front side door lock barrel (in handle) - r+r 7005C15 rC 7005C18 Front side door lock barrel (in handle) - replace with different version 7005C42 Front side door barrel/lock connecting linkage - r r _ with door panel removed _ 7005C43 Link connecting front side door barrels/catch - r+r -rr 7005C44 Interior handle panel 7005C50 Front side door interior opening mechnism r-r for _repair or replacement with door panel removed 7005C51 Front side door inner catch device - r+r for repair or _replacement _ 7005C52 Interior opening handle - r r 7005C53 Interior opening handle - r r 7005C54 Front side door internal opening return mechanism (with handle) - r r for repair or replace with different version 7005C55 Front side door interior opening return device (with _handle) - r+r for repair or replacement _ 7005C62 Front side door safety catch knob and seal r r 7005C66 Front side door safety catch link r r with door panel removed 7005C67 Front side door safety catch link r r WARNINGS When replacing the lock barrel, it is not possible to order a single lock barrel or to order barrels using a single part code.When ordering barrels, observe the special procedure set out in unit 5580E ANTITHEFT DEVICES - special accessories. 1 . Disconnect the link connecting the catch to the outer handle dowel. 2. Unscrew the bolts and nut retaining the plastic protection to the handle. 3. Remove the plastic protection. 4. Remove handle (4a) from the outer side of the door. Take care to release the catch control link (4b). PRECAUTIONS DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). OPERATIONS 7005C10 - FRONT DOOR OUTER HANDLE - R R WITH DOOR PANEL REMOVED Removal Follow the Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed Follow the Op. 7005D24 Front door window rear guide 14 - rr PA5106/00 06/1998 REPAIR PROCEDURES Passenger compartment front side door rC 7005 J // / / / / '3 / / / / / 4 / / 2 4a 1 3 1 4b 6 4b 1 3 6 Check the handle is working properly. Installation Complete with Op. 7005D24 Front door window rear guide - r r Complete with Op. 7005A04 Front side door water guard protection - r r or replace with door Check that the handle and the handle mecha¬ nism are undamaged. 1. Remove the catch retaining bolts and lower the catch to make it easier to fit the outer handle link. 2. Position the handle in its seat. 3. Insert the handle link in the catch. - Tighten the catch retaining bolts and tighten to the specified torque. u / / / - ]/ 5 2 Mounting Component Screw FRONTDOOR M8 LOCK MECHA¬ NISM 0 Value (daNm) 1.4 4. Position the inner handle protection. 5. Tighten the handle retaining bolts and nut. 6. Connect the dowel/catch link. panel removed 7005C11 - FRONTSIDE DOOR OUTSIDE HANDLE R R Removal - - Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r Follow the Op. 7005E38 Front side door interior handle-r r Follow the Op. 5570T90 Front speaker - r r Follow the Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Follow the Op. 7005C44 Interior handle panel rr Follow the Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Follow the Op. 700SA04 Front side door water guard protection - r r or replace with door panel removed Follow the Op. 7005D24 Front door window rear guide - r r Follow the Op. 7040E24 Lower courtesy light indoor panel - r+r Follow the Op. 7005C10 Front door outer handle - r r with door panel removed Installation Complete with Op. 7005C10 Front door outer handle - r r with door panel removed Complete with Op. 7040E24 Lower courtesy light indoor panel - r+r Complete with Op. 7005D24 Front door window rear guide - r r PA5106/00 06/1998 15 REPAIR PROCEDURES Passenger compartment front side door 7005 J Complete with Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed Complete with Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Complete with Op. 7005C44 Interior handle panel - r r Complete with Op. 5570T90 Front speaker - r r Complete with Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Complete with Op. 7005E38 Front side door interior handle-r r Complete with Op. 7005E12 Corner er of one front side door, Ih or rh r r 7005C15 - FRONT SIDE DOOR LOCK BARREL (IN HANDLE) R+R Removal coL - 7005C14 - FRONT SIDE DOOR LOCK BARREL (IN HANDLE) R R WITH HANDLE REMOVED Note: 1. Disconnect the dowel/catch link. 2. Remove the dowel/catch link control device - retaining pin. 3. Remove the link control device. 4. Remove the dowel retaining clip. 5. With the key in place, remove the lock barrel. Installation - 5 p <8 1 \ r < 4 Installation - - 16 - 3 VJ 2 Fit the barrel in its seat on the handle. Fit the retaining clip. Fit the link control device. Fit the link control device retaining pin. Connect the dowel/catch link. Test that the barrel works properly and that catch action is correct. Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r Follow the Op. 7005E38 Front side door interior handle-r r Follow the Op. 5570T90 Front speaker - r r Follow the Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Follow the Op. 7005C44 Interior handle panel rr Follow the Op. 7040E24 Lower courtesy light indoor panel r+r Follow the Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Follow the Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed Follow the Op. 7005D24 Front door window rear guide - r r Follow the Op. 7005D25 Front door window rear guide - r r Follow the Op. 7005C11 Front side door outside handle r r Follow the Op. 7005C14 Front side door lock barrel (in handle) r r with handle removed - It is not possible to order a single lock barrel or to order barrels using a single part code.When ordering barrels, observe the special procedure set out in op.5580 Special Accessories. Removal - rC Complete with Op. 7005C14 Front side door lock barrel (in handle) r r with handle removed Complete with Op. 7005C11 Front side door outside handle r r Complete with Op. 7005D25 Front door window rear guide - r r Complete with Op. 7005D24 Front door window rear guide - r r Complete with Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed Complete with Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Complete with Op. 7040E24 Lower courtesy light indoor panel - r+r Complete with Op. 7005C44 Interior handle panel - r r Complete with Op. 5570T90 Front speaker - r r Complete with Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Complete with Op. 7005E38 Front side door interior handle-r r Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r 7005C18 - FRONT SIDE DOOR LOCK BARREL (IN HANDLE) REPLACE WITH DIFFERENT VERSION Note: It is not possible to order a single lock barrel or to order barrels using a single part code. When ordering barrels, observe the special proce- PA5106/00 06/1998 REPAIR PROCEDURES Passenger compartment front side door rC J dure set out in op.5580E - Special Accessories. Refer to op.. 7005C15 Front side door lock barrel (in handle) - r+r Refer to op.. 7025B46 Boot lid lock block - r+r Refer to op.. 7040A15 Facia flap lock barrel Refer to op.. 5520A14 Ignition key block - r+r - 7005C42 - FRONT SIDE DOOR BARREL/LOCK CONNECTING LINKAGE - R R WITH DOOR PANEL REMOVED 7005C43 - LINK CONNECTING FRONTSIDE DOOR BARRELS/ CATCH - R + R Removal Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r Follow the Op. 7005E38 Front side door interior handle-r r Removal Follow the Op. 7005A04 Front side door water guard protection r r or replace with door panel - removed Follow the Op. 7005D24 Front door window rear guide - r r Follow the Op. 7005 CIO Front door outer handle - r r with door panel removed I.Open retaining clip (1a) and take out link (1b) connecting outer handle to catch. 2. Take the link connecting key dowel to catch (2b) out of handle (2a). / 1a removed 1b Installation Complete with Op. 7005C42 Front side door barrel/lock connecting linkage - r r with door panel removed Complete with Op. 7005C11 Front side door outside handle r r Front door Complete with Op. 7005D25 window rear guide - r r Front door Complete with Op. 7005D24 window rear guide - r r Complete with Op. 7005A04 Front side door water guard protection - r r or replace with door to. panel removed 2b Complete with Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Complete with Op. 7040E24 Lower courtesy light indoor panel - r+r Complete with Op. 7005C44 Interior handle panel - r r Complete with Op. 5570T90 Front speaker - r r Complete with Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Complete with Op. 7005E38 Front side door interior handle-r r Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r Installation - Fit the link connecting outer handle to catch in the retaining clip. Fit the link connecting key dowel to catch in the handle. Complete with Op. 7005C10 Front door outer - Follow the Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Follow the Op. 5570T90 Front speaker - r r Follow the Op. 7005C44 Interior handle panel rr Follow the Op. 7040E24 Lower courtesy light indoor panel - r+r Follow the Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Follow the Op. 7005A04 Front side door water guard protection r r or replace with door panel removed Follow the Op. 7005D24 Front door window rear guide - r r Follow the Op. 7005D25 Front door window rear guide - r r Follow the Op. 7005C11 Front side door outside handle r r Follow the Op. 7005C42 Front side door barrel/ lock connecting linkage - r r with door panel - - 2a 7005 handle - r r with door panel removed Front door Complete with Op. 7005D24 window rear guide - r r Complete with Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed 7005C44 PANEL - INTERIOR HANDLE R R - Removal - PA5106/00 06/1998 With the ignition key in the OFF position, disconnect the battery negative terminal. 1. Remove the trim plug. 2. Undo the panel retaining bolt. 3. Remove the panel using a cutter. 17 REPAIR PROCEDURES Passenger compartment front side door 7005 J □ 3 Description Code Blade 1.823.014.000 7005C50 - FRONT SIDE DOOR INTERIOR OPENING MECHNISM R-R FOR REPAIR OR REPLACEMENT WITH DOOR PANEL REMOVED 4. Disconnect the tweeter electrical connection. \Description 4 rC Removal Connector Front left tweeter speaker Follow the Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed 1. Disconnect the cable from the connector on the catch. 2. Disconnect the cable from the door opening lever. 3. Remove cable (3a) by releasing from retaining clip (3b) on the door. P45 IDescription Connector Front right tweeter speaker P46 5. Remove the interior handle trim. \\ ' r ' V & 2 4 La 5 \ * eP. r © o,\3b 3a Q l\ V / J 0 ■2 (Mi L'ntHlir Operations index Code Operation Validity 7005D14 Front side door descending window glass - r r with _door panel (and mount frame) removed_ 7005D15 Front side door descending window glass r r 7005D18 Front side door descending window glass channel r r 22 PA5106/00 06/1998 REPAIR PROCEDURES Passenger compartment front side door r-C 7005 j Code Operation Validity 7005D20 Front door window front guide - r r 7005D21 Front door window front guide - r r 7005D22 Front side door descending window glass guide (one) _- r r with door panel (and support frame) removed 7005D23 Front side door descending window glass guide one r r 7005D24 Front door window rear guide - r r 7005D25 Front door window rear guide - r r 7005D26 Front side descending window glass scraper (outer) r r 7005D30 Front side descending window glass scraper (inner) r r 7005D32 Foil of door descending glass inner guide (one Ih) or rh _on front side door - r r with door panel removed_ 7005D33 Channel of door descending glass inner guide (one) Ih or rh on front side door - r r PRECAUTIONS 3 DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). OPERATIONS (Oil 7005D14 - FRONT SIDE DOOR DESCENDING WINDOW GLASS - R R WITH DOOR PANEL (AND MOUNT FRAME) REMOVED iZ a Removal Follow the Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed Follow the Op. 7005D21 Front door window front guide - r r Follow the Op. 7005D25 Front door window rear guide - r r I.With the window fully raised, loosen both nuts securing the electrically-operated window device to the window. - Connect the battery temporarily. 2. Operate the electrically-operated window button to lower the window about half way, then unscrew retaining bolts (2a) and remove bracket (2b). 3. Tilt the window toward the front of the door frame and then withdraw from the door. 1 2b 2a Installation - - - PA5106/00 06/1998 |C Check the condition of the window, slide channel and safety retainers. Lower the window completely. Fit the window into the door until the window retainers are aligned with the electrically-oper¬ ated window device. Screw in both retaining bolts without tight¬ ening. Operate the window button to position the window about half way through its travel. Then fit the bracket and secure using the appropriate bolts. Operate the electrically-operated window button and guide the window up by hand until it is fully raised. Tighten the window retaining bolts. Complete with Op. 7005D25 Front door window rear guide - r r 23 REPAIR PROCEDURES 7005 Front door Complete with Op. 7005D21 window front guide - r r Complete with Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed 7005D15 - FRONT SIDE DOOR DESCENDING WINDOW GLASS R R 7005D18 - FRONT SIDE DOOR DESCENDING WINDOW GLASS CHANNEL R R Removal Follow the Op. 7005E50 Front side door pillar trim (one) Ih or rh - r r Follow the Op. 7005D26 Front side descending window glass scraper (outer) r r Follow the Op. 7005R30 Electrically controlled door mirror (one) - r+r Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r 1. Prise out the upper and front section of the window channel from the door. Removal - - - Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r Follow the Op. 7005E38 Front side door interior handle-r r Follow the Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Follow the Op. 5570T90 Front speaker - r r Follow the Op. 7005C44 Interior handle panel rr Follow the Op. 7040E24 Lower courtesy light indoor panel - r+r Follow the Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Follow the Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed Follow the Op. 7005D21 Front door window front guide - r r Follow the Op. 7005D25 Front door window rear guide - r r Follow the Op. 7005D14 Front side door descending window glass - r r with door panel (and mount frame) removed m Y m Installation - - 24 a Passenger compartment front side door Complete with Op. 7005D14 Front side door descending window glass - r r with door panel (and mount frame) removed Complete with Op. 7005D25 Front door window rear guide - r r Complete with Op. 7005D21 Front door window front guide - r r Complete with Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed Complete with Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Complete with Op. 7040E24 Lower courtesy light indoor panel - r+r Complete with Op. 7005C44 Interior handle panel - r r Complete with Op. 5570T90 Front speaker - r r Complete with Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Complete with Op. 7005E38 Front side door interior handle-r r Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r j 1 Li of- (iijcmrw Installation - - Fit the window slide channel to the door. Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r Complete with Op. 7005R30 Electrically controlled door mirror (one) - r+r Complete with Op. 7005D26 Front side descending window glass scraper (outer) r r Complete with Op. 7005E50 Front side door pillar trim (one) Ih or rh - r r 7005D20 - FRONT DOOR WINDOW FRONT GUIDE - R R Removal Follow the Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed I.With the window fully raised, unscrew retaining bolts (1a) and remove front guide (1b). PA5106/00 06/1998 REPAIR PROCEDURES a Passenger compartment front side door Complete with Op. 7005C44 panel - r r 7005 Interior handle Complete with Op. 5570T90 Front speaker - r r Complete with Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Complete with Op. 7005E38 Front side door interior handle-r r Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r O’ 1a 1b 7 ,9' v* 4 Removal O - Installation - - Check that the guide is undamaged. Fit the front guide in position. Screw in the retaining bolts without tightening. Lower the window. Tighten the guide retaining bolts. Check the window is working properly. Complete with Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed 7005D21 - FRONT DOOR WINDOW FRONT GUIDE 7005D22 - FRONT SIDE DOOR DESCENDING WINDOW GLASS GUIDE (ONE) - R R WITH DOOR PANEL (AND SUPPORT FRAME) REMOVED - RR Removal Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r Follow the Op. 7005E38 Front side door interior handle-r r Follow the Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Follow the Op. 5570T90 Front speaker - r r Follow the Op. 7005C44 Interior handle panel rr Follow the Op. 7040E24 Lower courtesy light indoor panel - r+r Follow the Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Follow the Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed Follow the Op. 7005D20 Front door window front guide - r r When working on the front guide, refer to oper¬ ation: Follow the Op. 7005D20 Front door window front guide - r r Installation - When working on the rear guide, refer to oper¬ ation: Complete with Op. 7005D24 Front door window rear guide - r r 7005D23 - FRONT SIDE DOOR DESCENDING WINDOW GLASS GUIDE ONE R R When working on the front guide, refer to oper¬ ation: Refer to op.. 7005D21 Front door window front guide - r r When working on the rear guide, refer to oper¬ ation: Refer to op.. 7005D25 Front door window rear guide - r r 7005D24 - FRONT DOOR WINDOW REAR GUIDE - R R Removal Follow the Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed I.With the window fully raised, unscrew both guide retaining bolts (1a) and remove the rear guide (1b). Installation Front door Complete with Op. 7005D20 window front guide r r Complete with Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed Complete with Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Complete with Op. 7040E24 Lower courtesy light indoor panel - r+r - PA5106/00 06/1998 25 REPAIR PROCEDURES Passenger compartment front side door 7005 rC J Complete with Op. 5570T90 Front speaker - r r Complete with Op. 7005E22 L/h or r/h front V door panel radio grille (one) - r+r Complete with Op. 7005E38 Front side door interior handle-r r Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r 7005D26 - FRONT SIDE DESCENDING WINDOW GLASS SCRAPER (OUTER) R R 'i 1a © o Removal Follow the Op. 700SE50 Front side door pillar trim (one) Ih or rh - r r 1. Prise out the exterior glass scraper. § A 1b A Installation - - Check that the guide is undamaged. Fit the rear guide into position. Lower the window. Tighten the retaining bolts. Check the window is working properly. Complete with Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed 1 7005D25 - FRONT DOOR WINDOW REAR GUIDE - R R Removal Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r Follow the Op. 7005E38 Front side door interior handle-r r Follow the Op. 5570T90 Front speaker - r r Follow the Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Follow the Op. 7005C44 Interior handle panel rr Follow the Op. 7040E24 Lower courtesy light indoor panel - r+r Follow the Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Follow the Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed Follow the Op. 7005D24 Front door window rear guide - r r Installation Complete with Op. 7005D24 Front door window rear guide - r r Complete with Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed Complete with Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Complete with Op. 7040E24 Lower courtesy light indoor panel - r+r Complete with Op. 7005C44 Interior handle panel - r r 26 Installation - Check that the glass scraper is undamaged. Fit the glass scraper to the pillar. Complete with Op. 7005E50 Front side door pillar trim (one) Ih or rh - r r 7005D30 - FRONT SIDE DESCENDING WINDOW GLASS SCRAPER (INNER) R R Removal Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r Follow the Op. 7005E38 Front side door interior handle-r r Follow the Op. 7005E22 L/h or r/h front door panel radio grille (one) r+r Follow the Op. 5570T90 Front speaker - r r Follow the Op. 7005C44 Interior handle panel rr Follow the Op. 7005E08 Front side door interior panel r r Follow the Op. 7040E24 Lower courtesy light indoor panel - r+r 1. Unscrew the bolts retaining the glass scraper to the door panel. - PA5106/00 06/1998 REPAIR PROCEDURES a Passenger compartment front side door 7005 2. Remove the interior glass scraper. 1 1b fli -1a a 2 Installation Installation - - Check that the glass scraper is undamaged. Fit the glass scraper to the panel. Tighten the seven bolts retaining the glass scraper to the panel. Complete with Op. 7040E24 Lower courtesy light indoor panel r+r Complete with Op. 7005E08 Front side door interior panel r r Complete with Op. 7005C44 Interior handle panel - r r Complete with Op. 5570T90 Front speaker - r r Complete with Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Complete with Op. 7005E38 Front side door interior handle-r r Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r - - 7005D32 - FOIL OF DOOR DESCENDING GLASS INNER GUIDE (ONE LH) OR RH ON FRONT SIDE DOOR - R R WITH DOOR PANEL REMOVED Removal Follow the Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed Follow the Op. 7005D25 rear guide - r r Front door window 1. Remove window channel (1a) from guide (1b). Fit the window channel to the guide. Complete with Op. 7005D25 Front door window rear guide - r r Complete with Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed 7005D33 - CHANNEL OF DOOR DESCENDING GLASS INNER GUIDE (ONE) LH OR RH ON FRONT SIDE DOOR - R R Removal Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r Follow the Op. 7005E38 Front side door interior handle-r r Follow the Op. 5570T90 Front speaker - r r Follow the Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Follow the Op. 7005C44 Interior handle panel rr Follow the Op. 7040E24 Lower courtesy light indoor panel - r+r Follow the Op. 7005Ell Lh or rh front door inner panel - r+r with fouling parts removed Follow the Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed Follow the Op. 7005D25 Front door window rear guide - r r Foil of door Follow the Op. 7005D32 descending glass inner guide (one Ih) or rh on front side door - r r with door panel removed Installation Foil of door descending glass inner guide (one Ih) or rh on front side door - r r with door panel removed Front door Complete with Op. 7005D25 window rear guide - r r Complete with Op. 7005D32 PA5106/00 06/1998 27 REPAIR PROCEDURES 7005 Passenger compartment front side door HT j Front side door - r r or replace with door Complete with Op. 7005A04 water guard protection - - 28 panel removed Complete with Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Complete with Op. 7040E24 Lower courtesy light indoor panel - r+r Complete with Op. 7005C44 Interior handle panel - r r Complete with Op. 5570TS0 Front speaker - r r Complete with Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Complete with Op. 7005E38 Front side door interior handle- r r Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r PA5106/00 06/1998 REPAIR PROCEDURES Passenger compartment front side door rC 7005 J 7005E - Front side door trim VIEW OF ASSEMBLY 2 u 10 VJ 5 ft a 7 0 51 8 9 3 O 6 4 1 Ref. Description 1 FRONT DOOR INTERIOR PANEL 2 CORNER COVER 3 FRONT DOOR PANEL SPEAKER GRILLE 4 FRONT DOOR INTERIOR PANEL POUCH 5 FRONT DOOR PANEL INTERIOR HANDLE 6 REIN FORC. BRACKET HANDLE ON FRONT DOOR 7 FRONT DOOR PILLAR TRIM 8 FRONT DOOR INTERIOR PANEL TRIM 9 DOOR REFLECTORS 10 FRONT DOOR SEAL AGAINST NOISE Operations index r*\ Code Operation 7005E08 Front side door interior panel r r PA5106/00 06/1998 Validity 29 REPAIR PROCEDURES 7005 Passenger compartment front side door j Validity Code Operation 7005E10 Front side door inner panel - r r for replacement 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed 7005E12 Corner cover of one front side door, Ih or rh r r 7005E20 Front door inner trim (one) Ih or rh - r r 7005E22 L/h or r/h front door panel radio grille (one) - r+r 7005E30 Object pouch on one front side door r r 7005E38 Front side door interior handle-r r 7005E39 Grab-handle reinforcement - r r 7005E50 Front side door pillar trim (one) Ih or rh - r r 7005E52 Weather strip on front side door pillar trim (one) Ih or rh - r r Reflector on front door panel - r r 7005E70 WARNINGS Use care when working on trim components and use the specified tools correctly in order to avoid damage. PRECAUTIONS DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). Complete with Op. 7005E38 Front side door interior handle-r r Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r 7005E10 - FRONT SIDE DOOR INNER PANEL - R R FOR REPLACEMENT Removal OPERATIONS 7005E08 - FRONT SIDE DOOR INTERIOR PANEL R R - Removal - - Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r Follow the Op. 700SE38 Front side door interior handle-r r Follow the Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Follow the Op. 5570T90 Front speaker - r r Follow the Op. 7005C44 Interior handle panel rr Follow the Op. 7040E24 Lower courtesy light indoor panel - r+r Follow the Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Installation Complete with Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Complete with Op. 7040E24 Lower courtesy light indoor panel - r+r Complete with Op. 7005C44 Interior handle panel - r r Complete with Op. 5570T90 Front speaker - r r Complete with Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r 30 rC Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r Follow the Op. 7005E38 Front side door interior handle-r r Follow the Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Follow the Op. 5570T90 Front speaker - r r Follow the Op. 7005C44 Interior handle panel rr Follow the Op. 7040E24 Lower courtesy light indoor panel - r+r Follow the Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Follow the Op. 7005E08 Front side door interior panel r r Follow the Op. 7005E70 Reflector on front door panel - r r Follow the Op. 7005E80 Data not yet available Follow the Op. 7005D30 Front side descending window glass scraper (inner) r r Follow the Op. 7005E39 Grab-handle rein¬ forcement - r r Follow the Op. 7005E30 Object pouch on one front side door r r Follow the Op. 5010C26 L/h or r/h diffuser for side window de-misting (one) - r+r Installation - Complete with Op. 5010C26 L/h or r/h diffuser for side window de-misting (one) - r+r Complete with Op. 7005E30 Object pouch on one front side door r r Complete with Op. 7005E39 Grab- handle rein¬ forcement - r r PA5106/00 06/1998 REPAIR PROCEDURES a Passenger compartment front side door Complete with Op. 700SD30 Front side descending window glass scraper (inner) r r Complete with Op. 7005E80 Data not yet avail¬ 5 able Complete with Op. 7005E70 Reflector on front door panel - r r Complete with Op. 7005E08 Front side door interior panel r r Complete with Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Complete with Op. 7040E24 Lower courtesy light indoor panel - r+r Complete with Op. 7005C44 Interior handle panel 7005 0 s 4 -rr Complete with Op. 5570T90 Front speaker - r r Complete with Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Complete with Op. 7005E38 Front side door interior handle-r r Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r /ÿN 7005E11 - LH OR RH FRONT DOOR INNER PANEL - R + R WITH FOULING PARTS REMOVED Removal 1. Prise up the bolt cover panel. 3 2 Installation 2. Unscrew the door panel retaining bolts. 3. Use the tool to prise the panel up from the underlying retainers. ES «EI \1 Description Code Blade 1.823.015.000 - - 4. Raise the panel and release from the door safety device. 5. Remove the door panel. Check that the panel is undamaged and that the retainers are undamaged and properly posi¬ tioned. Position the panel by fitting into the safety device. Check that the interior glass scraper is fitted to the door. Fit the panel to the door using press-fit retainers. Tighten the door panel retaining bolts and fit the bolt cover panel. 7005E12 - CORNER COVER OF ONE FRONTSIDE DOOR, LH OR RH R R Removal 1. Unscrew the bolt retaining the corner cover to the door. 2. Remove the corner cover. PA5106/00 06/1998 31 REPAIR PROCEDURES Passenger compartment front side door 7005 rC J 1a 1 O / 2 /Y 2 1b Installation - Check that the corner cover is undamaged. Fit the corner cover. Tighten the retaining bolt. - 7005E20 - FRONT DOOR INNER TRIM (ONE) LH OR RH - R R Removal - Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r Follow the Op. 7005E38 Front side door interior handle-r r Follow the Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Follow the Op. 5570T90 Front speaker - r r Follow the Op. 7005C44 Interior handle panel rr Follow the Op. 7005E08 Front side door interior panel r r Follow the Op. 7040E24 Lower courtesy light indoor panel - r+r 1. Remove trim retaining studs (1a) using tool Installation - Check the trim is in good condition. Fit the trim. Position the retaining studs and fit onto the trim pins. Complete with Op. 7040E24 Lower courtesy light indoor panel - r+r Complete with Op. 7005E08 Front side door interior panel r r Complete with Op. 7005C44 Interior handle panel - r r Complete with Op. 5570T90 Front speaker - r r Complete with Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Complete with Op. 7005E38 Front side door interior handle- r r Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r r\ (1b). H Description Code 1b Blade 1.823.015.000 2. Remove the finishing trim. 32 PA5106/00 06/1998 REPAIR PROCEDURES Passenger compartment front side door rC J 7005 7005E22 - L/H OR R/H FRONT DOOR PANEL RADIO GRILLE (ONE) - R + R Removal Q, I.Use tool (1a) to remove protection grille (1b) by undoing the three retaining clips (1c). 1 SD 1a l \ 2 Installation Iff®;: i - Check that the oddment pouch and fasteners are undamaged. Fit the oddment pouch. Tighten the five bolts securing the pouch to the panel. Complete with Op. 7040E24 Lower courtesy light indoor panel - r+r Complete with Op. 7005E08 Front side door interior panel r r Complete with Op. 7005C44 Interior handle panel - r r Complete with Op. 5570T90 Front speaker - r r Complete with Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Complete with Op. 7005E38 Front side door interior handle-r r Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r - 1b - \ Vt 4 1c \ - Installation - Check that the grille and the underlying speaker are not damaged, and that the retainers are in good condition. Fit the grille in its housing on the panel. 7005E30 - OBJECT POUCH ON ONE FRONT SIDE DOOR R R 7005E38 - FRONT SIDE DOOR INTERIOR HANDLE-R R Removal Removal 1. Remove the bolt cover panel. Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r Follow the Op. 700SE38 Front side door interior handle-r r Follow the Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Follow the Op. 5570T90 Front speaker - r r Follow the Op. 7005C44 Interior handle panel - rr Follow the Op. 7005E08 Front side door interior panel r r Follow the Op. 7040E24 Lower courtesy light indoor panel - r+r 1. Unscrew the oddment pouch retaining bolts. 2. Unscrew the bolts retaining the grab handle to the door panel. 3. Use the tool shown to take the grab handle out of its housing. H Description Code 3 Blade 1.823.014.000 1. Disconnect electrical connectors (4a), (4b) and (4c). 2. Remove the oddment pouch. I Description 4A Electric windows controls Connector H44 assembly on driver's door PA5106/00 06/1998 33 REPAIR PROCEDURES Passenger compartment front side door 7005 IDescription Connector IDescription J 1b -/ © Connector * H30 Data not yet available 4c © © H30 Data not yet available 4b rC 5. Remove the grab handle. □3 1a Installation 1 5 - 1 2 32® 3> 2 \ v is — 4bH; ) LB \ [4a \ Installation - Check that the interior grab handle is undam¬ aged. Connect the electrical connections. Position the grab handle in its housing. Check the electrical components on the grab handle are working properly. Tighten both bolts retaining the grab handle to the door panel. Refit the bolt cover panel. - (£)\ 7005E39 - GRAB-HANDLE REINFORCEMENT - R R Fit the bracket on the panel. Tighten both bolts securing the bracket to the panel. Complete with Op. 7040E24 Lower courtesy light indoor panel - r+r Complete with Op. 7005E08 Front side door interior panel r r Complete with Op. 7005C44 Interior handle panel - r r Complete with Op. S570T90 Front speaker - r r Complete with Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Complete with Op. 7005E38 Front side door interior handle- r r Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r 7005E50 - FRONT SIDE DOOR PILLAR TRIM (ONE) LH OR RH R R Removal 1. Lower the window and prise out the vertical section of the glass slide channel. 2. Unscrew the three bolts retaining the outer trim. 3. Remove the trim by prising out of the door together with the sealing strip. Removal Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r Follow the Op. 7005E38 Front side door interior handle-r r Follow the Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Follow the Op. 5570T90 Front speaker - r r Follow the Op. 7005C44 Interior handle panel rr Follow the Op. 7005E08 Front side door interior panel r r Follow the Op. 7040E24 Lower courtesy light indoor panel r+r 1. Unscrew retaining bolts (1a) and remove rein¬ forcement bracket (1b). - 34 PA5106/00 06/1998 REPAIR PROCEDURES 0 Passenger compartment front side door 7005 7005E52 - WEATHER STRIP ON FRONT SIDE DOOR PILLAR TRIM (ONE) LH OR RH - R R 3\J Removal 1. Remove the sealing strip by withdrawing from the pillar trim. o 1 2 1 Installation Remove the sealing strip to make it easier to fit the trim. - Position the outer trim and check it is fitted correctly in relation to the bolt holes. 1. Position the outer sealing strip on the trim and make it easier to fit by oiling the area lightly. 2. Tighten the three bolts retaining the outer trim. 3. Fit the vertical section of the slide channel and raise the window to ensure it moves properly. - \ o, Installation - Lightly oil the pillar trim and then fit the sealing strip. 7005E70 - REFLECTOR ON FRONT DOOR PANEL - R R Removal fc? 3 2 1 PA5106/00 06/1998 Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r Follow the Op. 7005E38 Front side door interior handle-r r Follow the Op. 700SE22 L/h or r/h front door panel radio grille (one) - r+r Follow the Op. 5570T90 Front speaker - r r Follow the Op. 7005C44 Interior handle panel rr Follow the Op. 7005E08 Front side door interior panel r r Follow the Op. 7040E24 Lower courtesy light indoor panel - r+r 1. Unscrew retaining bolt (1a) and remove the panel reflector. 35 REPAIR PROCEDURES 7005 Passenger compartment front side door HT J Cl 1a — 1b n Installation - - 36 Check the reflector is in good condition. Position the reflector. Tighten the bolt securing the reflector to the panel. Complete with Op. 7040E24 Lower courtesy light indoor panel - r+r Complete with Op. 7005E08 Front side door interior panel r r Complete with Op. 7005C44 Interior handle panel - r r Complete with Op. 5570TS0 Front speaker - r r Complete with Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Complete with Op. 7005E38 Front side door interior handle-r r Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r PA5106/00 06/1998 REPAIR PROCEDURES a Passenger compartment front side door 7005 7005M - Front electric windows VIEW OF ASSEMBLY y\ D \ V \ 1 Ref. Description 1 DRIVER SIDE FRONT WINDOW SWITCH 2 FRONT WINDOW MOTOR 2 Operations index Code Operation Validity 7005M10 Driver's side front side door glass control switch (one) rr 7005M12 Passenger side front door electrically operated window switch - r r 7005M20 Front side door electric window system - r r with door _panel/support frame removed _ 7005M21 Front side door electrically operated window - r r 7005M24 Mechanism of front side door electric window system - check position and fastening with door panel removed 7005M25 Front side door electrically operated window mecha_nism chech position and fastening _ 7005M40 Front electric window system ecu - r+r following elec_trical wiring check _ PA5106/00 06/1998 37 REPAIR PROCEDURES 7005 Passenger compartment front side door rC J PRECAUTIONS DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). 7005M12 - PASSENGER SIDE FRONT DOOR ELECTRICALLY OPERATED WINDOW SWITCH R R OPERATIONS Removal Follow the Op. 7005E38 Front side door interior handle-r r 1. Prise the switch out of its housing and press the switch in from the outside to remove. 7005M10 - DRIVER'S SIDE FRONT SIDE DOOR GLASS CONTROL SWITCH (ONE) R R Removal Follow the Op. 7005E38 Front side door interior handle-r r 1. Unscrew retaining bolts (1a) and remove switch unit protective cover (1b). 2. Apply slight pressure to switches (2a) and push sideways using tool (2b) to separate the printed circuit complete with switches (2c) from the three retaining pins on the grip and from the retainers inside the switch unit. Q 2b Description Code Blade 1.823.014.000 I 1 V I Installation - 2a V 2b 2c Check the condition of the switch. Position the switch. Fit into its seat. Complete with Op. 7005E38 Front side door interior handle-r r 7005M20 - FRONT SIDE DOOR ELECTRIC WINDOW SYSTEM R R WITH DOOR PANEL/ SUPPORT FRAME REMOVED Removal 1b © 1a Installation - - 38 Check the condition of the printed circuit and switches. Fit the switch unit into its housing on the handle and check that the rear electrically-operated window enablement button spring is fitted to the switch. Check the switch electrical system is working properly. Follow the Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed 1-With the window fully raised, arrange a device to support the window in raised position. 2. Unscrew the nuts retaining the window bracket. 3. Unscrew the nuts retaining the slide bracket. 4. Unscrew the window motor retaining bolts. 5. Adjust the electrically-operated window until the window is closed, disconnect the window motor electrical connection. 6. Remove the electrically-operated window from the door compartment. 5 \ Description Connector Front left electric window motor N60 Fitt the cover and tighten the retaining bolts. Complete with Op. 7005E38 Front side door interior handle-r r PA5106/00 06/1998 REPAIR PROCEDURES Passenger compartment front side door rC j Follow the Op. 7005A04 Front side door water guard protection r r or replace with door panel removed Follow the Op. 7005M20 Front side door elec¬ tric window system - r r with door panel/ support frame removed - \ Description Connector Front right electric window motor N61 Installation 1 S# 2 4 3 [c ilSS _A\\Q - 5 3 6 4 Installation - - - - - - 7005 Check the condition of the electrically-operated window and ensure the motor is working prop¬ erly. Fit the device into the door compartment. Tighten the four motor retaining bolts. Connect the window motor electrical connector. Position both slide guide nuts and tighten. Operate the electrically-operated window button and extend the device until both window retaining nuts can be screwed in without tight¬ ening. Remove the window support. Adjust the device as indicated in opera¬ tion:7005M24 Mechanism of front side door electric window system - check position and fastening with door panel removed 7005M21 - FRONT SIDE DOOR ELECTRICALLY OPERATED WINDOW - R R Complete with Op. 7005M20 Front side door electric window system - r r with door panel/ support frame removed Complete with Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed Complete with Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Complete with Op. 7040E24 Lower courtesy light indoor panel - r+r Complete with Op. 7005C44 Interior handle panel - r r Complete with Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Complete with Op. 5570T90 Front speaker - r r Complete with Op. 7005E38 Front side door interior handle-r r Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r 7005M 24 - MECHANISM OF FRONT SIDE DOOR ELECTRIC WINDOW SYSTEM - CHECK POSITION AND FASTENING WITH DOOR PANEL REMOVED Removal Follow the Op. 7005A04 Front side door water guard protection - r r or replace with door panel - removed Open and close the windows a few times to check for adjustment defects (window does not quite reach the top or the rear door pillar). I.With the window fully raised, loosen both nuts retaining the electrically-operated window device to the window. 2. Place the window in the correct closure position by hand (window reaches top and rear edges). 3. Operate the window device electrically, fit it against the glass and tighten the retaining bolts. Removal Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r Follow the Op. 7005E38 Front side door interior handle-r r Follow the Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Follow the Op. 5570T90 Front speaker - r r Follow the Op. 7005C44 Interior handle panel rr Follow the Op. 7040E24 Lower courtesy light indoor panel - r+r Follow the Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed PA5106100 06/1998 39 REPAIR PROCEDURES a Passenger compartment front side door 7005 Installation Complete with Op. 7005M24 Mechanism of front side door electric window system - check position and fastening with door panel removed Complete with Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed Complete with Op. 7005EU Lh or rh front door inner panel - r+r with fouling parts removed Complete with Op. 7005E24 Data not yet avail¬ able Complete with Op. 7005C44 Interior handle panel - r r Complete with Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Complete with Op. 5570T90 Front speaker - r r Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r Complete with Op. 7005E38 Front side door interior handle-r r 2 3 / 7 // 2 C23 (Oi ol > & fsSga 7005M40 - FRONT ELECTRIC WINDOW SYSTEM ECU - R+R FOLLOWING ELECTRICAL WIRING CHECK Removal Installation - - Ensure that the ignition key is in tthe OFF posi¬ tion, then disconnect the battery negative Open the close the window a few times to check it is correctly positioned. Complete with Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed 7005M 25 - FRONT SIDE DOOR ELECTRICALLY OPERATED WINDOW MECHANISM CHECH POSITION AND FASTENING terminal. \Description Connector A1B Battery I.Undo the bolts (1a) and remove the right and left trims (1b). // / Removal Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r Follow the Op. 7005E38 Front side door interior handle-r r Follow the Op. 5570T90 Front speaker - r r Follow the Op. 7005E22 L/h or r/h front door .'4V \\ \ m K ) REPAIR PROCEDURES Passenger compartment front side door r*C j IDescription 1b 7005 Connector Electric front windows control unit M81 // II T \ 1c & y/'& 1b 1a installation - - - Connect the electrical connections to the elec¬ tric windows control unit. Replace the electric windows control unit in its housing and secure it using the relevant nuts. Fit the right and left trims and secure using the relevant bolts. Connect the battery negative terminal. PA5106/00 06/1998 41 REPAIR PROCEDURES Passenger compartment front side door 7005 rC J 7005N - Front door central locking system VIEW OF ASSEMBLY Q a i? 1 o Ref. Description 1 FRONT DOOR LOCK MOTOR Operations index Code Operation Validity 7005N20 Front side door lock motor/catch assembly - rr with _door panel and support frame removed_ 7005N21 Front side door lock motor-lock assembley-r r 7005N40 Central locking electrical control unit - r r folowing _system check _ 7005N62 Central lockung remote control receiver - r r with _courtesy light removed _ PRECAUTIONS DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). 42 PA5106/00 06/1998 REPAIR PROCEDURES a Passenger compartment front side door OPERATIONS 7005N20 - FRONT SIDE DOOR LOCK MOTOR/CATCH ASSEMBLY - RR WITH DOOR PANEL AND SUPPORT FRAME REMOVED Connect the cable to the inner handle and secure to the spring on the door. Check operation. Tighten the catch retaining bolts. u Removal removed Move the window to closed position. 1. Disconnect the outer handle and dowel connec¬ tion links from the catch. 2. Unscrew the outer bolts retaining the striker to the door. 3. Disconnect the catch motor reduction unit elec¬ trical connectors. Component Screw FRONTDOOR M8 LOCK MECHA¬ NISM 0 1.4 7005N21 - FRONTSIDE DOOR LOCK MOTOR-LOCK ASSEMBLEY-R R Removal IDescription Connector Left front door lock geared motor 3 Mounting Value (daNm) Complete with Op. 7005A04 Front side door water guard protection - r r or replace with door panel removed Follow the Op. 7005A04 Front side door water guard protection - r r or replace with door panel - 7005 N50 \Description Connector Right front door lock geared motor N51 4. Disconnect cable (4a) from the inner door handle, take out control link retaining spring - removed 5. Remove the catch assembly. 4b 1 Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r Follow the Op. 7005E38 Front side door interior handle-r r Follow the Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Follow the Op. 5570T90 Front speaker - r r Follow the Op. 7005C44 Interior handle panel rr Follow the Op. 7005E24 Data not yet available Follow the Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Follow the Op. 7005A04 Front side door water guard protection - r r or replace with door panel Follow the Op. 7005D25 Front door window rear guide - r r Follow the Op. 7005N20 Front side door lock motor/catch assembly - rr with door panel and support frame removed Q Installation 3k PA - window rear guide - r r Complete with Op. 7005A04 Front side door water guard protection - r r or replace with door 'C i' 2 cl panel removed T 4a 3 5 Installation - Connect the electrical connections. Fit the catch in the door and check the links are - properly positioned. Connect the outer handle links. Tighten the catch retaining bolts. - PA5106/00 06/1998 Complete with Op. 7005N20 Front side door lock motor/catch assembly - rr with door panel and support frame removed Front door Complete with Op. 7005D25 Complete with Op. 7005E11 Lh or rh front door inner panel - r+r with fouling parts removed Complete with Op. 7005E24 Data not yet avail¬ able Complete with Op. 7005C44 Interior handle panel - r r Complete with Op. 5570T90 Front speaker - r r Complete with Op. 7005E22 L/h or r/h front door panel radio grille (one) - r+r Complete with Op. 7005E38 Front side door interior handle-r r Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r 43 REPAIR PROCEDURES 7005 Passenger compartment front side door El 7005N40 - CENTRAL LOCKING ELECTRICAL CONTROL UNIT R R FOLOWING SYSTEM CHECK Refer to op.. 5505A18 Multi-function control unit - r r 7005N62 - CENTRAL LOCKUNG REMOTE CONTROL RECEIVER R R WITH COURTESY LIGHT REMOVED - 44 Refer to op.. 7010N68 Receiver for central locking remote control - r r with any fouling parts removed PA5106/00 06/1998 REPAIR PROCEDURES a Passenger compartment front side door 7005 7005R - Front door mirrors VIEW OF ASSEMBLY 2 K 4 1 3 % Ref. Description 1 ELECTRIC DOOR MIRROR 2 DOOR MIRROR REFLECTOR 3 DOOR MIRROR POSITION MOTOR 4 ELECTRIC DOOR MIRROR BOOT a Operations index Code Operation Validity 7005R30 Electrically controlled door mirror (one) - r+r 7005R32 Electric door mirror r r 7005R35 Door mirror reflector - r r 7005R36 Door mirror motor - r r 7005R37 Door mirror boot - r r 7005R40 Rear view mirror-s and door mirror-s positioning switch unit - r r 7005R42 Electric mirror(s) control switch r r PRECAUTIONS DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). PA5106/00 06/1998 45 REPAIR PROCEDURES 7005 a Passenger compartment front side door OPERATIONS 7005R 30 - ELECTRICALLY CONTROLLED DOOR MIRROR (ONE) - R + R 3 f/JL) Removal Follow the Op. 7005E12 Corner cover of one front side door, Ih or rh r r - With the ignition key in the OFF position, disconnect the battery negative terminal. - Take out the connector carrier and open it. 1. Disconnect electric mirror wiring connectors (1a), (1b) and (1c). IDescription 1a Left door mirror IDescription 1b Left door mirror / 1c Left door mirror Connector P60B Connector P60D Connector P61 A IDescription Right door mirror 2b /v 2a ff P60A Right door mirror Right door mirror / Connector IDescription iDescription 2b / Installation - Check that the rear view mirror is not damaged. Fit the wiring, replace the mirror and check it is working properly. Tighten the three bolts retaining the mirror to the door. Refit the bolt cover panel. Connect the electric mirror wiring connector. Close the connector carrier and refit it. Complete with Op. 7005E12 Corner cover of one front side door, Ih or rh r r IDescription \ Connector P61B Connector P61D 2. Remove bolt cover panel (2a) and uncrew the bolts (2b) securing the mirror to the door. 3. Withdraw the wiring and remove the mirror. - - 7005R32 - ELECTRIC DOOR MIRROR R R Refer to op.. 7005R30 Electrically controlled door mirror (one) - r+r 7005R35 - DOOR MIRROR REFLECTOR - R R Removal - With the ignition key in the stop position, disconnect the battery negative terminal. I.Use tool (1a) to prise out reflector (1b). E9 Description Code 1a Blade 1.823.014.000 1. Disconnect the electrical connections from the reflector and then remove. 46 PA5106/00 06/ 1998 REPAIR PROCEDURES a Passenger compartment front side door 7005 7005R 37 - DOOR MIRROR BOOT - R R nia Removal - Follow the Op. 7005R35 Door mirror reflector rr Follow the Op. 7005R36 Door mirror motor - r r 1. Unscrew the bolts retaining the cover to the ( 3 o / o ,iS c / 4 t 1i Installation - With the aid of a second operator, raise the door and refit. Ensure the hinge pins are centred. Screw in the hinge retaining bolts and tighten to fl torque. u Mounting Component Screw M6 REAR SIDE DOOR HINGES 0 1.5 Connect the main wiring connector. Take out the limiter and extend it to the end of its travel. Tighten both bolts retaining the door opening limiter to the car and fit the plastic protective cover. Check the various appliances on the door are working properly. When the operation is complete, look to ensure the gap between door and front wing and between front and rear door is even. Connect the battery negative terminal. 7010A28 - REAR SIDE DOOR OPENING LIMITER-R R Removal Follow the Op. 7065C42 Ashtray (one) r+r Follow the Op. 7010C44 Interior handle panel rr Follow the Op. 7010E38 Rear side door interior handle-r r Follow the Op. 7040E26 Lower courtesy light in rear panel - r r Follow the Op. 7010E10 Rear side door inner panel - r r or replace PA5106/00 06/1998 ~2b Value (daNm) 'O Installation - - - - - Check that the limiter is undamaged. Lubricate the limiter with suitable grease. Fit the limiter in the door compartment together with the plastic protections. Tighten both bolts retaining the limiter to the door and pillar. Position the plastic covers protecting the limiter fastenings. Check the limiter is working properly by opening and closing the door partially. Complete with Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed Complete with Op. 7010E10 Rear side door inner panel - r r or replace Complete with Op. 7010C46 Data not yet avail¬ able Complete with Op. 7010E38 Rear side door interior handle-r r Complete with Op. 7040E26 Lower courtesy light in rear panel - r r Complete with Op. 7065C42 Ashtray (one) r+r 7 REPAIR PROCEDURES 7010 Passenger compartment rear side doors rC J 7010A34 - REAR SIDE DOOR COMPARTMENT SEAL R R U Removal Follow the Op. 7050A20 One-piece rear seat cushion - r r Follow the Op. 7040H36 Central trim lower element - r r Follow the Op. 7040L44 Rear compartment scuff strip - r r 1. Prise up the seal from its seat. □ 1 2a 2b © 3 k I -/ \ 2b '1 i i I ’ÿ Installation - 1 - Fit the seal to the door, beginning from the rear and lower sections. Fasten the retaining studs. Fit the upper vertical section of the seal to the door. Installation Check that the seal is in one piece and does not show signs of damage or deformation. Fit the seal Complete with Op. 7040L44 Rear compartment scuff strip - r r Complete with Op. 7040H36 Central trim lower element - r r Complete with Op. 7050A20 One-piece rear seat cushion - r r - - 7010A42 - SEAL ON REAR SIDE DOOR - R+R Removal 1. With the door closed, prise up the front vertical section of the sealing strip. 2. Open the door and use tool (2a) to undo studs (2b) retaining the lower and rear seal sections. 3. Finish removing the seal. □ 2a 8 Description Code Blade 1.823.015.000 PA5106/00 06/1998 r\ REPAIR PROCEDURES a Passenger compartment rear side doors 7010 701OB - Rear door mechanical locks VIEW OF ASSEMBLY i <2 Ref. Description 1 STRIKER ON REAR SIDE DOOR PILLAR Operations index Validity Code Operation 7010B14 Rear side door catch striker r r OPERATIONS 7010B14 - REAR SIDE DOOR CATCH STRIKER R R 2. Use the bolt slots to move the striker into the correct position. Fit new shims or refit old shims if necessary in order to adjust the striker accurately. Permitted adjustment movements are indicated by arrows. Removal 1. Unscrew both bolts retaining the striker to the door. 2. Remove the striker together with any under¬ lying shims. 1 * 1 2 2 1 1 Tighten the retaining bolts. u Installation - - Check that the striker is undamaged. Fit the striker. 1. Screw in both retaining bolts without tightening Mounting Component 0 Screw REAR DOOR LOCK STRIKER M8 Value (daNm) 2.4 Check the striker and catch fit together properly and ensure the door is aligned when closed. to torque. PA5106/00 06/1998 9 REPAIR PROCEDURES 7010 Passenger compartment rear side doors rC j 7010C - Rear lock controls VIEW OF ASSEMBLY s/ // 5 U-' 9 6 8 \ c Ref. Description 1 REAR DOOR EXTERIOR HANDLE 2 REAR DOOR RETURN HANDLE PLATE 3 Data not yet available 4 REAR SIDE DOOR RETURN HANDLE 5 REAR SIDE DOOR SAFETY KNOB 6 GAS LEVEL GAUGE 7 REAR DOOR SAFETY DEVICE LINK 8 REAR DOOR SAFETY CONTROL CABLE 9 REAR DOOR SAFETY DEVICE CABLE LINK conn* Operations index Code Operation Validity 7010C10 Rear door outer handle - r r with door panel removed 7010C11 10 Rear side door outside handle-r r PA5106/00 06/1998 REPAIR PROCEDURES Passenger compartment rear side doors rC 7010 J r*\ Code Validity Operation 7010C44 Interior handle panel - r r 7010C50 Rear side door interior opening mechanism-r r for _repair or replacement with door panel removed Rear side door inner catch return device - r+r for or replacement _ repair _ 7010C51 7010C54 Rear side door internal opening return mechanism (with handle) - r r for repair or replacement with door panel removed _ _ 7010C55 Rear side door interior opening return device (with _handle) - r+r for repair or replacement _ 7010C62 Rear side door safety catch knob and seal-r r 7010C64 Handle link yo lock - r r 7010C65 Handle link to lock - r r Rear side door safety catch link-r r with door panel removed 7010C67 Rear side door safety catch link-r r 7010C66 7010C68 Rear door catch return - r r 7010C69 Rear door catch return - r r 7010C71 Link with knob for rear side door safety catch - r+r PRECAUTIONS DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). 2 / OPERATIONS / 7010C10 - REAR DOOR OUTER HANDLE - R R WITH DOOR PANEL REMOVED / / /, / ]/ / // / 4a % Removal ‘3 Follow the Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed 1. Unscrew the nut and bolts retaining the outer handle protection to the door. 2. Remove the handle protection. 3. Unscrew the catch retaining bolts so that the catch can be lowered to make it easier to remove the handle. 4. Remove handle (4a) toward the outside by withdrawing catch control mechanism (4b) from its attachment on the catch. 4b Installation - - Check that the outer handle and the handle mechanism are undamaged. Fit the handle. Ensure that the catch control mechanism link fits into it. Tighten the catch retaining bolts. u PA5106/00 06/1998 Mounting Component Screw REAR DOOR M8 LOCK MECHA¬ NISM 0 Value (daNm) 1.4 11 REPAIR PROCEDURES 7010 Passenger compartment rear side doors Fit the handle protection inside the door. Tighten the protection retaining bolts. Check the handle is working properly by opening a closing the door a few times. Complete with Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed V 3b 7010C11 - REAR SIDE DOOR OUTSIDE HANDLE-R R Removal Follow the Op. 7065C42 Ashtray (one) r+r Follow the Op. 7010C44 Interior handle panel rr Follow the Op. 7010E38 Rear side door interior handle-r r Follow the Op. 7040E26 Lower courtesy light in rear panel - r r Follow the Op. 7010E10 Rear side door inner panel - r r or replace Follow the Op. 7010A10 Rear side door - adjust striker and adapt seal if necessary Follow the Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed Follow the Op. 7010C10 Rear door outer handle - r r with door panel removed Installation Complete with Op. 7010C10 Rear door outer handle - r r with door panel removed Complete with Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed Complete with Op. 7010A10 Rear side door adjust striker and adapt seal if necessary Complete with Op. 7010E10 Rear side door inner panel - r r or replace Complete with Op. 7010C44 Interior handle panel - r r Complete with Op. 7065C42 Ashtray (one) r+r Complete with Op. 7010E38 Rear side door interior handle-r r Complete with Op. 7040E26 Lower courtesy light in rear panel - r r 7010C44 - INTERIOR HANDLE PANEL - R R \\ 7 nr 3a□ 2 ErtJ \\ W\' w \\ \\ \1 '\ 0 1 Installation - - Check that the plate is undamaged. Position the plate and fit onto the panel. Tighten the plate retaining bolts. Position the bolt cover plate. Complete with Op. 7065C42 Ashtray (one) r+r 7010C50 - REAR SIDE DOOR INTERIOR OPENING MECHANISM-R R FOR REPAIR OR REPLACEMENT WITH DOOR PANEL REMOVED Removal Follow the Op. 7010A10 Rear side door - adjust striker and adapt seal if necessary Follow the Op. 7010C54 Rear side door internal opening return mechanism (with handle) - r r for repair or replacement with door panel removed 1. Disconnect the cable from the retaining clip. 2. Disconnect cable (2a) from catch (2b) and remove. Removal Follow the Op. 7065C42 Ashtray (one) r+r 1. Remove the panel retaining bolt cover plate. 2. Unscrew the bolts retaining the plate to the panel. 3. Use tool (3a) to prise up inner handle plate (3b). B8 3b 12 Description Code Blade 1.823.014.000 PA5106/00 06/1998 REPAIR PROCEDURES a Passenger compartment rear side doors Installation Rear side door interior opening mechanism-r r for repair or replacement with door panel removed Complete with Op. 7010C54 Rear side door internal opening return mechanism (with handle) - r r for repair or replacement with door panel removed Complete with Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed Complete with Op. 7010E10 Rear side door inner panel - r r or replace Complete with Op. 7040E26 Lower courtesy light in rear panel - r r Complete with Op. 7010E38 Rear side door interior handle-r r Complete with Op. 7010C44 Interior handle panel - r r Complete with Op. 7065C42 Ashtray (one) r+r Complete with Op. 7010C50 'a X2A C>, 2a 0 "7 2b 2a V.\ Installation - 7010 Check that the cable is undamaged. Connect the cable to the catch and the clip on the door. Complete with Op. 7010C54 Rear side door internal opening return mechanism (with handle) - r r for repair or replacement with door panel removed Complete with Op. 7010A10 Rear side door adjust striker and adapt seal if necessary REAR SIDE DOOR INTERNAL OPENING RETURN MECHANISM (WITH HANDLE) - R R FOR REPAIR OR REPLACEMENT WITH DOOR PANEL REMOVED 7010C54 - Removal Follow the Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed 1. Release the cable from the retainer on handle (1a) and from clip (1b). 2. Unscrew the bolts retaining the handle to the door. 3. Remove the return device. 7010C51 - REAR SIDE DOOR INNER CATCH RETURN DEVICE - R+R FOR REPAIR OR REPLACEMENT Removal Follow the Op. 7065C42 Ashtray (one) r+r Follow the Op. 7010C44 Interior handle panel rr Follow the Op. 7010E38 Rear side door interior handle-r r Follow the Op. 7040E26 Lower courtesy light in rear panel - r r Follow the Op. 7010E10 Rear side door inner panel - r r or replace Follow the Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel 1b 7 0 removed 1a Follow the Op. 7010C54 Rear side door internal opening return mechanism (with handle) - r r for repair or replacement with door panel removed Follow the Op. 7010C50 Rear side door interior opening mechanism-r r for repair or replacement with door panel removed — r 3 \ 2 Installation - PA5106/00 06/1998 Check that the handle and the control mecha¬ nism are undamaged. Connect the cable to the inner handle. Fit the handle and tighten both retaining bolts. 13 REPAIR PROCEDURES 7010 Passenger compartment rear side doors Check the handle and catch are working prop¬ erly. Complete with Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed E9 7010C55 - REAR SIDE DOOR INTERIOR OPENING RETURN DEVICE (WITH HANDLE) - R+R FOR REPAIR OR REPLACE¬ MENT Removal Follow the Op. 7065C42 Ashtray (one) r+r Follow the Op. 7010C44 Interior handle panel rr Follow the Op. 7010E38 Rear side door interior handle-r r Follow the Op. 7040E26 Lower courtesy light in rear panel - r r Follow the Op. 7010E10 Rear side door inner panel - r r or replace Follow the Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel rC j Description Code Blade 1.823.014.000 /7/ // t 2 \ V Installation - Check that the knob and gasket areundamaged. Position the knob guide gasket on the panel. Tighten the safety device knob onto the threaded link. removed - Follow the Op. 7010C54 Rear side door internal opening return mechanism (with handle) - r r for repair or replacement with door panel removed 7010C64 - HANDLE LINK YO Installation Complete with Op. 7010C54 Rear side door internal opening return mechanism (with handle) - r r for repair or replacement with door panel removed Complete with Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed Complete with Op. 7010E10 Rear side door inner panel - r r or replace Complete with Op. 7010C44 Interior handle panel - r r Complete with Op. 7065C42 Ashtray (one) r+r Complete with Op. 7010E38 Rear side door interior handle-r r Complete with Op. 7040E26 Lower courtesy light in rear panel - r r - LOCK - R R Removal Follow the Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed Follow the Op. 7010C10 Rear door outer handle - r r with door panel removed 1. Disconnect the link from the bush on the the outer handle. 7010C62 - REAR SIDE DOOR SAFETY CATCH KNOB AND SEAL-R R 1 Removal I.Open the door and unscrew the safety device knob from the threaded link. Keep the door open until the knob is refitted. 2. Use the cutter to remove the knob gasket from the panel. 14 Installation - - Check bush condition and replace if necessary. Check that the link is undamaged. Connect the link to the outer handle. Complete with Op. 7010C10 Rear door outer handle - r r with door panel removed Complete with Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed PA5106/00 06/1998 REPAIR PROCEDURES rC Passenger compartment rear side doors 7010 J 7010C65 - HANDLE LINK TO LOCK - R R Removal 3b / Follow the Op. 7010C42 Data not yet available Follow the Op. 7010C44 Interior handle panel rr Follow the Op. 7010E38 Rear side door interior handle-r r Follow the Op. 7040E26 Lower courtesy light in rear panel - r r Follow the Op. 7010E10 Rear side door inner panel - r r or replace Follow the Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed Follow the Op. 7010C10 Rear door outer handle - r r with door panel removed Follow the Op. 7010C64 Handle link yo lock rr Installation Complete with Op. 7010C64 Handle link yo lock - r r Complete with Op. 7010C10 Rear door outer handle - r r with door panel removed Complete with Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed Complete with Op. 7010E10 inner panel - r r or replace Complete with Op. 7040E26 Rear side door Lower courtesy light in rear panel - r r Complete with Op. 7010E38 Rear side door interior handle-r r Complete with Op. 7010C44 Interior handle panel - r r Complete with Op. 7010C42 Data not yet avail¬ able 7010C66 - REAR SIDE DOOR SAFETY CATCH LINK-R R WITH DOOR PANEL REMOVED Removal Follow the Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed 1. Disconnect the clip connecting the link to the control mechanism. 2. Prise out the clip retaining the link to the door. 3. Remove link (3a) from catch (3b), then remove. PA5106/00 06/1998 2 1 vVA M Installation - Check that the link is undamaged. Connect the link by attaching to the door by means of the clip. Connect the link to the catch and control mech¬ anism. Complete op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed 7010C67 - REAR SIDE DOOR SAFETY CATCH LINK-R R Removal Follow the Op. 7065C42 Ashtray (one) r+r Follow the Op. 7010C44 Interior handle panel rr Follow the Op. 7010D38 Rear side door manual window mechanism handle/ring-nut r r Follow the Op. 7010E38 Rear side door interior handle-r r Follow the Op. 7040E26 Lower courtesy light in rear panel - r r Follow the Op. 7010E10 Rear side door inner panel - r r or replace Follow the Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed Follow the Op. 7010C66 Rear side door safety catch link-r r with door panel removed Installation Complete with Op. 7010C66 Rear side door safety catch link-r r with door panel removed Complete with Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed Complete with Op. 7010E10 Rear side door inner panel - r r or replace Complete with Op. 7010C44 Interior handle panel - r r Complete with Op. 7010D38 Rear side door manual window mechanism handle/ring-nut r r Complete with Op. 7010E38 Rear side door interior handle-r r Complete with Op. 7040E26 Lower courtesy light in rear panel - r r Complete with Op. 7065C42 Ashtray (one) r+r 15 REPAIR PROCEDURES Passenger compartment rear side doors 7010 rC J 7010C68 - REAR DOOR CATCH RETURN - R R Removal Follow the Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed 1. Disconnect the safety device link from the control mechanism. 2. Turn the control mechanism to disengage it from the door and then remove. 3. Disconnect the link and knob from the control mechanism. 1 3 7' n O Follow the Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed Follow the Op. 7010C68 Rear door catch return -rr Installation Complete with Op. 7010C68 Rear door catch return - r r Complete with Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed Complete with Op. 7010E10 Rear side door inner panel - r r or replace Complete with Op. 7040E26 Lower courtesy light in rear panel - r r Complete with Op. 7010E38 Rear side door interior handle-r r Complete with Op. 7010D38 Rear side door manual window mechanism handle/ring-nut r r Complete with Op. 7010C44 Interior handle panel - r r Complete with Op. 7065C42 Ashtray (one) r+r 7010C71 - LINK WITH KNOB FOR REAR SIDE DOOR SAFETY CATCH - R + R Removal 2 1C Installation - - - Check that the control mechanism is undam¬ aged. Connect the link and knob to the control mech¬ anism. Fit the control mechanism in its seat and connect to the retaining clip. Connect the catch link to the control mecha¬ nism. Check the control mechanism is working prop¬ erly. Complete with Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed Follow the Op. 7065C42 Ashtray (one) r+r Follow the Op. 7010C44 Interior handle panel rr Follow the Op. 7010D38 Rear side door manual window mechanism handle/ring- nut r r Follow the Op. 7010E38 Rear side door interior handle-r r Follow the Op. 7040E26 Lower courtesy light in rear panel - r r Follow the Op. 7010E10 Rear side door inner panel - r r or replace Follow the Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed 1. Disconnect the link and knob from the control mechanism. 1 7010C69 - REAR DOOR CATCH RETURN - R R Removal - 16 Follow the Op. 7065C42 Ashtray (one) r+r Follow the Op. 7010C44 Interior handle panel rr Follow the Op. 7010D38 Rear side door manual window mechanism handle/ring-nut r r Follow the Op. 7010E38 Rear side door interior handle-r r Follow the Op. 7040E26 Lower courtesy light in rear panel - r r Follow the Op. 7010E10 Rear side door inner panel - r r or replace J 7' 70 n m / PA5106/00 06/1998 o REPAIR PROCEDURES rC Passenger compartment rear side doors j 7010 Installation - - Check that the link and the control mechanism are undamaged. Connect the link and knob to the control mech¬ anism. Check the control mechanism is working prop¬ erly. Complete with Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed Complete with Op. 7010E10 Rear side door inner panel - r r or replace Complete with Op. 7040E26 Lower courtesy light in rear panel - r r Complete with Op. 7010E38 Rear side door interior handle- r r Complete with Op. 7010D38 Rear side door manual window mechanism handle/ring-nut r r Complete with Op. 7010C44 Interior handle panel - r r Complete with Op. 7065C42 Ashtray (one) r+r r*\ PA5106/00 06/1998 17 REPAIR PROCEDURES Passenger compartment rear side doors 7010 j 7010D - Rear side door window glasses VIEW OF ASSEMBLY 2 1 A 1b Installation - - Check that the glass scraper is undamaged. Fit the exterior glass scraper. Complete with Op. 7010E52 Rear door front pillar trim - r r Complete with Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed Complete with Op. 7010E10 Rear side door inner panel - r r or replace Complete with Op. 7010C44 Interior handle panel - r r Complete with Op. 7065C42 Ashtray (one) r+r Complete with Op. 7010E38 Rear side door interior handle-r r Complete with Op. 7040E26 Lower courtesy light in rear panel - r r 1a Installation - - Check that the glass scraper is undamaged. Position the glass scraper and tighten the retaining bolts. Complete with Op. 7010E10 Rear side door inner panel - r r or replace Complete with Op. 7010C44 Interior handle panel - r r Complete with Op. 7065C42 Ashtray (one) r+r Complete with Op. 7010E38 Rear side door interior handle-r r Complete with Op. 7040E26 Lower courtesy light in rear panel - r r 7010D30 - REAR SIDE DESCENDING WINDOW GLASS SCRAPER (INNER) R R 7010D32 - CHANNEL OF DOOR DESCENDING GLASS INNER GUIDE (ONE) LH OR RH, OF REAR SIDE DOOR PANEL REMOVED Removal Removal - Follow the Op. 7065C42 Ashtray (one) r+r Follow the Op. 7010C44 Interior handle panel rr Follow the Op. 7010E38 Rear side door interior handle-r r Follow the Op. 7040E26 Lower courtesy light in rear panel - r r Follow the Op. 7010E10 Rear side door inner panel - r r or replace 1. Unscrew bolts (1a) retaining glass scraper (1b) to the panel and remove. PA5106/00 06/1998 Follow the Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed Rear side door Follow the Op. 7010D23 descending window glass guide one-r r 1. Remove window channel (1a) from guide (1b). 23 REPAIR PROCEDURES Passenger compartment rear side doors 7010 0 Complete with Op. 7010E10 Rear side door inner panel - r r or replace Complete with Op. 7010E26 Data not yet avail- able 1b 1a Complete with Op. 7010E38 Rear side door interior handle-r r Complete with Op. 7010C44 Interior handle panel - r r Complete with Op. 7065C42 Ashtray (one) r+r \ \© Installation - Check the condition of the channel and guide. Refit the window channel to the guide. Complete with Op. 7010023 Rear side door descending window glass guide one-r r Complete with Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed 7010D33 - CHANNEL OF DOOR DESCENDING GLASS INNER GUIDE (ONE) LH OR RH, OF REAR SIDE DOOR - R R Removal - - Follow the Op. 7065C42 Ashtray (one) r+r Follow the Op. 7010C44 Interior handle panel rr Follow the Op. 7010E38 Rear side door interior handle-r r Follow the Op. 7040E26 Lower courtesy light in rear panel - r r Follow the Op. 7010E10 Rear side door inner panel - r r or replace Follow the Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel o removed Follow the Op. 7010D23 Rear side door descending window glass guide one-r r Follow the Op. 7010D32 Channel of door descending glass inner guide (one) Ih or rh, of rear side door panel removed Installation Complete with Op. 7010D32 Channel of door descending glass inner guide (one) Ih or rh, of rear side door panel removed Complete with Op. 7010D23 Rear side door descending window glass guide one-r r Complete with Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed 24 PA5106/00 06/1998 REPAIR PROCEDURES Passenger compartment rear side doors rC j 7010 7010E - Rear side door trim VIEW OF ASSEMBLY 6 n l _L 4 J J?// A 5 7 4 8 l 1 3 2 fJiinicnrHVtnix// Ref. Description 1 REAR DOOR INTERIOR PANEL 2 DOOR REFLECTORS 3 POUCH ON REAR DOOR PANEL 4 REAR DOOR REAR PILLAR TRIM 5 INTERIOR HANDLE ON REAR DOOR PANEL 6 REAR DOOR FRONT PILLAR TRIM 7 REINFORCE.BRACKET FOR FRONT DOOR HANDLE. 8 REAR DOOR INTERIOR PANEL TRIM cunt i* Operations index Code Operation 7010E10 Rear side door inner panel - r r or replace 7010E11 Lh or rh rear door inner panel - r+r with fouling parts Validity removed PA5106/00 06/1998 25 REPAIR PROCEDURES 7010 Passenger compartment rear side doors J Code Operation 7010E30 Oddment pouch on one rear side door-r r 7010E38 Rear side door interior handle-r r 7010E39 Rear door reinforcement bracket - r r 7010E52 Rear door front pillar trim - r r 7010E54 Rear door rear pillar trim - r r 7010E70 Reflector on rear door panel - r r 7010E80 Rear door inner panel trim (one) Ih or rh - r r WARNINGS Observe the following instructions when working on the rear door assembly: - When working on the hinges, take care not to damage the paintwork. - If door adjustment requires the hinges to be moved, remove the door and touch up the paint¬ work in the hinge area. - After removing a door, lean the door against a stable support and avoid damage to the paint¬ Validity 7010E11 - LH OR RH REAR DOOR INNER PANEL - R+R WITH FOULING PARTS REMOVED Removal 1. Remove the bolt cover panel. 2. Unscrew the panel retaining bolts. 3. Unscrew tool (3a) and undo studs (3b). work. PRECAUTIONS DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). H 3a Description Code Blade 1 .823.01 5.000 4. Remove the panel and release from the door safety device. OPERATIONS 4 7010E10 - REAR SIDE DOOR INNER PANEL - R R OR REPLACE 3b CK Removal Follow the Op. 7065C42 Ashtray (one) r+r Follow the Op. 7010C44 Interior handle panel rr Follow the Op. 7010E38 Rear side door interior handle-r r Follow the Op. 7040E26 Lower courtesy light in rear panel - r r Follow the Op. 7010E11 Lh or rh rear door inner panel - r+r with fouling parts removed xn 3b 3; 3b •Ok1 2 Installation Complete with Op. 7010E11 Lh or rh rear door inner panel - r+r with fouling parts removed Complete with Op. 7010C44 Interior handle panel - r r Complete with Op. 7065C42 Ashtray (one) r+r Complete with Op. 7010E38 Rear side door interior handle-r r Complete with Op. 7040E26 Lower courtesy light in rear panel - r r 26 Installation - - Check that the panel is undamaged. Check that the retaining studs are correctly posi¬ tioned and secure the panel. Tighten the five bolts securing the panel. Fit the bolt cover panel. PA5106/00 06/1998 a REPAIR PROCEDURES Passenger compartment rear side doors 7010E30 - ODDMENT POUCH ON ONE REAR SIDE DOOR-R R Removal Follow the Op. 7065C42 Ashtray (one) r+r Follow the Op. 7010C44 Interior handle panel rr Follow the Op. 7010E38 Rear side door interior handle-r r Follow the Op. 7040E26 Lower courtesy light in rear panel - r r Follow the Op. 7010E10 Rear side door inner panel - r r or replace 1. Unscrew the bolts retaining the oddment pouch to the panel. 2. Use the cutter to remove the clips retaining the pouch to the panel. S3 7010 7010E38 - REAR SIDE DOOR INTERIOR HANDLE-R R Removal - With the ignition key in the stop position. disconnect the battery negative terminal. 1. Remove the bolt cover panel. 2. Unscrew the grab handle retaining bolts. 3. Disconnect the electrical connection. 4. Remove the interior grab handle. IDescription 3 Connector Electric window switch on rear right door H54 IDescription Description Code Blade 1.823.015.000 3 Connector Electric window switch on rear left door H53 3. Remove the pouch from the door panel. -- 2 2 0 L*. Installation Check that the pouch is undamaged. Complete with Op. 7010C44 3 1 3 Fit the pouch. Tighten the retaining bolts. Fit the retaining clips. Complete with Op. 7010E10 inner panel - r r or replace f 4 \x - 1 Installation - Rear side door Interior handle panel - r r Complete with Op. 7065C42 Ashtray (one) r+r Complete with Op. 7010E38 Rear side door interior handle-r r Complete with Op. 7040E26 Lower courtesy light in rear panel - r r - - Check that the grab handle is undamaged. Check the window switch electrical connection and ensure it is working properly. Position the grab handle and fit to the panel. Tighten the bolts retaining the grab handle to the door. Fit the bolt cover panels. With the ignition key in the stop position, connect the battery negative terminal. 7010E39 - REAR DOOR REIN¬ FORCEMENT BRACKET - R R Removal Follow the Op. 7065C42 Ashtray (one) r+r Follow the Op. 7010C44 Interior handle panel rr Follow the Op. 7010E38 Rear side door interior handle-r r PA5106/00 06/1998 27 REPAIR PROCEDURES Passenger compartment rear side doors 7010 j Follow the Op. 7040E26 Lower courtesy light in rear panel - r r Follow the Op. 7010E10 Rear side door inner panel - r r or replace 1. Unscrew the bolts retaining the bracket to the panel. 2. Remove the bracket. o o rC 0 0 0 0 3a 1 3b 0, 0 2 J 2 / 1 Installation Installation - Fit the bracket on the panel and tighten the retaining bolts. Complete with Op. 7010E10 Rear side door inner panel - r r or replace Complete with Op. 7010C44 Interior handle panel - r r Complete with Op. 7065C42 Ashtray (one) r+r Complete with Op. 7010E38 Rear side door interior handle-r r Complete with Op. 7040E26 Lower courtesy light in rear panel - r r 7010E52 - REAR DOOR FRONT PILLAR TRIM - R R Removal Follow the Op. 7065C42 Ashtray (one) r+r Follow the Op. 7010C44 Interior handle panel rr Follow the Op. 7010E38 Rear side door interior handle-r r Follow the Op. 7040E26 Lower courtesy light in rear panel - r r Follow the Op. 7010E10 Rear side door inner panel - r r or replace Follow the Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed I.Undo the clip retaining the window to to the electrically-operated window device and remove the plastic pin. 2. Lower the window inside the door and prise out the vertical section of the glass slide channel. 3. Unscrew the three bolts (3a) retaining the outer trim (3b) and remove from the door together - - - - Check the trim is in good condition. Position the outer trim and check it is fitted correctly in relation to the bolt holes. Tighten the outer trim retaining bolts. Fit the vertical section of the slide channel. Fit the window to the locating pin and connect the retaining clip. Check the device is working properly by raising and lowering the window. Complete with Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed Complete with Op. 7010E10 Rear side door inner panel - r r or replace Complete with Op. 7010C44 Interior handle panel - r r Complete with Op. 7065C42 Ashtray (one) r+r Complete with Op. 7010E38 Rear side door interior handle-r r Complete with Op. 7040E26 Lower courtesy light in rear panel - r r 7010E54 - REAR DOOR REAR PILLAR TRIM - R R Removal 1. Remove the bolt cover panel on the inside of the door. 2. Unscrew the inner trim retaining bolt. 3. Lower the window and prise out the vertical section of the glass slide channel. 4. Unscrew the bolts retaining the outer trim to the pillar located beneath the vertical channel section. 5. Remove the trim by prising out of the door. with the sealing strip. 28 PA5106/00 06/1998 REPAIR PROCEDURES a Passenger compartment rear side doors 2 5 7010 1 — *N // 4 / 1 3 'tSL. 2 Installation - - Position the outer trim and check it is fitted correctly. Tighten the two bolts retaining the outer trim. Tighten the bolt securing the trim to the inner side of the door. Fit the plug. Fit the vertical section of the slide channel and raise the window to ensure it moves properly. Installation - Check that the reflector is undamaged. Fit the reflector into its seat on the panel and tighten the retaining bolt. Complete op. 7010E10 Rear side door inner panel - r r or replace Complete op. 7010C44 Interior handle panel - - rr Complete op. 7065C42 Ashtray (one) r+r Complete op. 7010E38 Rear side door interior handle-r r Complete op. 7040E26 Lower courtesy light in rear panel - r r 7010E70 - REFLECTOR ON REAR DOOR PANEL - R R Removal Follow the Op. 706SC42 Ashtray (one) r+r Follow the Op. 7010C44 Interior handle panel rr Follow the Op. 7010E38 Rear side door interior handle-r r Follow the Op. 7040E26 Lower courtesy light in rear panel - r r Follow the Op. 7010E10 Rear side door inner panel - r r or replace 1. Unscrew the bolt retaining the reflector to the door panel. 2. Remove the reflector 7010E80 - REAR DOOR INNER PANEL TRIM (ONE) LH OR RH R R Removal Follow the Op. 7065C42 Ashtray (one) r+r Follow the Op. 7010C44 Interior handle panel rr Follow the Op. 7010E38 Rear side door interior handle-r r Follow the Op. 7040E26 Lower courtesy light in rear panel - r r Follow the Op. 7010E10 Rear side door inner panel - r r or replace 1. Use tool (1a) to prise open studs (1b) securing the trim to the panel. E3 1a Description Code Blade 1.823.015.000 2. Remove the trim. PA5106/00 06/1998 29 REPAIR PROCEDURES 7010 Passenger compartment rear side doors rC j rnh ia 2 fc£3 y J6 r*\ Installation - - Check that the trim is undamaged. Fit the trim. Do up the retaining studs. Complete with Op. 7010E10 Rear side door inner panel - r r or replace Complete with Op. 7010C44 Interior handle panel - r r Complete with Op. 7065C42 Ashtray (one) r+r Complete with Op. 7010E38 Rear side door interior handle-r r Complete with Op. 7040E26 light in rear panel - r r 30 Lower courtesy PA5106/00 06/1998 REPAIR PROCEDURES a Passenger compartment rear side doors 7010 7010M - Rear electric windows VIEW OF ASSEMBLY •*\ I v C\ m 1 2 Ref. Description 1 REAR WINDOW SWITCH (DRIVER SIDE) 2 REAR ELECTRIC WINDOW SWITCH 3 REAR ELECTRONICALLY OPERATED WINDOW MECH Operations index r Code Operation Validity 7010M10 Rear side door electrically operated window switch r r 7010M16 Rear electric window enablement switch - r+r 7010M20 Repeair side door electrically operated window motor _- r r with door panel-mount frame removed_ 7010M21 Rear side door electrically-operated window-r r 7010M24 Front side door electrically operated window mecha_nism - check positioning and fastening _ 7010M25 Lh rear side doorelectrically-operated window mechaposition and fastening _ _nism-check PRECAUTIONS DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). PA5106/00 06/1998 31 REPAIR PROCEDURES Passenger compartment rear side doors 7010 rC J OPERATIONS 7010M10 - REAR SIDE DOOR ELECTRICALLY OPERATED WINDOW SWITCH R R IDescription 4 Removal Follow the Op. 7010E38 Rear side door interior handle-r r 1. Prise the electrically-operated window switch out of the grab handle. 4 Connector Rear right electric window motor N66 {Description Connector Rear left electric window motor N65 4. Lower the device manually until it can be removed from the door compartment. 3 -2 my // 4 ./ - Refer to op.. 7005M10 Driver's side front side door glass control switch (one) r r 7010M20 - REPEAIR SIDE DOOR ELECTRICALLY OPER¬ ATED WINDOW MOTOR - R R WITH DOOR PANEL-MOUNT FRAME REMOVED Removal Follow the Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed 1. Unscrew the nuts retaining the electricallyoperated window device to the door. 2. Undo the clip retaining the window to to the electrically-operated window device and remove the plastic pin. 3. With the window fully raised, position a support hook to prevent accidental lowering of the window. 4. Disconnect the electrical connection. 32 Installation - - - Check the condition of the device. Fit the electrically-operated window device into the door. Tighten the nuts retaining the device to the door. Connect the electrical connection. Check the device is working properly by raising and lowering. Remove the support hook Fit the window to the locating pin and connect the retaining clip. Complete with Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed 7010M21 - REAR SIDE DOOR ELECTRICALLY-OPERATED WINDOW-R R Removal Follow the Op. 7065C42 Ashtray (one) r+r Follow the Op. 7010C44 Interior handle panel rr PA5106/00 - 06/1998 r*\ a - REPAIR PROCEDURES Passenger compartment rear side doors Follow the Op. 7010E38 Rear side door interior handle-r r Follow the Op. 7040E26 Lower courtesy light in rear panel - r r Follow the Op. 7010E10 Rear side door inner panel - r r or replace Follow the Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel 7010 '/ .o removed Follow the Op. 7010M20 Repeair side door electrically operated window motor - r r with door panel-mount frame removed / 9M \ 7 Installation p>( Complete with Op. 7010M20 Repeair side door electrically operated window motor - r r with door panel-mount frame removed Complete with Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed Complete with Op. 7010E10 Rear side door inner panel - r r or replace Complete with Op. 7040E26 Lower courtesy light in rear panel - r r Complete with Op. 7010E38 Rear side door interior handle-r r Complete with Op. 7010C44 Interior handle panel - r r Complete with Op. 7065C42 Ashtray (one) r+r 7010M24 - FRONT SIDE DOOR ELECTRICALLY OPERATED WINDOW MECHANISM CHECK POSITIONING AND FASTENING Removal Follow the Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed 1. Check the electrically-operated window device nuts are tightened to the specified torque. 2. Check the fastening anchorage clip and plastic pin are properly positioned and secured. - Check the device is working properly by raising and lowering the window. PA5106/00 06/1998 // Ui <#> Z! 1 * / // Installation Complete with Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed 7010M25 - LH REAR SIDE DOORELECTRICALLY-OPERATED WINDOW MECHANISMCHECK POSITION AND FASTENING - Carry out op. 7065C42 Ashtray (one) r+r Carry out op. 7010C44 Interior handle panel rr Carry out op. 7010E38 Rear side door interior handle-r r Carry out op. 7040E26 Lower courtesy light in rear panel - r r Carry out op. 7010E10 Rear side door inner panel - r r or replace Carry out op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed Carry out op. 7010M24 Front side door electri¬ cally operated window mechanism - check positioning and fastening 33 REPAIR PROCEDURES 7010 Passenger compartment rear side doors 701ON - Rear side door central locking system VIEW OF ASSEMBLY m //> 1 r\ 1 Ref. Description 1 REAR DOOR LOCK MECHANISM Operations index Code Operation Validity 7010N20 Rear side door lock motor/catch assembly - r r with _door panel and support frame removed_ 7010N21 Rear side door lock motor-lock assembly r r 7010N40 Door lock electrical system control unit - r+r following _system check _ 7010N68 Receiver for central locking remote control - r r with _any fouling parts removed _ WARNINGS Observe the following instructions when working on the rear door assembly: - When working on the hinges, take care not to damage the paintwork. 34 - If door adjustment requires the hinges to be moved, remove the door and touch up the paint¬ work in the hinge area. - After removing a door, lean the door against a stable support and avoid damage to the paint¬ work. PA5106/00 06/1998 a REPAIR PROCEDURES Passenger compartment rear side doors 7010 PRECAUTIONS DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). 2 ,o OPERATIONS 7010N20 - REAR SIDE DOOR LOCK MOTOR/CATCH ASSEMBLY - R R WITH DOOR PANEL AND SUPPORT FRAME REMOVED 1 V' 3 4b 4a Removal Follow the Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel 1b 1a removed /-*s 1. Disconnect the interior handle mechanism cable (1a) and the safety device mechanism link (1b) from the lever and control mechanism. 2. Release the link and cable from the retaining clips on the door. 3. Unscrew the bolts retaining the catch to the door. 4. Disconnect electrical connection (4a) and remove catch (4b) complete with link and cable. Installation - 4a iDescription Connector CAE control unit M55 IDescription Data not yet available Connector - Check the condition of all catch components. Fit the catch inside the door and connect the catch electrical connection. Tighten the three bolts retaining the catch to the door. U Mounting Component Screw REAR DOOR M8 LOCK MECHA¬ NISM M56 0 Value (daNm) 1.4 Secure the link and cable to the door using three retaining clips. Connect the cable to the inner handle. Connect the link to the safety device. Check the catch is working properly by opening and closing the door a few times. Complete with Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed 7010N21 - REAR SIDE DOOR LOCK MOTOR-LOCK ASSEMBLY R R Removal Follow the Op. 7065C42 Ashtray (one) r+r Follow the Op. 7010C44 Interior handle panel rr Follow the Op. 7010E38 Rear side door interior handie-r r Follow the Op. 7040E26 Lower courtesy light in rear panel - r r Follow the Op. 7010E10 Rear side door inner panel - r r or replace PA5106/00 06/1998 35 REPAIR PROCEDURES Passenger compartment rear side doors 7010 J Follow the Op. 7010A04 Rear side door water guard protection - r r or arrange with door panel removed Follow the Op. 7010N20 Rear side door lock motor/catch assembly - r r with door panel and support frame removed - rC Installation - - Check the receiver is in good condition. Connect the connector and tighten both bolts retaining the receiver to the parcel rack. Complete with Op. 5550D16 Third stop light - r r+r Installation Complete with Op. 7010N20 Rear side door lock motor/catch assembly r r with door panel and support frame removed Complete with Op. 7010A04 Rear side door water guard protection - r r or arrange with door - panel removed Complete with Op. 7010E10 inner panel - r r or replace Rear side door Complete with Op. 7040E26 Lower courtesy light in rear panel - r r Complete with Op. 7010E38 Rear side door interior handle- r r Complete with Op. 7010C44 Interior handle panel - r r Complete with Op. 7065C42 Ashtray (one) r+r o 7010N40 - DOOR LOCK ELEC¬ TRICAL SYSTEM CONTROL UNIT - R+R FOLLOWING SYSTEM CHECK Refer to op.. 5505A18 Multi-function control unit - r r 7010N68 - RECEIVER FOR CENTRAL LOCKING REMOTE CONTROL - R R WITH ANY FOULING PARTS REMOVED Removal Follow the Op. 5550D16 Third stop light - r+r 1. Unscrew the bolts retaining the receiver to the parcel rack. 2. Remove receiver (2a) by withdrawing from electrical connection (2b). 1 /\ 2a 2b 36 PA5106/00 06/1998 REPAIR PROCEDURES Compartment covers lids tC 7025 J Sub-group index - SUB-GROUP GRAPHIC INDEX Assembly drawings index Cmp Description 7025A Bonnet lid 7025B Boot lid 7025C Various flaps (exterior) Validity SUB-GROUP GRAPHIC INDEX 2 1 ■0 < 3 Ref. Description Cmp 1 Bonnet lid 7025A 2 Boot lid 7025B 3 Various flaps (exterior) 7025C PA5106/00 06/1998 1 REPAIR PROCEDURES Compartment covers lids 7025 r Fit a new cable and sheath by working from the passenger compartment using a probe. Complete with Op. 7025A24 Boot lid opening lever - r+r Complete with Op. 7040A43 Cover (one only) for wiring beneath facia - r r Disconnect the probe from the bonnet lid opening cable. Connect the bonnet lid opening cable sheath to the relevant collars. Complete with Op. 7025A34 Bonnet lid lock (one) - r+r or repair Complete with Op. 7055A43 Central front grille rr Complete with Op. 7055A41 Front grille(one) rr - 7025A34 - BONNET LID LOCK (ONE) - R+R OR REPAIR — 2a o o c P A 2a 2b o Installation - Check that the catch is undamaged. Connect the catch control cable. - Fit the catch and screw in the retaining nuts. 1. Adjust catch position.The arrows indicate possible movements. 2. A Removal - Follow the Op. 7055A43 Central front grille - r r Open the bonnet. 1. Unscrew the nuts retaining the catch to the mount. & 2. Disconnect catch control cable (2a) from both anchorage points (2b). 3. Remove catch (3). Complete with Op. 7055A43 Central front grille rr - 7025A40 - BONNET CATCH MOUNT WITH SAFETY LEVEL R R Removal - 6 Follow the Op. 7055A43 Central front grille - r r Follow the Op. 7025A34 Bonnet lid lock (one) - r+r or repair PA5106/00 06/1998 REPAIR PROCEDURES 0 Compartment covers lids 7025 1. Unscrew the retaining nuts. 2. Remove the catch mount. // 2 2 V 1b \ i0 ss © \r 2b & i 1 Ua, Xp \ Os1 5 a Installation - 2a - Complete with Op. 7040A67 Partition between passenger airbag and facia compartment - r r Check the boot lid central opening switch is working property before securing the air bag housing compartment flap. Complete with Op. 7040A31 Flap assembly - r r Note: Installation - Fit the boot lid central opening switch in its seat. Connect the motor electrical connections. Check operation. Tighten the nuts retaining the motor to the boot lid. Complete with Op. 7025B38 Boot lid lock - r+r Complete with Op. 7025B41 Boot lid lock Complete with Op. 7025B18 Boot lid lining - - r+r With the ignition key in the stop position, disconnect the battery negative terminal. 7025B80 - BOOT LID CENTRAL LOCKING SYSTEM ELECTRICAL CIRCUIT - CHECK COMPO¬ NENT OPERATION LINE CONTI¬ NUITY AND REPAIR CONTACTS - INCLUDES SWITCH REPLACE¬ MENT IF NECESSARY Removal - Follow the Op. 7040A31 Flap assembly r r Follow the Op. 7040A67 Partition between passenger airbag and facia compartment - r r 1. Remove boot lid central opening switch (1a) from its seat using tool (1b). ES WÿlDescription 1b 16 Blade Code 1.823.014.000 PA5106/00 06/1998 REPAIR PROCEDURES a Compartment covers lids 7025 7025C - Various flaps (exterior) VIEW OF ASSEMBLY 1 3 V 2 a Ref. Description 1 FUEL FILLER FLAP 2 FUEL FILLER FLAP RELEASE EMERG CONTROL 3 FUEL FLAP CONTROL MOTOR Operations index Code Operation Validity 7025C10 Fuel filler flap - r+r 7025C28 Fuel filler flap emergency opening control - repair 7025C40 Fuel filler flap control motor - r+r and check lock _supply line _ 7025C50 Fuel filler flap central locking system electrical wiring - check component operation, line continuity and repair contacts - includes switch replacement if neces_sary _ PA5106/00 06/1998 17 REPAIR PROCEDURES Compartment covers lids 7025 J OPERATIONS Screw on the fuel cap. Complete with Op. 7055B43 Rear supplemen¬ 7025C10 - FUEL FILLER FLAP R +R Removal - - Follow the Op. 4450B13 Rear wheels(2) r r Follow the Op. 7055B43 Rear supplementary wheel arch (one) - r+r 1 Open the fuel flap and remove the filler cap. 2. Remove fuel filler fitting rubber protection (2a) and unscrew both nuts (2b) securing the flap hinge to the body. 3. Remove the flap and hinge from the outside by releasing the retaining pins. . 1 a 2a / tary wheel arch (one) - r+r Complete with Op. 4450B13 Rear wheels(2) r r 7025C28 - FUEL FILLER FLAP EMERGENCY OPENING CONTROL - REPAIR Removal - With the ignition key in the stop position, disconnect the battery negative terminal. - Follow the Op. 7040B10 Load platform (luggage platform) trim - r+r Follow the Op. 7040B20 Back trim for luggage compartment/load platform - arrange Follow the Op. 7040B13 Load compartment/ load platform right side trim - r r 1. Disconnect the flap opening electrical connec¬ tion. IDescription \n Connector Fuel flap lock 1 N58 gearmotor 2. Unscrew the nuts retaining the opening control actuator. 3. Remove the flap opening control actuator. 4. Replace the emergency control cord and secure to the plunger. 3 V 2b HI 1 -A Installation - Check that the flap and hinge are in good condition. Refit the flap and hinge. Fit the retaining pins in their seats and screw in both retaining nuts. 1- If necessary, use the slots to adjust flap posi¬ tion.Permitted adjustment movements are indi¬ / \ cated by arrows. 3N KJ 2 o' mm Installation 0 Tighten the retaining bolts. Fit the fuel filler fitting rubber protection. 18 4 - Check the actuator is in good condition. Fit the motor and tighten both retaining bolts. Connect the electrical connector. Test to ensure it works properly. Complete with Op. 7040B13 Load compart¬ ment/load platform right side trim - r r Complete with Op. 7040B20 Back trim for luggage compartment/load platform - arrange Complete with Op. 7040B10 Load platform (luggage platform) trim - r+r PA5106/00 06/1998 REPAIR PROCEDURES 0 Compartment covers lids 7025C40 - FUEL FILLER FLAP CONTROL MOTOR - R + R AND CHECK LOCK SUPPLY LINE Removal - With the ignition key in the stop position, disconnect the battery negative terminal. Follow the Op. 7040BIO Load platform (luggage platform) trim - r+r Follow the Op. 7040B20 Back trim for luggage compartment/load platform - arrange - Follow the Op. 7040B13 Load compartment/ load platform right side trim - r r 1. Disconnect the flap opening electrical connector. Removal Connector Fuel flap lock 1 7025C50 - FUEL FILLER FLAP CENTRAL LOCKING SYSTEM ELECTRICAL WIRING - CHECK COMPONENT OPERATION, LINE CONTINUITY AND REPAIR CONTACTS - INCLUDES SWITCH REPLACEMENT IF NECESSARY - \Description N58 gearmotor 2. Unscrew the nuts retaining the opening control actuator. ll)| 1 - Follow the Op. 7040A31 Flap assembly r r Follow the Op. 7040A67 Partition between passenger airbag and facia compartment - r r 1. Remove fuel filler flap central opening switch (1a) from its seat using tool (1b). □ 1b 3. Remove the flap opening actuator. 7025 Description Code Blade 1.823.014.000 -A 0CV C\ I-, 1a !\ Us l TO \ CN' N egm s 3 £ 1bQ Installation - 2 Installation - - - Check the condition of the actuator. Fit the actuator and tighten both retaining bolts. Connect the electrical connector. Test engine operation. Complete with Op. 7040B13 Load compart¬ ment/load platform right side trim - r r Complete with Op. 7040B20 Back trim for luggage compartment/load platform - arrange Complete with Op. 7040B10 Load platform (luggage platform) trim - r+r PA5106/00 06/1998 Fit the fuel filler flap central opening switch in its seat. Complete with Op. 7040A67 Partition between passenger airbag and facia compartment - r r Note: Check the fuel filler flap central opening switch is working property before securing the air bag housing compartment flap Complete with Op. 7040A31 Flap assembly - r r 19 REPAIR PROCEDURES 7025 Compartment covers lids a o 20 PA5106/00 06/1998 REPAIR PROCEDURES H Sun roof and hood 7030 Sub-group index - SUB-GROUP GRAPHIC INDEX Assembly drawings index Cmp Description 7030B Sliding roof Validity SUB-GROUP GRAPHIC INDEX 1 ■<0 Ref. Description Cmp 1 Sliding roof 7030B PA5106/00 06/1998 1 REPAIR PROCEDURES Sun roof and hood 7030 J 7030B - Sliding roof VIEW OF ASSEMBLY 2 1 6 3 5 I > 7 9 > 9 4 •o o O I o **o o 11 •o t) O m 8 9 o 10 o a 12 i tbuitmrMY /ota/ Ref. Description 1 SUN-ROOF PANEL 2 SUNROOF PANEL SEAL 3 SUNROOF BLIND 4 SUNROOF ORNAMENTAL SEAL 5 SUNROOF DRAINAGE PIPES 6 SLIDING ROOF DRAINAGE CHANNEL 7 SUNROOF SPOILER 8 SUNROOF CABLES 9 SUNROOF BLIND SLIDE RAILS 10 SUN ROOF SWITCH 11 SUNROOF ECU RELAY 12 SUNROOF MOTOR »ÿ r count Operations index 2 PA5106/00 06/1998 REPAIR PROCEDURES El Code Sun roof and hood 7030 Validity Operation 7030B10 Sliding roof (assembly) - r+r with roof panel removed 7030B12 Sliding roof (assembly) - r+r 7030B14 Sliding roof - dismantle and rebuild with assembly removed 7030B15 Sliding roof panel (in sheet metal) - align 7030B16 Steel panel for sunroof - r+r 7030B19 Sliding roof panel seal(in panel)- r r with panel removed 7030B28 Sliding roof blind - r+r 7030B34 Sliding roof compartment decorative seal - r+r 7030B38 Sliding roof drainage pipes (water drain) - check 7030B40 Drainage channel - r r 7030B42 Sliding roof spoiler - r+r 7030B45 Cable - r r 7030B46 Sun roof cables , one . Ih or rh - r r 7030B50 Sun roof guide , one , Ih or rh - r r 7030B54 Sun roof systems 7030B64 Sun- roof control switch - r+r 7030B66 Sun-roof movement ecu - r+r 7030B70 Sun-roof control switch - r+r WARNINGS Use care when working on trim components and use the specified tools correctly in order to avoid damage.Following operations that alter the drive train between motor and sun-roof, carry out the sun-roof alignment procedure. PRECAUTIONS DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). IDescription 1 Data not yet available Connector N35 2. Disconnect the water drainage pipes. 3. Unscrew the bolts retaining the chassis to the body. 4. Unscrew the sun-roof perimeter retaining bolts 5. Remove the sun-roof frame (5a) with the aid of a second operator and recover brackets (5b). OPERATIONS 7030B10 - SLIDING ROOF (ASSEMBLY) - R + R WITH ROOF PANEL REMOVED Removal - With the ignition key in the stop position, disconnect the battery negative terminal. 1. Disconnect the sun-roof motor electrical connection. S PA5J06/00 06/1998 3 REPAIR PROCEDURES Sun roof and hood 7030 HT J o N a 2 o y M 2 I O o l \ 4 PM \ fez I o 3 2 9\4i 3 o' 4 2 4 2 3 Installation - - - Check that the sun-roof components are undamaged. With the aid of a second operator, refit the sun¬ roof frame and brackets. Take care to refit only when the panel is closed. With the aid of a second operator, tighten the first 4 perimeter nuts and 4 bolts securing the frame and brackets. Tighten the remaining nuts and bolts. Connect the drainage pipes. Check the motor electrical connection. Complete with Op. 7030B15 Sliding roof panel (in sheet metal) - align 7030B12 - SLIDING ROOF (ASSEMBLY) - R + R Removal - 4 5a Follow the Op. 7005A20 Front side door adjust centring and moulding - includes adapta¬ tion of hinges Follow the Op. 7065C34 L/h or r/h sun blind (one) - r+r Follow the Op. 7040E40 Modular front courtesy light - r r Follow the Op. 7040E28 Courtesy light on sun blind - r r 5b 3 4 Follow the Op. 7030B34 Sliding roof compart¬ decorative seal - r+r Follow the Op. 7040H32 Sliding roof switch door panel - r r Follow the Op. 7065C30 Interior l/h or r/h grab handle (one) - r+r Follow the Op. 7040H30 Front pillar trim - r r Follow the Op. 7040H34 Central pillar trim - r r Follow the Op. 7040E17 Lh or rh rear courtesy light - r r Follow the Op. 7065C68 Rear view mirror - r+r Follow the Op. 7065C59 Interior rear view mirror with automatic antiglare device - r r Follow the Op. 7040H16 Roof panel lining - r r Sliding roof Follow the Op. 7030B10 (assembly) - r+r with roof panel removed ment Installation Complete with Op. 7030B10 Sliding roof (assembly) - r+r with roof panel removed Complete with Op. 7040H16 Roof panel lining -rr Complete with Op. 7065C59 Interior rear view mirror with automatic antiglare device - r r Complete with Op. 7065C68 Rear view mirror - r+r Complete with Op. 7040E17 Lh or rh rear cour¬ -rr Complete with Op. 7040H34 Central pillar trim tesy light -rr PA5106/00 06/1998 REPAIR PROCEDURES Sun roof and hood HT 7030 J - - Complete with Op. 7040H30 Front pillar trim rr Complete with Op. 7065C30 Interior l/h or r/h grab handle (one) - Installation - - r+r Complete with Op. 7040H32 Sliding roof switch door panel - r r Complete with Op. 7040B34 Data not yet avail¬ able Check the pads for wear and ensure the slide is undamaged. 1. check that the slide pads are properly fitted in their seats. 2. Fit clip (2a) into seat (2b) and then fit slide (2c) into guide (2d) and attach the control cable. Complete with Op. 7040E28 Courtesy light on sun blind r r Complete with Op. 7040E40 Modular front 2b - courtesy light -rr Complete with Op. 7065C34 <3 L/h or r/h sun blind (one) - r+r Complete with Op. 7005A20 Front side door adjust centring and moulding - includes adapta¬ tion of hinges 7030B14 - SLIDING ROOF DISMANTLE AND REBUILD WITH ASSEMBLY REMOVED 2a % 2d 1 Removal - Follow the Op. 7030B45 Cable - r r 1. Remove guide slide (1a) from frame (1b). / 2d J 1 1 / 2c 1 *J Check the spoiler is in good condition. Fit the spoiler and tighten both retaining bolts. Complete with Op. 7030B45 Cable - r r 1 2c 1 1. Undo the retaining bolts. 2. Remove the spoiler. 7030B15 - SLIDING ROOF PANEL (IN SHEET METAL) ALIGN Removal - 1 2 o Adjust the sun-roof panel until it is partly open. Release the lower blind from the panel and push back until it can be heard to click into place. 1. Adjust the sun-roof panel to closed position. - Move the blind fully back and release. 2. Loosen the bolts (three on the rightand three on the left) securing the panel to the frame. 3. Adjust panel position in relation to the roof profile. The arrows indicate permitted movements. o PA5106/00 06/1998 5 REPAIR PROCEDURES El Sun roof and hood 7030 Installation Check that the panel is undamaged. Fit the panel. 1. Screw in the bolts without tightening. - Move the sun-roof panel to closed position. 2. Adjust panel position in relation to roof profile.The arrows indicate permitted move¬ - 1 - ments. 2 A \ A3* 2 1 A ♦ Installation - - Undo the panel retaining bolts. Adjust the panel to partly open position. Connect the blind to the panel so that the fastenings can be heard to click into place. Test the sun-roof and blind to ensure they are working properly. 7030B16 - STEEL PANEL FOR SUNROOF - R + R Removal - Adjust the sun-roof panel until it is partly open. Release the lower blind from the panel and push back until it can be heard to click into place. 1. Move the sun-roof panel until it is tilted open. 2. Unscrew the bolts retaining the panel to the frame. 3. Remove the panel. Tighten the panel retaining bolts. Push the blind forward. Test the sun-roof to ensure it is sliding properly. Test the sun-roof and blind to ensure they are working properly. 7030B19 - SLIDING ROOF PANEL SEAL(IN PANEL)- R R WITH PANEL REMOVED Removal I.Take out the panel seal. 1 2 6 1 2 PA5106/00 06/1998 REPAIR PROCEDURES Sun roof and hood rC J Installation 1. Fit seal (1a).Ensure joint (1b) coincides with the front panel centre line. 7030 Installation - Check that the blind is undamaged. 1- Fit the blind in its guide and insert blind pad (1a) into seat (1b) on the guide. 1a 1 1a >1H| 1b G /—N 1b 7030B28 - SLIDING ROOF BLIND - R + R Removal Follow the Op. 7030B16 Steel panel for sunroof - r+r 1. Move the blind forward and turn slightly. Then push gently downward to release pad (1a) from its guide (1b). 2. Remove the blind. i Complete with Op. 7030B16 sunroof - r+r Steel panel for 7030B34 - SLIDING ROOF COMPARTMENT DECORATIVE SEAL- R+R Removal - \ 2 Slide the sun-roof to open position. I.Take out seal (1a) beginning with seal (1b) at the rear. /***\ '0, 1b 1a —7/ 1a, 1b Installation - - PA5106/00 06/1998 Check that the seal is undamaged. Fit the seal, beginning at the joint which must lie in the middle of the lower edge. Test the sun-roof to ensure it is sliding properly. - 7 REPAIR PROCEDURES Sun roof and hood 7030 J 1. Remove foreign bodies from channels (1a) and drainage holes (1b) in the sun-roof. 7030B38 - SLIDING ROOF DRAINAGE PIPES (WATER DRAIN) - CHECK 1a Removal - Operate the sun-roof until the slides are fully open. - Remove foreign bodies (leaves etc.) from the sun-roof compartment. 1. Blow compressed air into the upper ends of the front drainage pipes. o) 1b U2I 1a Installation - 1 - O - © 7030B40 - DRAINAGE CHANNEL - R R 1. Working beneath the front bumpers, disconnect one-way valve (1a) from the lower ends of rear drainage pipes (1b). Blow compressed air into the lower ends of the front drainage pipes. S3 / Pour a small amount of water into the channels and drainage holes. Ensure the water comes out of the pipes. Check the one-way valves are working properly. Slide the sun-roof closed. 1b Removal - Follow the Op. 7030B16 Steel panel for sunroof - r+r 1. Disconnect drainage channel pins from the guides. 2. Remove drainage channel (2a): begin in the middle and finally detach side pads (2b) from guides (2c). O 1 1a v ¥M 2c 2a r 2b Installation - 8 Check the condition of pads, springs and pins. Slide the channel back. Connect the pins. Check the channels and sun-roof are working properly. Complete with Op. 7030B16 Steel panel for sunroof - r+r PA5106/00 06/1998 REPAIR PROCEDURES Sun roof and hood rC 7030 J 7030B42 - SLIDING ROOF SPOILER - R + R 7030B45 - CABLE Removal - - - Fully open the sun-roof. 1. Unscrew the spoiler retaining bolts. 2. Remove the spoiler. - R R Removal Move the motor pinion pin by hand to slide open the sun-roof sheet steel panel partially. Release the lower blind from the panel and push back until the anchorage clips can be heard to click. Move the motor pinion pin by hand until the sun-roof sheet steel panel is open in tilted posi¬ tion. - Move the blind fully back. 1. Unscrew the bolts retaining the panel to the - 1 2 chassis. 2. Remove the panel. 3. Unscrew bolts (3a) retaining motor (3b) to the chassis in order to release the control cables. 4. Disconnect pins (4a) of drainage channel (4b) from the guides. 5. Remove the channel from the guides. 6. Unscrew the rear end stop bolt. 7. Remove the sealant between the water drainage terminal and the guide. 8. Remove the water drainage terminal. 9. Move the slide backward until the cable can be disconnected. - Withdraw the control cable. O O Installation 1. Fit the spoiler. 2. Screw in the spoiler retaining bolts without tightening. 3. Adjust spoiler position to ensure it is aligned with the front profile of the housing compart¬ ment and check it does not foul sun-roof travel. The arrows indicate possible movements. 2 1 O O 3 Tighten the retaining bolts. Check sun-roof operation by opening and closing a few times. PA5106/00 06/1998 9 REPAIR PROCEDURES a Sun roof and hood 7030 2 \ 4a 4b 9 r 6 8 7 \ Lÿ' - 1 -4 r*\ 5 © © 0 o 3b 3a Installation Check that the control cable is undamaged. Thread the control cable into the sliding seat. - Connect the control cable to the slide. Refit the exhaust tail-pipe. - Apply polyurethane sealant to the exhaust tail¬ pipe, then level to prevent water entering. - Tighten the end stop screw. - Fit the channel into the guides. - Fit the channel pins into the guides. 1. Working on both guides, move slides (1a) by hand fully forward to the end of their travel (1b) - - 1a ,0ÿ (tilted open position). o, a 1b c 10 PA5106/00 06/1998 REPAIR PROCEDURES Sun roof and hood rC 7030 j 1. Before refitting the motor, connect it to connec¬ tion (1a) and turn cam (1b) to point S where it is aligned with microswitch (1c).Turn the cam anticlockwise so that it passes through point C first. Off Complete with Op. 7040H16 Roof panel lining -rr Complete with Op. 7065C59 Interior rear view mirror with automatic antiglare device r r Complete with Op. 7065C68 Rear view mirror - r+r C Complete with Op. 7040E17 Lh or rh rear cour¬ rr Complete with Op. 7040H34 Central pillar trim -rr Complete with Op. 7040H30 Front pillar trim rr Complete with Op. 7065C30 interior l/h or r/h grab handle (one) r+r Complete with Op. 7040H32 Sliding roof switch door panel - r r Complete with Op. 7030B34 Sliding roof compartment decorative seal - r+r Complete with Op. 7040E28 Courtesy light on sun blind - r r Complete with Op. 7040E40 Modular front courtesy light - r r Complete with Op. 7065C34 L/h or r/h sun blind (one) - r+r Complete with Op. 7005A20 Front side door adjust centring and moulding - includes adapta¬ tion of hinges tesy light 1b 1c Wm3 o A Fit the motor and secure with bolts. Fit the panel and screw in bolts without tight¬ ening. Move the motor pinion pin by hand until the panel is in closed position. Check the sun-roof is working properly. 7030B46 - SUN ROOF CABLES , ONE , LH OR RH - R R Removal - Follow the Op. 7005A20 Front side door adjust centring and moulding - includes adapta¬ tion of hinges Follow the Op. 7065C34 L/h or r/h sun blind (one) - r+r Follow the Op. 7040E40 Modular front courtesy light - r r Follow the Op. 7040E28 Courtesy light on sun blind - r r Follow the Op. 7030B34 Sliding roof compart¬ ment - decorative seal - r+r Follow the Op. 7040H32 Sliding roof switch door panel - r r Follow the Op. 7065C30 Interior l/h or r/h grab handle (one) - r+r Follow the Op. 7040H30 Front pillar trim - r r Follow the Op. 7040H34 Central pillar trim - r r Follow the Op. 7040E17 Lh or rh rear courtesy light - r r Follow the Op. 7065C68 Rear view mirror - r+r Follow the Op. 7065C59 Interior rear view mirror with automatic antiglare device - r r Follow the Op. 7040H16 Roof panel lining - r r Sliding roof Follow the Op. 7030B10 (assembly) - r+r with roof panel removed Sliding roof Follow the Op. 7030B12 (assembly) - r+r Follow the Op. 7030B45 Cable - r r - - o' D - 7030B50 - SUN ROOF GUIDE , ONE , LH OR RH - R R Removal - - - Follow the Op. 7005A20 Front side door adjust centring and moulding - includes adapta¬ tion of hinges Follow the Op. 7065C34 L/h or r/h sun blind (one) - r+r Follow the Op. 7040E40 Modular front courtesy light - r r Follow the Op. 7040E28 Courtesy light on sun blind - r r Follow the Op. 7030B34 Sliding roof compart¬ ment decorative seal - r+r Follow the Op. 7040H32 Sliding roof switch door panel - r r Follow the Op. 7065C30 Interior l/h or r/h grab handle (one) - r+r - Follow the Op. 7040H30 Front pillar trim - r r - Follow the Op. 7040H34 Central pillar trim - r r - Follow the Op. 7040E17 Lh or rh rear courtesy light - r r Follow the Op. 7065C68 Rear view mirror - r+r Follow the Op. 7065C59 Interior rear view mirror with automatic antiglare device - r r Follow the Op. 7040H16 Roof panel lining - r r Sliding roof Follow the Op. 7030B10 (assembly) - r+r with roof panel removed - Follow the Op. 7030B45 Cable - r r 1. Remove slide (1a) from chassis (1b). Installation Complete with Op. 7030B45 Cable - r r Sliding roof Complete with Op. 7030B12 (assembly) - r+r Sliding roof Complete with Op. 7030B10 (assembly) - r+r with roof panel removed PA5106/00 06/1998 11 REPAIR PROCEDURES Sun roof and hood 7030 rC J 2d 1 J ( J ■b o. 1b o • \ ///A 2c 1 7030B64 - SUN-ROOF CONTROL SWITCH - R + R Removal Complete with Op. 7030B45 Cable - r r Complete with Op. 7030B10 Sliding roof (assembly) - r+r with roof panel removed Complete with Op. 7040H16 Roof panel lining -rr Complete with Op. 7065C59 Interior rear view mirror with automatic antiglare device - r r Complete with Op. 7065C68 Rear view mirror - r+r Follow the Op. 7040H32 Sliding roof switch door panel - r r Follow the Op. 7030B70 Sun -roof control switch - r+r 1. Disconnect the electrical connections from the control unit base. 2. Disconnect the electrical supply undoing the connector. 3. Recover the switch. lead by Complete with Op. 7040E17 Lh or rh rear cour¬ tesy light - r r Complete with Op. 7040H34 Central pillar trim -rr Complete with Op. 7040H30 Front pillar trim rr 72 PA5106/00 06/1998 REPAIR PROCEDURES Sun roof and hood rC 7030 j 7030B70 - SUN ROOF CONTROL SWITCH - R + R 3 1 1 a o 2 j @X— oj ■ o' mIf -.U Removal Follow the Op. 7040H32 Sliding roof switch door panel - r r - Move the sun-roof to spoiler position by hand or by operating the electrical control. 1. Disconnect the motor electrical connection. o. \ Description 1 - Data not yet available Check that the switch is undamaged. Connect the switch electrical wires. Carry out an electrical test on the switch. With the ignition key in stop position, connect the battery negative terminal. Complete with Op. 7030B70 Sun-roof control switch - r+r Complete with Op. 7040H32 Sliding roof switch door panel - r r c r 3 7030 B66 - SUN ROOF MOVE¬ MENT ECU - R + R 2=42 Removal - N35 2. Unscrew the sun-roof motor retaining bolts. 3. Take the motor out through the hole in the roof panel. If necessary, disconnect the electrical leads from the control unit block. Installation - Connector Follow the Op. 7040H32 Sliding roof switch door panel - r r Follow the Op. 7030B70 Sun -roof control switch - r+r 1. Disconnect the control unit from the connector. 2 0} D' \LJ o Installation J © Iw o' JQ/OZ O 1 - Check that the motor is undamaged. If necessary, check the connections between control unit, motor and switch. Connect the electrical wires to the control unit base, if disconnected previously. Check the motor is working properly. 1. Before refitting the motor, connect to electrical connection (1a) and turn cam (1b) until its TDC is aligned with microswitch (1c).Turn cam anti¬ clockwise so that it passes point C first. Installation - Check that the control unit is undamaged. Connect the control unit to the connector. Complete with Op. 7030B70 Sun-roof control switch - r+r Complete with Op. 7040H32 Sliding roof switch door panel - r r PA5106/00 06/1998 13 REPAIR PROCEDURES Sun roof and hood 7030 c 0 1b 1c 1a TW43 o' D A Fit the motor in its seat. Tighten the retaining bolts. Connect the electrical connection. Check the sun-roof is working properly. Complete with Op. 7040H32 Sliding roof switch door panel - r r 14 PA5106/00 06/1998 REPAIR PROCEDURES a Body window glasses 7035 Sub-group index - SUB-GROUP GRAPHIC INDEX Assembly drawings index Cmp Description 7035A Windscreen 7035 B Rear window Validity SUB-GROUP GRAPHIC INDEX 2 1 r Ref. Description Cmp 1 Windscreen 7035A 2 Rear window 7035B PA5106100 06/1998 1 REPAIR PROCEDURES 7035 rC Body window glasses J 7035A - Windscreen VIEW OF ASSEMBLY 1 ■0 Ref. Description 1 WINDSCREEN GLASS Operations index Code Operation Validity 7035A04 Windscreen - eliminate water infiltration 7035A14 Windscreen glass (bonded type) - r+r - includes _cleaning edge of glass and body housing_ 7035A18 Windscreen glass (bonded type) - r+r for replacement _- includes cleaning body housing _ WARNINGS PRECAUTIONS Use care when working on trim components and use the specified tools correctly in order to avoid damage.Use the special equipment required for glass removal operations and work with great care to avoid damage to the glass and body.Strictly observe the sealant manufacturer's instructions with regard to mode of use and operation times. DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.).Use the special equipment required for glass removal operations and work with great care to avoid accidents.Always ask a second operator to help move the glass. 2 PA5106/00 06/1998 REPAIR PROCEDURES 0 Body window glasses 7035 OPERATIONS 7035A04 - WINDSCREEN ELIMINATE WATER INFILTRA¬ TION 1 Removal Follow the Op. 7055A18 Windscreen base trim - r+r Follow the Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r Follow the Op. 7025A66 L/h or r/h bonnet lid support damper (one) - r+r Follow the Op. 7025A14 Bonnet lid - r+r Follow the Op. 7030B34 Sliding roof compart¬ ment decorative seal - r+r Follow the Op. 7040E40 Modular front courtesy light - r r Follow the Op. 7040E28 Courtesy light on sun blind - r r Follow the Op. 7040H32 Sliding roof switch door panel - r r Follow the Op. 7040H30 Front pillar trim - r r Follow the Op. 7055A10 Moulding on roof panel (one), l/h or r/h - r+r Follow the Op. 7065C30 Interior l/h or r/h grab handle (one) - r+r Follow the Op. 7065C34 L/h or r/h sun blind (one) - r+r Follow the Op. 7065C59 Interior rear view mirror with automatic antiglare device - r r Follow the Op. 7065C68 Rear view mirror - r+r 1. Unscrew the three bolts located under the cour¬ tesy light which secure the front part of the roof panel. A A. w w FHV?/ 1 (3 . 1 Check for leaks by applying soapy water around the outer edge. 2. Blow compressed air out from the inside. Seal the area (using sealant for rubber gaskets). 2 Installation - Tighten the roof panel retaining bolts. Complete with Op. 7065C68 Rear view mirror - r+r Complete with Op. 7065C59 Interior rear view mirror with automatic antiglare device - r r Complete with Op. 7065C34 L/h or r/h sun blind (one) - r+r Complete with Op. 7065C30 Interior l/h or r/h grab handle (one) - r+r Complete with Op. 7055A10 Moulding on roof panel (one), l/h or r/h - r+r Complete with Op. 7040H30 Front pillar trim rr Sliding roof Complete with Op. 7040H32 switch door panel - r r Complete with Op. 7040E28 Courtesy light on sun blind - r r Complete with Op. 7040E40 Modular front courtesy light - r r Sliding roof Complete with Op. 7030B34 compartment decorative seal - r+r Complete with Op. 7025A14 Bonnet lid - r+r Complete with Op. 7025A66 L/h or r/h bonnet lid support damper (one) - r+r Complete with Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r Complete with Op. 7055A18 Windscreen base trim - r+r 7035A14 - WINDSCREEN GLASS (BONDED TYPE) - R + R INCLUDES CLEANING EDGE OF GLASS AND BODY HOUSING Removal Follow the Op. 7055A18 Windscreen base trim - r+r Follow the Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r Follow the Op. 7025A66 L/h or r/h bonnet lid support damper (one) r+r Follow the Op. 7025A14 Bonnet lid - r+r - PA5106/00 06/1998 3 REPAIR PROCEDURES Body window glasses 7035 rC J Follow the Op. 7030B34 Sliding roof compart¬ ment decorative seal - r+r Follow the Op. 7040E40 Modular front courtesy light r r Follow the Op. 7040E28 Courtesy light on sun blind - r r Follow the Op. 7040E14 Data not yet available Follow the Op. 7040H30 Front pillar trim - r r Follow the Op. 7055A10 Moulding on roof panel (one), l/h or r/h - r+r Follow the Op. 7065C30 Interior l/h or r/h grab handle (one) - r+r Follow the Op. 7065C34 L/h or r/h sun blind (one) - r+r Follow the Op. 7065C59 Interior rear view mirror with automatic antiglare device - r r Follow the Op. 7065C68 Rear view mirror - r+r Protect the facia and wings using covers. 1. Remove the press-fitted roof panel moulding retaining studs from both sides of the car. - 1. Unscrew the three bolts located under the cour¬ tesy light which secure the front part of the roof panel. *1 >V W FBI/ 1 / S3 1 / 1. Working from outside the car, remove the five spacers located between window and body. 1 1 =V"/i 1. Working inside the car, use a vibrating cutter ( 1a) with blade (1b) to cut the sealant strip along the sides and on the upper part of the windscreen. S3 Description Code Vibrating blade 1.823.011.000 Description Code Blade 1 .870.691 .000 1a S3 1b 2. Place a set of adhesive tape strips between window and roof panel to prevent the window slipping once the sealant has been cut. 3. Disconnect the electrical connection and fold the connector and wires back onto the glass. Secure in place using adhesive tape. 4 PA5106/00 06/1998 r ■‘s REPAIR PROCEDURES Body window glasses rC 7035 J \Description Heated windscreen 3 □1b Connector P56 4. Working from outside the car, use the vibrating cutter fitted with a new blade to cut the sealant strip along the bottom of the windscreen. Take care not to cut the wiring previously folded back onto the windscreen. H 4 £ 1c Description Code Blade 1.870.692.000 5. Apply sucker handles to the windscreen. 6. Cut the strips of adhesive tape and remove the windscreen with the aid of a second operator. 1b r*\ 4 □ 2 3 □ H 1b 5 6 ntoiinnirniv/ CAT 5 -rv/ 1. Use vibrating knife (1a) and blade (1b) to cut and level the sealant strip in the windscreen compartment. Leave 0.25 /1 mm thickness without scratching the paint and ensure the locating holes (1c) present at the corners of the windscreen are left free. ES Description Code 1a Vibrating blade 1 .823.01 1 .000 Description Code Blade 1.870.691.000 E9 *•. Description Code Vibrating blade 1 .823.011 .000 Description Code Blade 1.870.691.000 2. Clean the screen-printed area around the edge carefully using compressed air and degrease thorougly using heptane. Check that the glass is undamaged and is not scratched or grazed. 3. Fit a new trim moulding at the top of the wind¬ screen. IXOOmMtV/OW/_ Installation □ I.Use vibrating cutter (1a) and blade (1b) to cut and level the sealant strip to reduce its thick¬ ness. Leave 0.25/1 mm and remove the remains of locating pins (1c). 1a 1a 1b 1a 2 V 2 3 ib n 1c 1a / / / 3 2. Clean the windscreen housing carefully using compressed air and degrease thorougly using heptane. Touch up the paintwork if necessary. Remove the trim moulding at the top of the windscreen. PA5106100 06/1998 5 REPAIR PROCEDURES El Body window glasses 7035 1. Fit the five spacers (1a) removed previously in the windcreen housing using double-sided adhesive tape (1b). 2. If the original locating pins are not available, fit and centre provisionally.Mark the reciprocal positions of windscreen and housing using strips of adhesive tape. Fit appropriate spacers to the lower part of the screen to support the glass. Cut the adhesive tape strips and remove the 1. Fit retaining belt (1a) to apply uniform pressure over the entire windscreen in order to ensure effective mating between glass (1b), sealant (1c) and windscreen (1d). 1b 1d m windscreen. Fit the three clips securing the trim moulding. 3. Use an air gun to extrude a sealant strip around the edge of the windscreen. Begin from the 1c middle. 4. Working with the aid of a second operator, use sucker handles to position the windscreen in its housing immediately after applying the sealant. Check it is properly aligned with the adhesive < 1a tape strips positioned previously. 2 2 1b 4 1d 1c 1d m 1b 1c Check for leaks by applying soapy water around the outer edge and then blowing compressed air through from the inside. Tighten the bolts securing the front of the roof panel. Complete with Op. 7065C68 Rear view mirror - r+r Complete with Op. 7065C59 Interior rear view mirror with automatic antiglare device - r r Complete with Op. 7065C34 L/h or r/h sun blind (one) - r+r 1a 3 1b Complete with Op. 7065C30 Interior l/h or r/h grab handle (one) - r+r Complete with Op. 7055A10 Moulding on roof panel (one), l/h or r/h - r+r Complete with Op. 7040H30 Front pillar trim rr Complete with Op. 7040H32 Sliding roof switch door panel - r r Complete with Op. 7040E28 Courtesy light on sun blind - r r Complete with Op. 7040E40 Modular front courtesy light - r r Complete with Op. 7030B34 Sliding roof compartment decorative seal - r+r Complete with Op. 7025A14 Bonnet lid - r+r Complete with Op. 7025A66 L/h or r/h bonnet lid support damper (one) - r+r Complete with Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r Complete with Op. 7055A18 Windscreen base trim - r+r 6 PA5106/00 06/1998 /ÿS REPAIR PROCEDURES a Body window glasses 7035A18 - WINDSCREEN GLASS (BONDED TYPE) - R+R FOR REPLACEMENT INCLUDES CLEANING BODY HOUSING 7035 1. Unscrew the three bolts located under the cour¬ tesy light which secure the front part of the roof panel. \\ Removal Follow the Op. 7055A18 Windscreen base trim - r+r Follow the Op. 5050B34 - - Windscreen wiper arm/s complete with blade - r+r Follow the Op. 7025A66 L/h or r/h bonnet lid support damper (one) - r+r Follow the Op. 7025A14 Bonnet lid W - r+r Follow the Op. 7030B34 Sliding roof compart¬ ment 1 decorative seal - r+r Follow the Op. 7040E40 Modular front courtesy light - r r Follow the Op. 7040E28 Courtesy light on sun blind - r r Follow the Op. 7040H32 Sliding roof switch door panel - r r Follow the Op. 7040H30 Front pillar trim - r r Follow the Op. 7055A10 Moulding on roof panel (one), l/h or r/h - r+r Follow the Op. 7065C30 Interior l/h or r/h grab handle (one) - r+r Follow the Op. 7065C34 L/h or r/h sun blind (one) - r+r Follow the Op. 7065C59 Interior rear view mirror with automatic antiglare device - r r Follow the Op. 7065C68 Rear view mirror - r+r 1. Remove the press-fitted roof panel moulding retaining studs from both sides of the car. Protect the facia and wings using covers. 1. Working from outside the car, remove the five spacers located between window and body. 1 / 1 1 / 1. Working inside the car, use a vibrating cutter ( 1a) with blade (1b) to cut the sealant strip along the sides and on the upper part of the windscreen. Cl MkJDescription 1a Vibrating blade C3 1b Code 1 .823.01 1 .000 Description Code Blade 1 .870.691.000 2. Place a set of adhesive tape strips between window and roof panel to prevent the window slipping once the sealant has been cut. 3. Disconnect the electrical connection and fold the connector and wires back onto the glass. Secure in place using adhesive tape. PA5106/00 06/1998 7 REPAIR PROCEDURES Body window glasses 7035 ns Connector IDescription 3 J 1 \ P56 Heated windscreen 4. Working from outside the car, use the vibrating cutter fitted with a new blade to cut the sealant strip along the bottom of the windscreen. Take care not to cut the wiring previously folded back onto the windscreen. E9 4 Code Blade 1.870.692.000 5. Apply sucker handles to the windscreen. 6. Cut the strips of adhesive tape and remove the windscreen with the aid of a second operator. 1b ( ores 4 1a 2 n Description Code Vibrating blade 1.823.011.000 — ES 5 Installation I.Use vibrating knife (1a) and blade (1b) to cut and level the sealant strip in the windscreen compartment in order to leave 0.25 /1 mm thickness without scratching the paint. The sealant left in the housing will act as a backing for the new bond. 1A 3 6 3a 3b Description □ 2 5 CAT Check the windscreen glass is in good condi¬ tion. 1. Degrease the screen-printed edge of the new windscreen using heptane. 2. Fit the locating pins into the threaded sockets in the glass and screw in. 3. Apply glass adhesion promoter (primer) (3b) to the screen printed area round the outside using applicator (3a) provided in the kit. Note: Wait for 15 minutes before carrying out the next operation to give the primer thinner time to evaporate. 1B JDescription Code Blade 1 .870.691.000 2. Clean the windscreen housing carefully using compressed air and degrease thorougly using heptane. Touch up the paintwork if necessary. □tb r - 1a 2 sO □ 1 . Fit the five spacers (1a) removed previously in the windcreen housing using double-sided adhesive tape (1b). Fit the three clips securing the trim moulding. 2. Fit the trim moulding at the top of the window. 3. Use an air gun to extrude a sealant strip around the edge of the windscreen. Begin from the lower edge of the windscreen. 4. Working with the aid of a second operator, use sucker handles to position the windscreen in its housing immediately after applying the sealant. 8 PA5106/00 06/1998 n REPAIR PROCEDURES Body window glasses j r*\ 7035 5. Fit retaining belt (5a) to apply uniform pressure over the entire windscreen in order to ensure effective mating between glass (5b), sealant (5c) and windscreen (5d). 2 5b 5c 3 5a < /• 4 5b. 5b 3 5c 1b 1a 5c Check for leaks by applying soapy water around the outer edge and then blowing compressed air through from the inside. Tighten the bolts securing the front of the roof panel. Complete with Op. 7065C68 Rear view mirror r+r Complete with Op. 7065C59 Interior rear view mirror with automatic antiglare device - r r Complete with Op. 7065C34 L/h or r/h sun blind (one) - r+r Complete with Op. 7065C30 Interior l/h or r/h grab handle (one) - r+r Complete with Op. 7055A10 Moulding on roof panel (one), l/h or r/h - r+r Complete with Op. 7040H30 Front pillar trim rr Sliding roof Complete with Op. 7040H32 switch door panel - r r Complete with Op. 7040E28 Courtesy light on sun blind - r r Complete with Op. 7040E40 Modular front courtesy light - r r Sliding roof Complete with Op. 7030B34 compartment decorative seal - r+r Complete with Op. 7025A14 Bonnet lid - r+r Complete with Op. 7025A66 L/h or r/h bonnet lid support damper (one) - r+r Complete with Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r Complete with Op. 7055A18 Windscreen base trim - r+r PA5106/00 06/1998 9 REPAIR PROCEDURES 7035 E Body window glasses 7035B - Rear window VIEW OF ASSEMBLY 1 v Ref. Description 1 REAR WIN DOW GLASS r*\ Operations index Code Operation Validity 7035B10 Rear window glass (bonded type) - r+r - includes _cleaning edges of glass and body housing_ 7035B14 Rear window glass (bonded type) - r+r for replace_ment - includes cleaning housing on body _ 7035B18 Rear window glass - repair leaks WARNINGS PRECAUTIONS Use care when working on trim components and use the specified tools correctly in order to avoid damage.Use the special equipment required for glass removal operations and work with great care to avoid damage to the glass and body.Strictly DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical components, wiring etc.).Use the special equipment required for glass removal operations and work with great care to avoid accidents.Always ask a second operator to help move the glass. observe the sealant manufacturer's instructions with regard to mode of use and operation times. 10 PA5106/00 06/1998 REPAIR PROCEDURES Body window glasses 7035 j OPERATIONS 2 7035B10 - REAR WINDOW GLASS (BONDED TYPE) - R + R INCLUDES CLEANING EDGES OF GLASS AND BODY HOUSING 'C Removal Follow the Op. 7055A10 Moulding on roof panel (one), l/h or r/h - r+r - Follow the Op. 7025B26 L/h or r/h boot lid lift device (one) - r+r 1. Unscrew bolts (1a) retaining the lid to the hinges and move lid (1b) back as far as it will go. Then tighten the bolts again and protect the r*\ wing. 2. Take out the upper part of the boot compart¬ ment seal \\ 1 1. Working outside the car, use a vibrating cutter ( 1a) with blade (1b) to cut sealant strip (1c) around the edge of the back window. Cl 1a 1a Description Code Vibrating blade 1 .823.01 1 .000 Cl Description Code 1b Blade 1 .823.022.000 2. Apply sucker handles (2a) to the back window and lift off with the aid of a second operator. Disconnect electrical connection (2b) to the back window and electrical connections between aerial control unit and back window (2c, 2d). Then remove the back window and rest it on a stand. y 1b 2b 2c 1. Remove the seal trim around the edge of the back window. 2. Protect the boot lid, wings and rear interior using covers then apply adhesive tape to protect the edges of the body in contact with the back window. PA5106/00 06/1998 iDescription Connector Data not yet available P55 iDescription Connector Data not yet available IDescription 2d Data not yet available P55 Connector P55 11 REPAIR PROCEDURES 7035 n / a 2d 2 1a 1b| '7> / / & l •2i 2a: I.Use vibrating knife (1a) and blade (1b) to cut and level the sealant strip in the back window compartment in order to leave 0.25 /1 mm thickness without scratching the paint and ensuring that locating holes (1c) in the upper corners of the compartment are left free.The sealant left in the housing will act as a backing for the new bond. 2. Remove the tape and clean the back window 'C- * 1c fa, 1b □ 1a housing carefully using compressed air and degrease thorougly using heptane. Touch up the paintwork if necessary. Installation - - Check that the window is undamaged. Check that the back window element is working properly and check operation if neces¬ H sary. 1a I.Work on back window (1a) using vibrating knife (1b) and blade (1c) to cut and level the sealant strip in order to reduce the thickness to 0.25 /1 mm at most.The sealant left in the housing will act as a backing for the new bond. PIJ Description Code Vibrating blade 1.823.011.000 Description Code Blade 1.870.691.000 E9 1b Take care not to damage the black screen printing around the edge of the window. □1b 2. Remove the remains of the locating pins. 3. Clean the screen-printed area around the edge carefully using compressed air and degrease thorougly using heptane. O 1a Description Code Vibrating blade 1.823.011.000 H 1b J 3 2b 2c /V. 1a rC Body window glasses □ 2 Description Code Blade 1.870.691.000 1 . Fit a new seal trim around the edge of the back window. 2. If the original locating pins (2a) are not avail¬ able, carry out a provisional fitting. Mark the reciprocal positions of back window and housing with strips of adhesive tape (2b).Cut the strips of adhesive tape and remove the back window. 12 PA5106/00 06/1998 REPAIR PROCEDURES a Body window glasses 3. Use an air gun to extrude a sealant strip as evenly as possible around the edge of the back window. Begin applying the sealant from the middle of the lower edge and continue without any breaks around the entire edge of the back window. 1 3 .\w\\ 2a 1 7035 2b 2a 1 a 'C 2a 2c 2d 2b 2c 2e 2d \\w 2b fa I.With the aid of a second operator, connect the electrical connections and fit the back window. 2. Fit retaining belt (2a) and strips of adhesive tape (2b) as shown in the figure and adjust belt tension to apply uniform pressure over the entire back window in order to ensure effective mating between glass (2c), sealant (2d) and back window (2e). Check for leaks by applying soapy water around the outer edge and then blowing compressed air through from the inside. Refit the boot compartment seal. Unscrew the boot lid retaining bolts and reposi¬ tion to align the boot. Refer to operation 7025BIO Boot lid - square . Complete with Op. 7025B26 L/h or r/h boot lid lift device (one) - r+r Complete with Op. 7055A10 Moulding on roof panel (one), l/h or r/h - r+r 7035B14 - REAR WINDOW GLASS (BONDED TYPE) - R+R FOR REPLACEMENT INCLUDES CLEANING HOUSING ON BODY Removal Follow the Op. 7055A10 Moulding on roof panel (one), l/h or r/h - r+r Follow the Op. 7025A26 Bonnet lid opening control - repair 1. Unscrew bolts (1a) retaining the lid to the hinges and move lid (1b) back as far as it will go. Then tighten the bolts again and protect the wing. 2. Take out the upper part of the boot compart¬ ment seal PA5106/00 06/1998 13 REPAIR PROCEDURES Body window glasses 7035 rC J 2. Apply sucker handles (2a) to the back window and lift off with the aid of a second operator. Disconnect electrical connection (2b) to the back window and electrical connections between aerial control unit and back window (2c, 2d). Then remove the back window and rest it on a stand. 1a IDescription Connector P55 Data not yet available 2b IDescription P55 Data not yet available 2c A| Connector 1b Connector \Description Data not yet available 2d P55 o I /2 tvn.«*>r*v fiHVi .*• eticotiin 1 . Remove the seal trim around the edge of the back window. 2. Protect the boot lid, wings and rear interior using covers then apply adhesive tape to protect the edges of the body in contact with the back window. / 2 ' / 2b 2c 1d V L 2< 1d 'C 1c t.n> ooonnv to tvr . J*._ Description Code Vibrating blade 1.823.011.000 E9 Description Code 1b Blade 1.823.022.000 14 (a ib a 1a Installation - 1a 2a 'rC * 1 1 .Working outside the car, use a vibrating cutter ( 1a) with blade (1b) to cut sealant strip (1c) around the edge of the back window. 2d Check that the window is undamaged. Check that the back window element is working properly and check operation if neces¬ sary. 1 . Fit locating pins. 2. Degrease the screen printed area around the edge of the new window. 3. Apply glass adhesion promoter (primer) (3b) to the screen printed area round the outside using applicator (3a) provided in the kit. Note: Wait for 15 minutes before carrying out the next operation to give the primer thinner time to evaporate. PA5106/00 06/1998 REPAIR PROCEDURES a Body window glasses 7035 1 A 2 3 1 WAV' 1 2a 2a 'd 3a 3b I.Use vibrating knife (1a) and blade (1b) to cut and level the sealant strip in the back window compartment in order to leave 0.25 /1 mm thickness without scratching the paint and ensuring that locating holes (1c) in the upper corners of the compartment are left free.The sealant left in the housing will act as a backing for the new bond. 2. Remove the tape and clean the back window housing carefully using compressed air and degrease thorougly using heptane. - Touch up the paintwork if necessary. S3 1a Code Vibrating blade 1.823.011.000 WkJDescription 1b Do not move the car until the time specified rli by the sealant manufacturer has elapsed. 2a Description S3 I.With the aid of a second operator, connect the electrical connections and fit the back window. 2. Fit retaining belt (2a) as shown in the figure and adjust belt tension to apply uniform pressure over the entire back window in order to ensure effective mating between glass (2b), sealant (2c) and back window (2d). 1 Code 1.870.691.000 Blade \ 'C □1b 2b 2I 1a □ 2 $ 1. Fit a new seal trim around the edge of the back window. Avoid touching the newly-treated screenprinted area. 2. Use an air gun to extrude a sealant strip as evenly as possible around the edge of the back window. Begin applying the sealant from the middle of the lower edge and continue without any breaks around the entire edge of the back 2c 2d 2c ww Check for leaks by applying soapy water around the outer edge and then blowing compressed air through from the inside. Refit the boot compartment seal. Unscrew the boot lid retaining bolts and reposi¬ tion to align the boot. Refer to operation 7025BIO Boot lid - square . Complete with Op. 7025A26 Bonnet lid opening control - repair Complete with Op. 7055A10 Moulding on roof panel (one), l/h or r/h - r+r window. PA5106/00 06/1998 15 REPAIR PROCEDURES Body window glasses 7035 7035B18 - REAR WINDOW GLASS - REPAIR LEAKS Removal - 1 Follow the Op. 7025B26 L/h or r/h boot lid lift device (one) - r+r Follow the Op. 7055A10 Moulding on roof panel (one), l/h or r/h - r+r 1. Unscrew bolts (1a) retaining the lid to the hinges and move lid (1b) back as far as it will go. Then tighten the bolts again and protect the wing. 2.Take out the upper part of the boot compart¬ \\ ment seal 2 .\\ 1a - After ascertaining the Icoation of the leak, remove the corresponding inner part covering the edge of the back window. If the leak is small, seal the relevant part from the inside and wait for the sealant to dry. Then repeat the test. Installation - A| 1b - - If the leak is more extensive, refer to op. 7035BIO Rear window glass (bonded type) r+r - includes cleaning edges of glass and body housing Refit the outer seal. Unscrew the boot lid retaining bolts and reposi¬ tion to align the boot. Refer to operation 7025B10 Boot lid - square . Complete with Op. 7055A10 Moulding on roof panel (one), l/h or r/h - r+r Complete with Op. 7025B26 L/h or r/h boot lid lift device (one) r+r - 1. Remove the seal trim around the edge of the back window. Protect the boot lid, wings and rear interior using covers then apply adhesive tape to protect the edges of the body in contact with the back window. 2. Check for leaks by applying soapy water around the outer edge and then blowing compressed air through from the inside. 16 PA5106/00 06/1998 REPAIR PROCEDURES El Body interior upholstery and trim 7040 Sub-group index - SUB-GROUP GRAPHIC INDEX Assembly drawings index Cmp Description 7040A Passenger compartment trim 7040B Luggage compartment and load platform trims 7040D Engine bay lining 7040E Interior courtesy light system 7040G Vehicle compartment lightening system 7040H Roof panel lining 7040L Cabin floor covering Validity SUB-GROUP GRAPHIC INDEX 2 4 6 1 ■0 r*\ 7 'o'' 3 Ref. Description Cmp 1 Passenger compartment trim 7040A 2 Luggage compartment and load platform trims 7040 B PA5106/00 06/1998 1 REPAIR PROCEDURES 7040 a Body interior upholstery and trim Ref. Description Cmp 3 Interior courtesy light system 7040E 4 Engine bay lining 7040D 5 Vehicle compartment lightening system 7040G 6 Roof panel lining 7040H 7 Cabin floor covering 7040L 2 PA5106/00 06/1998 REPAIR PROCEDURES Body interior upholstery and trim rC 7040 J 7040A - Passenger compartment trim VIEW OF ASSEMBLY 3 1 12 7 11 0 &• lo\ S3 n <§ z i Tg 4 2 9 IP 8 10 5 13 6 11 t m mmmv /o&/ Ref. Description 1 TOP INSTRUMENT FACIA LINING 2 BRACKET FASTENING INST.FACIA TO BODY 3 PASSENGER AIR BAG COMPARTMENT COVER 4 FLAP ON FACIA 5 FACIA FLAP LOCK BARREL 6 STEERING COLUMN TRIM 7 UPPER FACIA COMPARTMENT 8 FACIA COMPARTMENT FLAP HANDLE 9 COMPARTMENT FLAP TRIM 10 COVER ON FUSE PANEL 11 FACIA SIDE TRIM 12 FACIA SIDE TRIM 13 TRIM SIDE FASTENING PA5106/00 06/1998 lOl l(=>l cn>nii* 3 REPAIR PROCEDURES 7040 a Body interior upholstery and trim Operations index Code Validity Operation 7040A05 Facia/body bracket - fasten 7040A10 Instrument facia trim - r+r 7040A15 Facia flap lock barrel 7040A26 Steering column trim - r+r 7040A31 Flap assembly - r r 7040A32 Flap handle - r r 7040A35 Flap trim - r r 7040A37 Fuse box cover - r r 7040A41 Glove compartment flap lock barrel - replace with _different part _ 7040A43 Cover (one only) for wiring beneath facia - r r 7040A44 Facia Ih side cover - r r 7040A45 Facia rh side cover - r r 7040A55 Facia trim upper compartment - r r 7040A65 Passenger compartment box lock , one , r r 7040A67 Partition between passenger airbag and facia _compartment - r r _ 7040A97 Facia trim support beam - r r WARNINGS — % Use care when working on trim components and use the specified tools correctly in order to avoid damage. la 1b PRECAUTIONS [0, DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ V Jl| o nents, wiring etc.). 1b OPERATIONS 7040A05 - FACIA/BODY BRACKET - FASTEN 1a Removal - Use a socket wrench specially shortened to reach the bolt positioned near the windscreen. 1. Unscrew retaining bolts (1a) and remove facia attachment bracket (1b). Installation - Check that the brackets are in good condition. Position the brackets. Tighten the bolts retaining the brackets to the body. 4 PA5106/00 06/1998 REPAIR PROCEDURES Body interior upholstery and trim J 7040 7040A10- INSTRUMENT FACIA TRIM - R+R Removal Follow the Op. 5505A18 Multi-function control unit - r r Follow the Op. 5580E12 Immobiliser device ecu - r+r following electric circuit check Follow the Op. 5010D30 Passenger compart¬ ment air temperature sensor - r+r following electrical wiring check operation Follow the Op. 5540A22 Exterior lighting control switch - r+r Follow the Op. 7040A44 Facia Ih side cover - r r Follow the Op. 7040A45 Facia rh side cover - r r Follow the Op. 5580C26 Passenger air bag switch - r r Follow the Op. 5010C34 Air outlet on console - r+r Follow the Op. 5560B11 Analogue control panel - r+r or replace Follow the Op. 7040A26 Steering column trim - - r*\ - r+r Follow the Op. 5550C16 Hazard warning light/ fog lamp/ reversing light combined switch - r r Follow the Op. 5040D18 Air conditioner control unit - r r Follow the Op. 5570T80 Car radio unit - r+r Follow the Op. 7065C42 Ashtray (one) r+r Follow the Op. 5570T80 Car radio unit - r+r Follow the Op. 7065C42 Ashtray (one) r+r Follow the Op. 5580C18 Air bag module - r+r Follow the Op. 1056B79 Injection/ignition contro unit guard - r r Follow the Op. 4110A11 Steering wheel - r+r for replacement or check for versions with air bag Follow the Op. 5550A12 Complete stalk unit r+r for versions with air bag Follow the Op. 7040A31 Flap assembly - r r - Follow the Op. 7040G24 Switch for facia compartment light - r+r Follow the Op. 5580C22 Air bag module (passenger side) -r + r Follow the Op. 7040A67 Partition between passenger airbag and facia compartment - r r Follow the Op. 7040A43 Cover (one only) for wiring beneath facia - r r Follow the Op. 5505C32 (one) securing wiring connectors beneath instrument facia - r r 1. Disconnect the outlet air duct from the air distribution console. 2. Unscrew bolts (2a) retaining gear lever support bracket (2b) and move the bracket out of the way. 3. Unscrew the nuts and bolts retaining the facia to the support frame. 4. Use tool (4a) to unscrew bolts (4b) located on the facia upper glove compartment. E9 4a Description Code Key 1.822.1 32.000 5. With the aid of a second operator, remove the facia trim. PA5106/00 06/1998 5 REPAIR PROCEDURES 0 Body interior upholstery and trim 7040 4a 4b 5 yÿ4b r\ 7 to 0 0® A 1« o'! X \ 3 m K 1 2a 2b Installation - With the aid of a second operator, fit the facia trim. Position the wiring correctly and respect anchorage points. Use the appropriate tool to tighten both bolts located in the facia upper glove compartment. n BkJDescription Key Code 1.822.132.000 Tighten the nuts and bolts retaining the facia to the underlying frame. Fit the gear lever bracket and tighten the bolts retaining it to the car floor pan. Connect the outlet air duct to the air distribution console. Complete with Op. 5505C32 (one) securing wiring connectors beneath instrument facia - r r Complete with Op. 7040A43 Cover (one only) for wiring beneath facia - r r Complete with Op. 7040A67 Partition between passenger airbag and facia compartment - r r Complete with Op. 5580C22 Air bag module (passenger side) -r + r Complete with Op. 7040G24 Switch for facia compartment light - r+r Complete with Op. 7040A31 Flap assembly - r r 6 Complete with Op. 5550A12 Complete stalk unit - r+r for versions with air bag Complete with Op. 4110A11 Steering wheel r+r for replacement or check for versions with air bag Complete with Op. 1056B79 Injection/ignition contro unit guard - r r Complete with Op. 5580C18 Air bag module - r+r Complete with Op. 7065C42 Ashtray (one) r+r Complete with Op. 5570T80 Car radio unit - r+r Complete with Op. 5040D18 Air conditioner control unit - r r Complete with Op. 5570T80 Car radio unit - r+r Complete with Op. 7065C42 Ashtray (one) r+r Complete with Op. 5550C16 Hazard warning light/fog lamp/reversing light combined switch -rr Complete with Op. 7040A26 Steering column trim - r+r Complete with Op. 5560B11 Analogue control panel - r+r or replace Complete with Op. 5010C34 Air outlet on console - r+r Complete with Op. 5580C26 Passenger air bag switch - r r Complete with Op. 7040A45 Facia rh side cover -rr Complete with Op. 7040A44 Facia Ih side cover -rr PA5106/00 06/1998 REPAIR PROCEDURES Body interior upholstery and trim rC j Complete with Op. 5540A22 Exterior lighting control switch - r+r Complete with Op. 5010D30 rPassenger compartment air temperature sensor - r+r following electrical wiring check operation Complete with Op. 5580E12 immobiliser device ecu - r+r following electric circuit check Complete with Op. 5505A18 Multi-function control unit - r r // 7040 "V 2b •1 *S. & a ) 7040A15 - FACIA FLAP LOCK BARREL Note: It is not possible to order a single lock barrel or to order barrels using a single part code.When ordering barrels, observe the special procedure set out in op.5580E - Special Accessories. Open the compartment flap. Insert the key in the lock barrel. 1. Working through hole (1a) in the compartment trim, use an appropriate tool to pull up clip (1b) retaining the lock barrel slightly without deforming it. 2. Remove the lock barrel from its housing. - 1a 1b bV 1a v 2a Installation - - % Fit the steering column trim housing half and secure using the appropriate bolts. Close the fuse access cover and secure with the relevant bolt. Position the steering wheel correctly. 7040A31 - FLAP ASSEMBLY - R R Removal 1. Unscrew the upper bolts securing the injection V - ignition control unit protection. 2. Unscrew bolts (2a) and remove facia compart¬ ment unit ( 2b). 2 0/ % rc\ // 1 Installation - - ip. Fit a new barrel. Check that the clip is engaged. Check operation. 7040A26 - STEERING COLUMN TRIM - R+R Removal - '/ y Removal - 7 / Lower the steering wheel and move back. 1. Unscrew bolt (1a) and open fuse access cover (1b). 2. Unscrew bolts (2a) and remove steering column trim housing half (2b). II I \ \ T y/' / 2a \ ,u * 2b A Installation - - PA5106/00 06/1998 Fit the facia compartment unit and secure with the appropriate bolts. Tighten the upper bolts securing the injection ignition control unit protection. 7 REPAIR PROCEDURES a Body interior upholstery and trim 7040 7040A32 - FLAP HANDLE - R R Installation - Check that the trim is undamaged. Fit the trim and check that the opening/closure mechanism is working properly. Tighten the trim retaining bolts. Complete with Op. 7040A31 Flap assembly - r r - Removal Follow the Op. 7040A31 Flap assembly - r r Follow the Op. 7040A35 Flap trim - r r I.Use a drift of appropriate size to remove the handle hinge pin from its seat. 2. Withdraw the handle and recover the return spring. 2 - 7040A37 - FUSE BOX COVER - R R Removal 1. Unscrew bolt (1a) and open fuse access cover (1b). M 4 Jy 5) V // & \ - Remove the catch dowel if necessary. __ Installation - - Refit the catch dowel if removed previously. Fit the handle complete with return spring. Fit the handle hinge pin. Complete with Op. 7040A35 Flap trim - r r Complete with Op. 7040A31 Flap assembly - r r V Follow the Op. 7040A31 Flap assembly 1. Unscrew the trim retaining bolts. 2. Remove the facia compartment trim. \ I a \ % i) \ 1b k 1a 7040A35 - FLAP TRIM - R R Removal A* fc - rr 1 1. Unscrew bolt (1a) and disconnect cord link (1b). 2. Release the fuse access cover from its hinges and take off the facia. // & 3 i I) l\ v e. a. 'V 4 rtr*! 1b 1a i £ 'v 2 8 PA5106/00 06/1998 REPAIR PROCEDURES Body interior upholstery and trim rC 7040 j Installation - Refit the fuse access cover to the facia and attach to its hinges. Connect the cord link and secure using the appropriate bolt. Close the fuse access cover and secure using the appropriate bolt. - 7040A41 - GLOVE COMPART¬ MENT FLAP LOCK BARREL REPLACE WITH DIFFERENT PART Installation - - Connect the electrical connection to the underfacia courtesy light. Fit the under-facia wiring connector cover together with the under-facia courtesy light and secure it using the appropriate bolts. Connect the negative (-) battery terminal. 7040A44 - FACIA LH SIDE COVER - R R Removal 1. Unscrew bolt (1a) and open fuse access cover (1b). 2. Unscrew bolts (2a) and remove facia left side trim (2b). Refer to op.. 7005C18 Front side door lock barrel (in handle) replace with different version 7040A43 - COVER (ONE ONLY) FOR WIRING BENEATH FACIA RR r__v / & B Removal - Ensure that the ignition key is in tthe OFF posi¬ tion, then disconnect the battery negative terminal. \Description / 1. Unscrew the bolts (1a), move the facia wiring connector cover back as far as necessary and disconnect the electrical connection (1b) from the courtesy light under the facia. 2. Remove the under-facia wiring connector cover together with the under-facia courtesy light. // V p // a 1b X X 1a I Installation - 33: IX f y A1B 2b / Connector Battery // i I) Fit the facia left side trim and secure using the relevant bolts. Close the fuse access cover and secure using the appropriate bolt. \ 3 ) J H1b / X & PA5106/00 06/1998 2 1a 9 REPAIR PROCEDURES Body interior upholstery and trim 7040 7040A45 - FACIA RH SIDE COVER - R R Installation Removal 7040A55 - 1. Unscrew bolts (1a) and remove facia right side trim (1b). rC j Fit the facia right side trim and secure using the appropriate bolts. FACIA TRIM UPPER COMPARTMENT - R R - Removal 1b Follow the Op. 5010C34 Air outlet on console - r+r Installation - Complete with Op. 5010C34 Air outlet on - r+r 7040A65 - PASSENGER COMPARTMENT BOX LOCK , ONE , R R console "T'' _ v — / Removal U, 1. Unscrew bolt (1a) retaining side trim (1b) and remove. \ y' Wj 1a mortm*HV mot .*> A+.CID o 1b 1a moDtmrHv mu?/ ■»' A u- cot inn Installation - - Check that the trim is undamaged. Fit the trim and tighten the retaining bolt. 7040A67 - PARTITION BETWEEN PASSENGER AIRBAG AND FACIA COMPARTMENT - R R Removal Ensure that the ignition key is in tthe OFF posi¬ tion, then disconnect the battery negative terminal. /I 10 Description Connector Battery A1B PA5106/00 06/1998 r\ REPAIR PROCEDURES E Body interior upholstery and trim Follow the Op. 7040A31 Flap assembly - r r 1. Unscrew the bolts (1a) and prise the Air Bag housing compartment flap (1b) from its seat. 2. Disconnect the electrical connection from the bulb holder for the compartment light in the dashboard. 2 iDescription Connector Glove compartment light G30 3. Disconnect the electrical connection from the boot lid central locking opening switch. 7040A97 - FACIA TRIM SUPPORT BEAM - R R Removal Follow the Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload Follow the Op. 5050B38 Windscreen wiper assembly - r+r or repair Follow the Op. 7055A18 Windscreen base trim - r+r Follow the Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r Follow the Op. 5010B21 Climate control unit compartment -rr Follow the Op. 5040C10 Air conditioner box IDescription 3 7040 Boot central opening switch - Connector r+r H33 Follow the Op. 5040C82 Air shroud on air blender port - r r Follow the Op. 5505A18 Multi-function control unit - r r Follow the Op. 5580E12 Immobiliser device ecu 4. Disconnect the electrical connection from the fuel filler flap central locking open switch. - r+r following electric circuit check IDescription 4 Connector Data not yet available Remove the passenger Air Bag housing compartment flap. □3 // 3 Follow the Op. 5010D30 Passenger compart¬ ment air temperature sensor - r+r following electrical wiring check operation Exterior lighting Follow the Op. 5540A22 control switch - r+r Follow the Op. 7040A44 Facia Ih side cover - r r Follow the Op. 7040A45 Facia rh side cover - r r Follow the Op. 5580C26 Passenger air bag switch - r r Follow the Op. 5010C34 Air outlet on console - r+r L '© 2 4 Follow the Op. 5560B11 Analogue control panel - r+r or replace Follow the Op. 7040A26 Steering column trim - r+r / T i 5* \ 1a \ \ Installation - - - 1 1b Connect the electrical connection to the fuel filler flap central opening switch. Connect the electrical connection to the boot lid central opening switch. Connect the electrical connection to the facia compartment lighting bulb holder. Refit the Air Bag housing compartment flap and secure it with the relevant bolts. Complete with Op. 7040A31 Flap assembly - r r Connect the negative (-) battery terminal. . PA5106/00 06/1998 Follow the Op. 5550C16 Hazard warning light/ fog lamp/reversing light combined switch - r r Follow the Op. 5040D18 Air conditioner control unit - r r Follow the Op. 5570T80 Car radio unit - r+r Follow the Op. 7065C42 Ashtray (one) r+r Follow the Op. 5580C18 Air bag module - r+r Follow the Op. 1056B79 Injection/ignition contra unit guard - r r Follow the Op. 4110A11 Steering wheel - r+r for replacement or check for versions with air bag Follow the Op. 5550A12 Complete stalk unit r+r for versions with air bag Follow the Op. 7040A31 Flap assembly - r r Follow the Op. 7040G24 Switch for facia compartment light - r+r Follow the Op. S580C22 Air bag module (passenger side) -r + r Follow the Op. 7040A67 Partition between passenger airbag and facia compartment - r r Follow the Op. 7040A43 Cover (one only) for wiring beneath facia - r r Follow the Op. 5505C32 (one) securing wiring connectors beneath instrument facia - r r Follow the Op. 7040A10 Instrument facia trim - r+r Follow the Op. 5580C14 Air bag ecu - r+r Follow the Op. 7040L20 Tunnel trim - r r Follow the Op. 7045A10 L/h or r/h front seat (one) - r+r Pull up the floor carpet. 11 REPAIR PROCEDURES Body interior upholstery and trim 7040 1. Uncrew the three bolts retaining the joint cover to the body. 2. Remove the joint cover. 3. Unscrew the bolts retaining the steering column to the steering box pinion. 4. Move the steering column joint back. 3 m 4 2 J 1a Zli’ 2a B0 C © & 2c| V 1fc© a V N2b 1 1. Remove the connector safety protection (1a) and disconnect door wiring connector (1b). 2. Use tool (2a) to unscrew retaining bolts (2b). Then disconnect half-connector (2c) from its seat on the body.Carry out the same operation on both front doors. IDescriptionÿ 1B Front left door connection □ 2a Connector rH 1. Disconnect electrical connection (1a) between engine wiring and facia wiring, electrical connection (1b) between facia wiring and roof wiring - and electrical connection (1c) between facia wiring and rear service wiring. 2. Release airbag wiring sections secured to the facia wiring from the retaining collars. 3. Disconnect electrical connectors (3a) and (3b). 4. Unscrew upper nut (4a) securing the steering column strut and remove strut (4b). IDescription 1A Front/dashboard connection D1 D30 IDescription Description Code Key 1.822.132.000 1B Connector Dashboard/courtesy lights connection IDescription 1C Dashboard/rear left connection IDescription 3A Brake pedal switch IDescription 3B 12 Connector Clutch pedal switch D42 Connector D25A Connector 130 Connector 131 PA5106/00 06/1998 REPAIR PROCEDURES Body interior upholstery and trim rC 7040 j r* s 2 mcjibbi-j 0ÿ fTÿl7 4a A ,2 3) l| ■ 9 97 $ sn 1a 4b ,3b' wr 3a \ 1b / 1. Remove the radiant element from the heater unit and move to one side. Take care not to damage the two coolant pipes. Installation - - 0 - - M - \ 1 \K 1. Unscrew the nuts retaining the facia frame to the body. 2. With the aid of a second operator, remove the frame complete with air distributor box, steering column and facia wiring. PA5106/00 06/1998 - Fit the facia frame to the body. Take care to refit the facia wiring correctly. Tighten the nuts retaining the frame to the body to the specified torque. Fit the radiant element in its seat in the heater/ air conditioner unit housing. Fit the steering column strut. Tighten the upper strut retaining nut. Connect the electrical connection, pull through the airbag electrical lead and replace the retaining collar. Connect the electrical connection betwen engine wiring and facia wiring, the electrical connection between facia wiring and roof wiring - and the electrical connection betwen facia wiring and rear service wiring. Fit the door wiring into its seat and secure the half-connector to the body using the tool shown. E9 Description Code Key 1.822.132.000 Connect the front door wiring electrical connector and refit the protection. Fit the steering column joint. Tighten the steering column retaining bolt. Position the steering wheel so that it is straight. Tighten the three nuts retaining the joint cover to the body. Fit the floor carpet. Complete with Op. 7045A10 L/h or r/h front seat (one) - r+r Complete with Op. 7040L20 Tunnel trim - r r Complete with Op. 5580C14 Air bag ecu - r+r Complete with Op. 7040A10 Instrument facia trim - r+r Complete with Op. 5505C32 (one) securing wiring connectors beneath instrument facia - r r Complete with Op. 7040A43 Cover (one only) for wiring beneath facia - r r Complete with Op. 7040A67 Partition between passenger airbag and facia compartment - r r 13 REPAIR PROCEDURES Body interior upholstery and trim 7040 rC J Complete with Op. 5580C22 Air bag module (passenger side) - r + r Complete with Op. 7040G24 Switch for facia compartment light - r+r Complete with Op. 7040A31 Flap assembly - r r Complete with Op. 5550A12 Complete stalk unit - r+r for versions with air bag Complete with Op. 4110A11 Steering wheel r+r for replacement or check for versions with air bag Complete with Op. 1056B79 Injection/ignition contro unit guard - r r Complete with Op. 5580C18 Air bag module - r+r Complete with Op. 7065C42 Ashtray (one) r+r Complete with Op. 5570T80 Car radio unit - r+r Complete with Op. 5040D18 Air conditioner control unit - r r Complete with Op. 5570T80 Car radio unit - r+r Complete with Op. 7065C42 Ashtray (one) r+r Complete with Op. 5550C16 Hazard warning light/fog lamp/reversing light combined switch -rr Complete with Op. 7040A26 Steering column trim - r+r Complete with Op. 5560B11 Analogue control panel - r+r or replace Complete with Op. 5010C34 Air outlet on console - r+r Complete with Op. 5580C26 Passenger air bag switch - r r Complete with Op. 7040A45 Facia rh side cover -rr Complete with Op. 7040A44 Facia Ih side cover -rr Complete with Op. 5540A22 Exterior lighting control switch - r+r Complete with Op. 5010D30 Passenger compartment air temperature sensor - r+r following electrical wiring check operation Complete with Op. 5580E12 Immobiliser device ecu - r+r following electric circuit check Complete with Op. 5505A18 Multi-function control unit - r r Complete with Op. 5040C82 Air shroud on air blender port r r Complete with Op. 5040C10 Air conditioner - box - r+r Complete with Op. 5010B21 Climate control unit compartment - r r Complete with Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r Complete with Op. 7055A18 Windscreen base trim - r+r Complete with Op. 5050B38 Windscreen wiper assembly - r+r or repair Complete with Op. 5040A10 Air conditioner cooling circuit - dehydrate and reload 14 PA5106/00 06/1998 REPAIR PROCEDURES a Body interior upholstery and trim 7040 7040B - Luggage compartment and load platform trims VIEW OF ASSEMBLY o) 9 9 9 O O 3 2 V 1 5 Ref. Description 1 LOAT PLATFORM TRIM (LUGGAGE) 2 LUGGAGE PLATFORM SIDE TRIM 3 REAR LUGGAGE COMPARTMENT TRIM 4 LUGGAGE COMPARTMENT 5 SUITCASE RETAINING BELT RING 4 Operations index Code Operation Validity 7040B10 Load platform (luggage platform) trim - r+r 7040B12 Load compartment/load platform left side trim - r r 7040B13 Load compartment/load platform right side trim - r r 7040B19 Rear luggage compartment trim - r+r 7040B20 Back trim for luggage compartment/load platform _arrange _ 7040B22 Luggage compartment/load platform moulding - r+r 7040B46 Luggage belt ring - r r PA5106/00 06/1998 15 REPAIR PROCEDURES Body interior upholstery and trim 7040 WARNINGS Use care when working on trim components and use the specified tools correctly in order to avoid damage. 7040B12 - LOAD COMPART¬ MENT/LOAD PLATFORM LEFT SIDE TRIM - R R PRECAUTIONS Removal DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). Follow the Op. 7025B66 Boot compartment seal - r+r Follow the Op. 7025B41 Boot lid lock Follow the Op. 7040B20 Back trim for luggage compartment/load platform - arrange Load platform Follow the Op. 7040B10 (luggage platform) trim - r+r Follow the Op. 5530B54 Battery cover - r+r Follow the Op. 5530B10 Battery - r+r Follow the Op. 5530B52 Battery cradle - r r 1. Unscrew the knob securing the side trim with the inner tail-light assembly. 2. Remove the screw stud retaining the trim to the body. 3. Remove the left side trim by withdrawing the luggage holder anchorage hooks. Follow the Op. 7040B22 OPERATIONS 7040B10 - LOAD PLATFORM (LUGGAGE PLATFORM) TRIM R +R Removal Open the luggage compartment lid. I.Use tool (1a) to undo studs (1b) retaining the load platform trim. 2. Remove the load compartment trim. E9 1a Description Code Blade 1.823.015.000 V Luggage compart¬ ment/load platform moulding - r+r b 'T' In 1b 2 tr 2 Q1a O o 3 V Installation - Check that the trim is undamaged. Refit the left side trim. Fit the trim by means of the stud. Installation Complete with Op. 5530B52 Battery cradle - r r Complete with Op. 5530B10 Battery - r+r Complete with Op. 5530BS4 Battery cover - r+r Complete with Op. 7040B10 Load platform - Complete with Op. 7040B20 Back trim for luggage compartment/load platform - arrange Complete with Op. 7025B41 Boot lid lock Complete with Op. 7025B66 Boot compart¬ - Check that the trim is undamaged. Fit the trim in the load compartment. Secure the trim to the load platform by means of the studs. Close the luggage compartment lid. (luggage platform) trim - r+r - ment seal - r+r Complete with Op. 7040B22 Luggage compart¬ ment/load platform moulding - r+r 16 PA5106/00 06/1998 REPAIR PROCEDURES a Body interior upholstery and trim 7040B13 - LOAD COMPART¬ MENT/LOAD PLATFORM RIGHT SIDE TRIM - R R 7040B19 - REAR LUGGAGE COMPARTMENT TRIM - R + R Removal Follow the Op. 7040B10 Load platform (luggage platform) trim - r+r I.Use cutter (1a) to remove trim retaining studs (1b). Removal Follow the Op. 7040B22 Luggage compart¬ ment/load platform moulding - r+r Follow the Op. 7025B66 Boot compartment seal - r+r Follow the Op. 7040B20 Back trim for luggage compartment/load platform - arrange Follow the Op. 7025B41 Boot lid lock Follow the Op. 7040B10 Load platform (luggage platform) trim - r+r 1. Unscrew the knob retaining the side trim to the body. 2. Use the appropriate tool to undo studs (2a) retaining the trim to the body and unscrew screw stud (2b). S3 7040 E9 Description Code Blade 1.823.015.000 2. Slightly bend the trim and remove it from the boot compartment. 7 © G> Description Code Blade 1.823.015.000 3. Remove the luggage compartment right side trim. s © 2 D -/ 1a 1 2a ? 2b A 1 ( Installation - Check that the trim is undamaged. Refit the trim and secure by means of studs. Complete with Op. 7040B10 Load platform (luggage platform) trim - r+r i 3 Refit the right side trim. Fasten the trim by means of the appropriate studs. Secure the trim to the tail-light by means of the appropriate fastening. Complete with Op. 7040B22 Luggage compart¬ ment/load platform moulding - r+r Complete with Op. 7025B66 Boot compart¬ ment seal - r+r Complete with Op. 7040B20 Back trim for luggage compartment/load platform - arrange Complete with Op. 7025B41 Boot lid lock Complete with Op. 7040B10 Load platform (luggage platform) trim - r+r PA5106/00 06/1998 □ Installation - i i 1b 7040B20 - BACK TRIM FOR LUGGAGE COMPARTMENT/ LOAD PLATFORM - ARRANGE Removal Follow the Op. 7040B22 Luggage compart¬ ment/load platform moulding - r+r Follow the Op. 7025B66 Boot compartment seal - r+r Follow the Op. 7025B41 Boot lid lock I.Use cutter (1a) to undo trim retaining studs (1b). S3 1a Description Code Blade 1.823.015.000 2. Remove the luggage compartment rear trim. 17 REPAIR PROCEDURES a Body interior upholstery and trim 7040 Installation - - Check that the guard is undamaged. Fit the guard in the boot compartment. Tighten the retaining bolts and close the boot lid. 7040B46 - LUGGAGE BELT RING - R R Removal - - Open the boot lid. Raise the luggage compartment trim. 1. Unscrew the retaining bolt. 2. Remove the luggage strap ring. i Installation - Check that the trim is undamaged. Fit the trim in the boot compartment. Secure the trim by means of appropriate studs. Complete with Op. 7025B41 Boot lid lock Complete with Op. 7040B22 Luggage compart¬ ment/load platform moulding - r+r Complete with Op. 7025B66 Boot compart¬ ment seal - r+r - a 1 7040B22 - LUGGAGE V -2 COMPARTMENT/LOAD PLAT¬ FORM MOULDING - R + R Installation Removal - Open the boot lid. 1. Unscrew the retaining bolts. 2. Remove the lock striker guard from the engine bay. 1 - - Tighten the bolt retaining the strap ring to the floor pan. Refit the trim. Close the luggage compartment lid. css 1 1 1 2 18 PA5106/00 06/1998 REPAIR PROCEDURES a Body interior upholstery and trim 7040 7040D - Engine bay lining VIEW OF ASSEMBLY 1 _ \ 3 Sa * jfesX, 2 1 Ref. Description 1 ENGINE BAY FRONT SIDE COVER 2 ENGINE PAY FRONT BEAM COVER 3 ENGINE BAY REAR SIDE COVER Operations index Code Operation Validity 7040D12 Engine front side cover (one) Ih or rh - r r 7040D14 Engine bay rear side cover (one) Ih or rh - r r 7040D30 Engine bay front beam cover - r r WARNINGS Use care when working on trim components and use the specified tools correctly in order to avoid damage. PRECAUTIONS DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). PA5106/00 0611998 19 REPAIR PROCEDURES a Body interior upholstery and trim 7040 OPERATIONS 7040D12 - ENGINE FRONTSIDE COVER (ONE) LH OR RH - R R 1c 1a 1b Removal I.Undo studs (1a) and remove the engine bay front side half-cover (1b). \ 1b _ \ Sa •W 13 1a o -> 3#4 Proceed as follows to remove the right rear side half-cover. 1. Undo stud (1a) and bolts (1b), then remove the engine bay right rear side half-cover (1c). ■-S.O 1b o o. V J7 1a Installation - Fit the engine bay front side half-cover and secure by means of the studs and bolt. X 7040D14 - ENGINE BAY REAR SIDE COVER (ONE) LH OR RH R R rs Ss— Removal Follow the Op. 7040D12 Engine front side cover (one) Ih or rh - r r . Proceed as follows to remove the left rear side half-cover. I.Undo stud (1a) and bolts (1b), then remove the engine bay left rear side half-cover (1c). 1c ± X m Installation - - Fit the engine bay right rear side half-cover and secure by means of the bolts and stud. Fit the engine bay left rear side half-cover and secure by means of the bolts and stud. Complete with Op. 7040D12 Engine front side cover (one) Ih or rh - r r . 7040D30 - ENGINE BAY FRONT BEAM COVER - R R Removal Follow the Op. 7040D12 Engine front side cover (one) Ih or rh - r r . 1. Unscrew bolts (1a) and remove front beam cover (1b). 20 PA5106/00 06/1998 m REPAIR PROCEDURES Body interior upholstery and trim Iff w 7040 1b Z// 1a) i Installation - /*"*N Fit the front beam cover and secure with the bolts. Complete with Op. 7040D12 Engine front side cover (one) Ih or rh - r r . PA5106/00 06/1998 21 REPAIR PROCEDURES Body interior upholstery and trim 7040 rC J 7040E - Interior courtesy light system VIEW OF ASSEMBLY 2 1-= 6 22 r\ 4 3 5 titjdiinit'M v/ocs/ . Ref. Description 1 SUN BUND MIRROR LIGHT BULB 2 FRONT MODULAR COURTESY LIGHT UNIT 3 DOOR PANEL LOWER LIGHT 4 REAR DOOR PANEL COURTESY LIGHT 5 UNDER FACIA LIGHTING 6 REAR LIGHT *• Operations index Code Operation 7040E17 Lh or rh rear courtesy light - r r 7040E22 Courtesy light under instrument facia 7040E24 Lower courtesy light indoor panel - r+r 7040E26 Lower courtesy light in rear panel - r r 7040E28 Courtesy light on sun blind - r r 22 Validity - r+r PA5106/00 06/1998 REPAIR PROCEDURES Body interior upholstery and trim tC 7040 j Code Operation 7040E40 Modular front courtesy light - r r Validity WARNINGS Use care when working on trim components and use the specified tools correctly in order to avoid damage. 7040E22 - COURTESY LIGHT UNDER INSTRUMENT FACIA R+R Removal OPERATIONS Ensure that the ignition key is in tthe OFF posi¬ tion, then disconnect the battery negative - terminal. 7040E17 - LH OR RH REAR COURTESY LIGHT - R R \Description Removal r*\ n 1a Code ES Blade 1.823.014.000 1b and Description Code Blade 1.823.014.000 2. Disconnect the electrical connection from the under-facia courtesy light and remove it. Connector \Description 2 A1B 1. Remove the under-facia courtesy light (1a) using the tool (1b). Description 2. Disconnect the electrical connection remove the courtesy light. Connector Battery With the ignition key in the stop position, disconnect the battery negative terminal. I.Use tool (1a) to prise out courtesy light(1b). - A G25 Rear left courtesy light // // /3 IDescription 2 & B Connector G26 Rear right courtesy light ) N £ 2 % 2 A 1b -v 1a - - - Check the condition of the courtesy light. Connect the electrical connector and check the courtesy light is working properly. Refit the courtesy light in its seat. Connect the battery negative terminal. PA5106/00 06/1998 / -4. A/ 1a ibQ Installation - Installation - Connect the electrical connection to the under¬ facia courtesy light and then replace in its seat. Connect the negative (-) battery terminal. 7040E24 - LOWER COURTESY LIGHT INDOOR PANEL - R + R Removal - With the ignition key in the stop position, disconnect the battery negative terminal. I.Use the tool shown to take the courtesy light out of its housing on the panel. 23 REPAIR PROCEDURES 7040 CS 1 El Body interior upholstery and trim Description Code Blade 1.823.014.000 \ Description Connector G56 Rear right door light 1 . Disconnect electrical cable (2a) from courtesy light (2b) and remove. \Description Front left door light 2a Connector G51 — :a IDescription Connector Front right door light G52 1 - !a 2b Installation Connect the courtesy light electrical connector. Fit the courtesy light on the panel. Connect the battery negative terminal. - 1 !a 2b 7040E28 - COURTESY LIGHT ON SUN BLIND - R R Removal With the ignition key in the stop position, disconnect the battery negative terminal. 1. Use the tool to prise out the courtesy light. - Installation Check the condition of the courtesy light. Connect the electrical connector to the courtesy light and check it works properly. Fit the courtesy light into its seat on the panel and ensure the retaining clip has clicked home. Connect the battery negative terminal. - - H 1 - Code Blade 1.823.014.000 2. Disconnect electrical connection (2a) and remove courtesy light (2b). 7040E26 - LOWER COURTESY LIGHT IN REAR PANEL - R R IDescription 2a Removal Description Connector Passenger's sunshade light G32 With the ignition key in the stop position, disconnect the battery negative terminal. 1 . Use the tool to prise the lower courtesy light out of the panel. E9 1 Description Code Blade 1.823.014.000 2. Disconnect electrical connector (2a) from cour¬ tesy light (2b) and remove. IDescription 2a 24 Rear left door light Connector G55 PA5106/00 06/1998 REPAIR PROCEDURES Body interior upholstery and trim rC J 7040 /21 r Ref. Description 1 FACIA GLOVE COMPART LIGHT BULB HOLDER 2 FACIA GLOVE COMPARTMENT LIGHT SWITCH 3 BOOT LIGHT BULB HOLDER Operations index Code Operation Validity 7040G20 Facia compartment light bulb holder - r+r 7040G24 Switch for facia compartment light - r+r 7040G30 Boot light bulb holder - r r WARNINGS PRECAUTIONS Use care when working on trim components and use the specified tools correctly in order to avoid damage. DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). 26 PA5106/00 06/1998 REPAIR PROCEDURES Body interior upholstery and trim rC 7040 j OPERATIONS 7040G20 - FACIA COMPART¬ MENT LIGHT BULB HOLDER R+R IDescription Battery A1B Follow the Op. 7040A31 Flap assembly - rr. 1. Remove the glove compartment light switch (1a) from its housing, disconnect electrical connection (1b) and then remove it. Removal - Connector Ensure that the ignition key is in tthe OFF posi¬ tion, then disconnect the battery negative terminal. I Description IDescription Connector Battery 1b // .0, ES Description Code Blade 1.823.014.000 \Description 1c 115 A1B 1-Open the compartment and remove the facia glove compartment bulb holder (1a) using the tool (1b) after disconnecting the electrical connection (1c). 1b Connector Glove compartment light // \ \ Connector Glove compartment light T y/ G30 1a % \ H !bCl Installation ?// / 1a Connect the electrical connection to the glove compartment switch and fit into its seat. - XipiJiJ y Connect the negative (-) battery terminal. - 7040G30 - BOOT LIGHT BULB HOLDER - R R Removal - Installation - Connect the electrical connection to the glove compartment light bulb holder and then replace in its seat. Connect the negative (-) battery terminal. 7040G24 - SWITCH FOR FACIA COMPARTMENT LIGHT - R + R With the ignition key in the stop position, disconnect the battery negative terminal. 1. Open the boot lid amd use tool (1a) to prise out courtesy light (1b). H 1 Ensure that the ignition key is in tthe OFF posi¬ tion, then disconnect the battery negative terminal. Code Blade 1.823.014.000 2. Disconnect the electrical connection. Removal - Description \Description 2 Boot courtesy light Connector G40 3. If necessary, remove the bulb from the retaining clip. PA5106/00 06/1998 27 REPAIR PROCEDURES Body interior upholstery and trim 7040 a 1a □ 1b 2 r Installation - 28 Check that the courtesy light is undamaged. If the bulb was removed, refit in its socket. Connect the electrical connection. Test to ensure it works properly. Fit the courtesy light. Connect the battery terminal. PA5106/00 06/1998 REPAIR PROCEDURES a Body interior upholstery and trim 7040 7040H - Roof panel lining VIEW OF ASSEMBLY 6 1 ■s.' “ 2 5 3 M s Ref. Description 1 ROOF PANEL TRIM 2 FRONT PILLAR TRIM 3 CENTRAL PILLAR TRIM LOWER ELEMENT 4 CENTRAL PILLAR TRIM UPPER ELEMENT 5 REAR PILLAR TRIM 6 PARCEL RACK 7 SLIDING ROOF SWITCH PANEL 4 Operations index Code Operation Validity 7040H10 Roof panel lining - r r 7040H16 Roof panel lining - r r 7040H30 Front pillar trim - r r 7040H32 Sliding roof switch door panel - r r 7040H34 Central pillar trim - r r 7040H36 Central trim lower element - r r 7040H38 Central pillar upper element - r r 7040H42 Rear pillar trim - r r 7040H82 Cover for oddment compartment in parcel rack - r r PA5106/00 06/1998 29 REPAIR PROCEDURES 7040 Code 51 Body interior upholstery and trim Validity Operation 7040H84 Parcel rack plus speaker - r r 5. Remove the roof panel from the adhesive fastenings and take out through the right front door opening. WARNINGS Use care when working on trim components and use the specified tools correctly in order to avoid damage. 1b PRECAUTIONS DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). 1a $ 1c 3 1a OPERATIONS 7040H10 - ROOF PANEL LINING - R R 5 Removal Follow the Op. 7005A20 Front side door adjust centring and moulding - includes adapta¬ tion of hinges Follow the Op. 7065C34 L/h or r/h sun blind (one) - r+r Follow the Op. 7040E40 Modular front courtesy light - r r - Follow the Op. 7040E28 Courtesy light on sun blind - r r Follow the Op. 7040H32 Sliding roof switch door panel - r r Follow the Op. 7065C30 Interior l/h or r/h grab handle (one) - r+r Follow the Op. 7040H30 Front pillar trim - r r Follow the Op. 7040H36 Central trim lower element - r r Follow the Op. 7040H38 Central pillar upper element - r r Follow the Op. 7040H34 Central pillar trim - r r Follow the Op. 7040E17 Lh or rh rear courtesy light - r r Follow the Op. 7065C68 Rear view mirror - r+r Follow the Op. 7065C59 Interior rear view mirror with automatic antiglare device - r r 1. Unscrew bolts (1a) retaining rear sun blind mounting hooks (1b).Unscrew rear roof panel retaining bolt (1c). Pull away the upper ends of the rear pillar trim and driver's side central trim. n MkJDescription Blade 2 Code 1.823.014.000 s tD 4 4' Installation - - - 2. Pull away the part of the door seal on the driver's side in contact with the roof panel trim. Use adhesive tape to protect any parts that could be damaged by roof removal. Lower the front seat squabs and move the seats forward. 3. Unscrew the roof panel retaining bolts located beneath the rear courtesy lights. 4. Unscrew the front roof panel retaining bolts in the courtesy light compartment. 30 2 - Fit the roof panel in its seat. Tighten the front roof panel retaining bolts in the courtesy light compartment. Tighten the roof panel retaining bolts beneath the rear courtesy lights. Raise the front seat squabs and move the seats back into the correct position. Remove the protective tape applied previously. Refit the door sealing strip. Fit the pillar trim in its seat. Tighten the rear roof panel retaining bolt. Tighten the rear sun blind mount hook retaining bolts. Complete with Op. 7065C59 Interior rear view mirror with automatic antiglare device - r r Complete with Op. 7065C68 Rear view mirror - r+r Complete with Op. 7040E17 Lh or rh rear cour¬ tesy light r r Complete with Op. 7040H34 Central pillar trim -rr - PA5106/00 06/1998 r*\ REPAIR PROCEDURES Body interior upholstery and trim r*\ Complete with Op. 7040H38 Central pillar upper element - r r Complete with Op. 7040H36 Central trim lower element - r r Complete with Op. 7040H30 Front pillar trim rr Complete with Op. 7065C30 Interior l/h or r/h grab handle (one) - r+r Complete with Op. 7040H32 Sliding roof switch door panel - r r Complete with Op. 7040E28 Courtesy light on sun blind - r r Complete with Op. 7040E40 Modular front courtesy light - r r Complete with Op. 7065C34 L/h or r/h sun 7040 4. Unscrew the front roof panel retaining bolts in the courtesy light compartment. 5. Remove the roof panel from the adhesive fastenings and take out through the right front door opening. 1b 1a 1c 1a blind (one) - r+r Complete with Op. 7005A20 Front side door adjust centring and moulding - includes adapta¬ tion of hinges 7040H16 - ROOF PANEL LINING - R R 5 Removal Follow the Op. 7005A20 Front side door adjust centring and moulding - includes adapta¬ tion of hinges Follow the Op. 7065C34 L/h or r/h sun blind (one) - r+r Follow the Op. 7040E40 Modular front courtesy light - r r Follow the Op. 7040E28 Courtesy light on sun blind - r r Follow the Op. 7030B34 Sliding roof compart¬ ment decorative seal - r+r Follow the Op. 7040H32 Sliding roof switch door panel - r r Follow the Op. 7065C30 Interior l/h or r/h grab handle (one) - r+r Follow the Op. 7040H30 Front pillar trim - r r Follow the Op. 7040H36 Central trim lower element - r r Follow the Op. 7040H38 Central pillar upper element - r r Follow the Op. 7040H34 Central pillar trim - r r - Follow the Op. 7040E17 Lh or rh rear courtesy light - r r Follow the Op. 7065C68 Rear view mirror - r+r Follow the Op. 7065C59 Interior rear view mirror with automatic antiglare device - r r 1. Unscrew bolts (1a) retaining rear sun blind mounting hooks (1b).Unscrew rear roof panel retaining bolt (1c). - Pull away the upper ends of the rear pillar trim and driver's side central trim. ES Description Code Blade 1.823.014.000 2. Pull away the part of the door seal on the driver's side in contact with the roof panel trim. Use adhesive tape to protect any parts that could be damaged by roof removal. Lower the front seat squabs and move the seats forward. 3. Unscrew the roof panel retaining bolts located beneath the rear courtesy lights. PA5106/00 06/1998 2 2 0 [D A 4 Installation - - - Fit the roof panel in its seat. Tighten the front roof panel retaining bolts in the courtesy light compartment. Tighten the roof panel retaining bolts beneath the rear courtesy lights. Raise the front seat squabs and move the seats back into the correct position. Remove the protective tape applied previously. Refit the door sealing strip. Fit the pillar trim in its seat. Tighten the rear roof panel retaining bolt. Tighten the rear sun blind mount hook retaining bolts. Complete with Op. 7065C59 Interior rear view mirror with automatic antiglare device - r r Complete with Op. 7065C68 Rear view mirror r+r Complete with Op. 7040E17 Lh or rh rear cour¬ tesy light - r r Complete with Op. 7040H34 Central pillar trim -rr Complete with Op. 7040H38 Central pillar upper element - r r Complete with Op. 7040H36 Central trim lower element - r r - 31 REPAIR PROCEDURES El Body interior upholstery and trim 7040 Complete with Op. 7040H30 Front pillar trim rr Complete with Op. 7065C30 Interior l/h or r/h 7040H32 - SLIDING ROOF SWITCH DOOR PANEL - R R Sliding roof Complete with Op. 7040H32 switch door panel - r r Complete with Op. 7040B34 Data not yet avail¬ Removal grab handle (one) - r+r - With the ignition key in the stop position, disconnect the battery negative terminal. 1-Use the tool to prise up the switch panel. able Complete with Op. 7040E28 Courtesy light on sun blind - r r Complete with Op. 7040E40 Modular front courtesy light - r r Complete with Op. 7065C34 L/h or r/h sun blind (one) - r+r Complete with Op. 7005A20 Front side door adjust centring and moulding - includes adapta¬ tion of hinges 7040H30 - FRONT PILLAR TRIM - R R (3 1 Description Code Blade 1.823.014.000 2. Prise out sun-roof switch (2a), then remove panel (2b). IDescription 2a Connector Data not yet available N35 Removal 1. Partly pull out the door compartment seal in the front pillar trim area. 2. Use tool (2a) to release pillar trim (2b) from the underlying retainers (2c) and remove. E9 2a Description Code Blade 1.823.015.000 m w <3 2b & 2b Hi 1 2c, 2a □ / // Installation - Check that the plate is undamaged. - Connect the switch and ensure it is working properly. - Refit the panel in its seat. - With the ignition key in the stop position, disconnect the battery negative terminal. Installation - Check that the trim is undamaged. Refit the pillar trim and secure to the retainers. Fit the sealing strip around the door compart¬ 7040H34 - CENTRAL PILLAR TRIM - R R Removal - ment. - Fit the door compartment seal. Follow the Op. 7040H36 Central trim lower element - r r Follow the Op. 7040H38 Central pillar upper element - r r Installation - 32 Complete with Op. 7040H38 Central pillar upper element - r r Complete with Op. 7040H36 Central trim lower element - r r PA5106/00 06/1998 /ÿi REPAIR PROCEDURES Body interior upholstery and trim rC 7040 j 7040H36 - CENTRAL TRIM LOWER ELEMENT - R R n 4a Removal - Description Code Blade 1.823.014.000 Slide the seat fully forward and raise it fully with the squab folded forward. Pull away the rear end of the front scuff strip and the front end of the rear scuff strip using the knife. - 4b H 4a Description Code Blade 1.823.014.000 y\ Vl 2 /> lo .2 1. Use tool (1a) to remove central pillar trim lower element (1b). ES 1a 4I Description Code Blade 1.823.014.000 5 I0 4b V 3 $ 1 1a Installation 1b >v c r< - Fit the seat belt to the pillar trim. Tighten the lower trim retaining bolts. Fit the door sealing strip vertical sections. Tighten the lower bolt retaining the seat belt to the seat. Complete with Op. 7040H36 Central trim lower element - r r - - 7040H42 - REAR PILLAR TRIM R R installation - - Fit the central pillar trim lower element. Fit the lower end of the front scuff strip and the front end of the lower scuff strip. Return the seat to its normal position. 7040H38 - CENTRAL PILLAR UPPER ELEMENT - R R Removal Follow the Op. 7040H36 Central trim lower element - r r 1. Unscrew the bolt retaining the seat belt to the seat. 2. Pull away the vertical sections of the door sealing strip. 3. Unscrew the lower trim retaining bolts. 4. Use tool (4a) to undo trim retaining clips (4b). 5. Remove the pillar trim by releasing from the seat - Removal Follow the Op. 7050A20 One-piece rear seat cushion - r r Follow the Op. 7050A19 Rear seat squab - r r 1. Pull out the rear section of the rear door sealing strip. 2. Use tool (2a) to undo lower retaining stud (2b). C3 3a Description Code Blade 1.823.014.000 3. Use tool (3a) to undo remaining rear trim fasteners (3b). 4. Remove the trim. belt. PA5106/00 06/1998 33 REPAIR PROCEDURES a Body interior upholstery and trim 7040 Tighten the bolts retaining the lid hinges to the parcel rack. Close the lid. 3b 1 7040H84 - PARCEL RACK PLUS SPEAKER - R R Removal Tv 4/ / 3a ' Tv / ll / M2b 0™ Installation - Fit the trim and check the fasteners are secured. Replace if necessary. Fit the lower retaining stud. Fit the lower section of the rear door sealing strip. Complete with Op. 7050A19 Rear seat squab - - - rr Complete with Op. 7050A20 seat cushion - r r Follow the Op. 7050A20 One-piece rear seat cushion - r r Follow the Op. 7050A19 Rear seat squab - r r Follow the Op. 7040H42 Rear pillar trim - r r 1. Unscrew bolts (1a) retaining the parcel rack to the body located inside the passenger compart¬ ment and remove locating plugs (1b). 2. Unscrew the parcel rack retaining nuts located inside the luggage compartment. Release the rear seat belts from their seats through the slots on the seats. 3. Lift the rear compartment lid, remove central plug (3a) and unscrew parcel rack retaining bolt (3b) located inside the compartment. - Raise the parcel rack. 4. Disconnect electrical connections (4a) and (4b) to the speakers, (1c) to the third brake light and (4d) to the alarm control receiver. \Description 4a Rear left loudspeaker (on parcel P30 shelf) One-piece rear 7040H82 - COVER FOR ODDMENT COMPARTMENT IN PARCEL RACK - R R Connector 4b IDescription Connector Rear right speaker (on parcel shelf) P31 IPascription Connector Additional rear light (third stop F40 Removal - Open the lid. 1. Unscrew the bolts retaining the lid hinges to the parcel rack. 2. Remove the lid. 4c light) 2 4d IPescription Connector Alarm remote control receiver M35 5. Remove parcel rack (5a) by undoing rear fittings (5b) from the body. 1 Installation - 34 Check the condition of lid and hinges. Fit the lid. PA5106/00 06/1998 REPAIR PROCEDURES 0 Body interior upholstery and trim 5a 3b 3a 5b 7040 ? 5b la 1 4bl 4a 4c ■a m /. 4d ®-2 2 Installation - Fit the parcel rack inside the passenger compart¬ and connect the electrical connections. Check the electrical components are working properly. Fit the parcel rack in its seat and ensure the rear body retaining hooks are properly fitted. Tighten the parcel rack retaining bolts located inside the oddment compartment. Fit the central stowage compartment plug. Close the rear compartment flap. Fit the rear seat belts in their seats through the slots in the seats. Tighten the parcel rack retaining nuts located inside the luggage compartment. Fit the locating plugs and tighten the bolts retaining the parcel rack to the body located inside the passenger compartment. Complete with Op. 7040H42 Rear pillar trim - r r Complete with Op. 7050A19 Rear seat squab ment - rr Complete with Op. 7050A20 seat cushion - r r PA5106/00 06/1998 One-piece rear 35 REPAIR PROCEDURES 7040 rC Body interior upholstery and trim j 7040L - Cabin floor covering VIEW OF ASSEMBLY 4 V D w m 3 ff'M 5 1 2 Ref. Description 1 FLOOR CARPET 2 TUNNEL TRIM 3 FRONT DOOR COMPARTMENT SCUFF STRIP 4 REAR DOOR COMPARTMENT SCUFF STRIP 5 DRIVERS SIDE FOOT REST Operations index Code Operation 7040L10 Cabin floor carpet - r r 7040L20 Tunnel trim - r r 7040L40 Front compartment scuff strip - r r 7040L44 Rear compartment scuff strip - r r 7040L50 Driver side foot rest - r r 36 Validity PA5106/00 06/1998 REPAIR PROCEDURES Body interior upholstery and trim HT 7040 J WARNINGS Tighten the accelerator pedal adjustment clip. Complete with Op. 7040A65 Passenger compartment box lock , one , r r Complete with Op. 7040L50 Driver side foot rest - r r Complete with Op. 1056B79 Injection/ignition contro unit guard - r r Complete with Op. 7040L20 Tunnel trim - r r Complete with Op. 7040H36 Central trim lower element - r r Complete with Op. 7040L44 Rear compartment scuff strip - r r Complete with Op. 7050A20 One-piece rear seat cushion - r r Complete with Op. 7040L40 Front compart¬ ment scuff strip - r r Complete with Op. 7050A20 One-piece rear seat cushion - r r Complete with Op. 7045A10 L/h or r/h front seat (one) - r+r - - Use care when working on trim components and use the specified tools correctly in order to avoid damage. PRECAUTIONS DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). OPERATIONS 7040LI 0 - CABIN FLOOR CARPET - R R Removal Follow the Op. 7045A10 L/h or r/h front seat (one) - r+r Follow the Op. 7050A20 One-piece rear seat cushion - r r Follow the Op. 7040L40 Front compartment scuff strip - r r Follow the Op. 7050A20 One-piece rear seat cushion - r r Follow the Op. 7040L44 Rear compartment scuff strip - r r Follow the Op. 7040H36 Central trim lower element - r r Follow the Op. 7040L20 Tunnel trim - r r Follow the Op. 1056B79 Injection/ignition contro unit guard - r r Follow the Op. 7040L50 Driver side foot rest rr Follow the Op. 7040A65 Passenger compart¬ ment box lock , one , r r 1. Unscrew the accelerator pedal adjustment clip. 2. Take up the floor carpet and remove from a rear door. 7040L20 - TUNNEL TRIM - R R Removal - With the ignition key in the stop position, disconnect the battery negative terminal. 1. Release the gear lever boot from its seat on the console. 2. Undo the handbrake lever boot stud from its seat on the console and release from the lever. 3. Unscrew the console retaining bolts. 4. Disconnect the cigar lighter electrical connec¬ tion. IDescription 4 Connector P50 Cigarette lighter/power socket 5. Remove the trim by withdrawing from the hand¬ brake lever. 1 1 IA 7 3 2 D\/x i m i J- 1 5 S' )X 2 rj, i 4 'S' Installation Installation - - Check that the carpet is undamaged. Position the carpet on the car floor pan. PA5106/00 06/1998 - - Check the tunnel trim is in good condition. Connect the cigar lighter electrical connection. 37 REPAIR PROCEDURES Body interior upholstery and trim 7040 rC J 2. Remove the sill plate by undoing the underlying clips. Position the trim and fit the handbrake boot and rear air duct. Tighten the trim retaining bolts. Do up the handbrake lever boot stud to its seat on the console. Position the gear lever boot in its seat on the console. Connect the battery negative terminal. r*\ 2 7040L40 - FRONT COMPART¬ MENT SCUFF STRIP - R R AU □1a 1b Removal 1. Unscrew the retaining bolt in the upper corner of the sill plate. 2. Use tool (2a) to prise sill plate (2b) up from the underlying retainers. H \S 0 Description Code Blade 1.823.014.000 2 a J / 1 o X Installation - X, Complete with Op. 7050A20 seat cushion - r r 2b 7040L50 - DRIVER SIDE FOOT REST - R R Removal 1. Unscrew bolts (1a) retaining the driver's side footrest and remove. □ C2: \ Installation - One-piece rear Complete with Op. 7040H36 Central trim lower element - r r > 2a Position the sill plate and do up the clips. Fit the press-studs. Check that the sill plate and retaining clips are undamaged. Refit the sill plate. Tighten the retaining bolt. - u 7040L44 - REAR COMPART¬ MENT SCUFF STRIP - R R Removal 1b Follow the Op. 7050A20 One-piece rear seat cushion - r r Follow the Op. 7040H36 Central trim lower element - r r I.Use tool (1a) to prise open studs (1b) securing the sill plate. t 1} \ Installation E3 Description Code 1a Blade 1.823.015.000 38 1a - Check that the foot rest is undamaged. Position the driver's side footrest and tighten both retaining bolts. PA5106/00 06/1998 REPAIR PROCEDURES Body interior upholstery and trim 7040 J Sub-group index - SUB-GROUP GRAPHIC INDEX Assembly drawings index Validity Cmp Description 7040A Passenger compartment trim 7040L Cabin floor covering SUB-GROUP GRAPHIC INDEX 2 4 6 1 ■<0 m m | 7 3 Ref. Description Cmp 1 Passenger compartment trim 7040A 2 Luggage compartment and load platform trims 7040 B 3 Interior courtesy light system 7040E 4 Engine bay lining 7040D 5 Vehicle compartment lightening system 7040G 6 Roof panel lining 7040H 7 Cabin floor covering 7040L PA5106/03 10H 998 166 1 REPAIR PROCEDURES 7040 2 Body interior upholstery and trim a PA5106/03 10/1998 REPAIR PROCEDURES Body interior upholstery and trim 7040 J 7040A - Passenger compartment trim VIEW OF ASSEMBLY 3 1 _ )) - 12 7 11 \ / \ £04 S3 4 / \ t / L - [//// - r+r - 4 Follow the Op. 5550C16 Hazard warning light/ fog lamp/reversing light combined switch - r r Follow the Op. 5040D18 Air conditioner control unit - r r Follow the Op. 5570T80 Car radio unit - r+r Follow the Op. 7065C42 Ashtray (one) r+r Follow the Op. 5570T80 Car radio unit - r+r Follow the Op. 7065C42 Ashtray (one) r+r Follow the Op. 5580C18 Air bag module - r+r Follow the Op. 1056B79 Injection/ignition contro unit guard - r r Follow the Op. 4110A11 Steering wheel - r+r for replacement or check for versions with air bag Follow the Op. 5550A12 Complete stalk unit r+r for versions with air bag Follow the Op. 7040A31 Flap assembly - r r Follow the Op. 7040G24 Switch for facia com¬ partment light - r+r Follow the Op. 5580C22 Air bag module (pas¬ senger side) -r + r Follow the Op. 7040A67 Partition between pas¬ senger airbag and facia compartment - r r Follow the Op. 7040A43 Cover (one only) for wiring beneath facia - r r Follow the Op. 5505C32 (one) securing wiring connectors beneath instrument facia - r r Follow the Op. 5580C14 Air bag ecu - r+r Follow the Op. 7040L20 Tunnel trim - r r Follow the Op. 7045A10 L/h or r/h front seat (one) - r+r Pull up the floor carpet. 11 txoieonvTCKr * A97cmatir 1. Remove the connector safety protection (1a) and disconnect door wiring connector (1b). 2. Use tool (2a) to unscrew retaining bolts (2b). Then disconnect half-connector (2c) from its seat on the body. Carry out the same operation on both front doors. \ Description 1B 2a Front left door connection Connector D30 Description Code Key 1.822.132.000 PA5106/03 10/1998 REPAIR PROCEDURES Body interior upholstery and trim 7040 j 2 1a 0 :4a \ 2a ©rad © t-, III 2c V tjtajoo*) v *' A 9: cozsvr tl_l— 1a / 1b Front/dashboard connection D1 Description Connector Dashboard/courtesy lights con¬ D42 ' \ Q si Connector rati wI nection 1 / 1c / 3a / 3b 'Description D25 Description Connector Brake pedal switch 1 30 Description Connector Clutch pedal switch 131 W/1998 \K V Connector Dashboard/rear left connection PA5106/03 y 1. Remove the radiant element from the heater unit and move to one side. Take care not to damage the two coolant pipes. 2. Release airbag wiring sections secured to the facia wiring from the retaining collars. 3. Disconnect electrical connectors (3a) and (3b). 4. Unscrew upper nut (4a) securing the steering column strut and remove strut (4b). \Description 4b ,1bA icD 1 . Disconnect electrical connection (1a) between engine wiring and facia wiring, electrical con¬ nection (1b) between facia wiring and roof wiring - and electrical connection (1c) between facia wiring and rear service wiring. / € A ’3a|| v> -7 I a ©s\3bx 1a Jf© 1b 2 1. Unscrew the nuts retaining the facia frame to the body. 2. With the aid of a second operator, remove the frame complete with air distributor box, steering column and facia wiring. mss 5 REPAIR PROCEDURES Body interior upholstery and trim 7040 J Complete with Op. 7040G24 Switch for facia 2 't: fTÿT7 compartment light - r+r Complete with Op. 7040A31 Flap assembly □CQS i— i p ®"T V r+r N 0 Complete with Op. 7065C42 Ashtray (one) r+r Complete with Op. 5570T80 Car radio unit - r+r Complete with Op. 5040D18 Air conditioner control unit - r r Complete with Op. 5570T80 Car radio unit - r+r Complete with Op. 7065C42 Ashtray (one) r+r Complete with Op. 5550C16 Hazard warning light/fog lamp/reversing light combined switch -rr Complete with Op. 7040A26 Steering column >l| ( / / TMOjce** trim - r+r row « Complete with Op. 5560B11 Analogue control panel - r+r or replace Complete with Op. 5010C30 Central air outlet on fascia - r+r Complete with Op. 5580C26 Passenger air bag switch - r r Complete with Op. 7040A45 Facia rh side cover -rr Complete with Op. 7040A44 Facia Ih side cover -rr Complete with Op. 5540A22 Exterior lighting 4 t’cetn* Installation - - - - Fit the facia frame to the body. Take care to refit the facia wiring correctly. Tighten the nuts retaining the frame to the body to the specified torque. Fit the radiant element in its seat in the heater/ air conditioner unit housing. Fit the steering column strut. Tighten the upper strut retaining nut. Connect the electrical connection, pull through the airbag electrical lead and replace the retaining collar. Connect the electrical connection betwen engine wiring and facia wiring, the electrical connection between facia wiring and roof wiring - and the electrical connection betwen facia wiring and rear service wiring. Fit the door wiring into its seat and secure the half-connector to the body using the tool shown. CS Description Code Key 1.822.132.000 control switch - r+r Complete with Op. 5010D30 Passenger com¬ partment air temperature sensor - r+r following electrical wiring check operation Complete with Op. 5580E12 Immobiliser device ecu - r+r following electric circuit check Complete with Op. 5505A18 Multi-function control unit - r r Complete with Op. 5580M10 On-board navi¬ gator panel unit - r r Complete with Op. 1068A30 Accelerator con¬ trol cable -r + r 2.QTB 6M Connect the front door wiring electrical con¬ nector and refit the protection. Fit the steering column joint. Tighten the steering column retaining bolt. Position the steering wheel so that it is straight. Tighten the three nuts retaining the joint cover to the body. Fit the floor carpet. Complete with Op. 7045A10 L/h or r/h front seat (one) - r+r Complete with Op. 7040L20 Tunnel trim - r r Complete with Op. 5580C14 Air bag ecu - r+r Complete with Op. 5505C32 (one) securing wiring connectors beneath instrument facia - r r Complete with Op. 7040A43 Cover (one only) for wiring beneath facia - r r Complete with Op. 7040A67 Partition between passenger airbag and facia compartment - r r Complete with Op. 5580C22 Air bag module (passenger side) -r + r 6 -rr Complete stalk unit - r+r for versions with air bag Complete with Op. 4110A11 Steering wheel r+r for replacement or check for versions with air bag Complete with Op. 1056B79 Injection/ignition contro unit guard - r r Complete with Op. 5580C18 Air bag module Complete with Op. 5550A12 1BB 1 1 2.5 VB II g.S V6 CAE Complete with Op. 1068A50 Accelerator poten¬ tiometer - r+r PA5106/03 10/1998 REPAIR PROCEDURES Body interior upholstery and trim 7040 j 7040L - Cabin floor covering VIEW OF ASSEMBLY : : i ; / / ■<&\ m '7 m 7, I wwy / / /' / / / / \ x--; ®c mm i \ / 7X 3 5 4 y X, v 1 2 IMOOOOPKV70K7 Ref. Description 1 FLOOR CARPET 2 TUNNEL TRIM 3 FRONT DOOR COMPARTMENT SCUFF STRIP 4 REAR DOOR COMPARTMENT SCUFF STRIP 5 DRIVERS SIDE FOOT REST 40 L COlHl'f Operations index Code Operation 7040L10 Cabin floor carpet - r r PA5106/03 10/1998 Validity 7 REPAIR PROCEDURES Body interior upholstery and trim 7040 J OPERATIONS 7040LI 0 HT Complete with Op. 7050A20 One-piece rear -rr Complete with Op. 7040L40 Front compart¬ ment scuff strip - r r Complete with Op. 7050A20 One-piece rear seat cushion - r r Complete with Op. 7045A10 L/h or r/h front seat (one) - r+r seat cushion CABIN FLOOR CARPET - R R - Removal Follow the Op. 7045A10 L/h or r/h front seat (one) - r+r Follow the Op. 7050A20 One-piece rear seat cushion - r r Follow the Op. 7040L40 Front compartment scuff strip - r r Follow the Op. 7050A20 One-piece rear seat cushion - r r Follow the Op. 7040L44 Rear compartment scuff strip - r r Follow the Op. 7040H36 Central trim lower ele¬ ment - r r Follow the Op. 7040L20 Tunnel trim - r r Follow the Op. 1056B79 Injection/ignition contro unit guard - r r Follow the Op. 7040L50 Driver side foot rest rr Follow the Op. 7040A65 Passenger compart¬ ment box lock , one , r r 1 . Unscrew the accelerator pedal adjustment clip. 2. Take up the floor carpet and remove from a rear Complete with Op. 1068A30 Accelerator con¬ trol cable -r + r >.5 ve Complete with Op. 1068A50 Accelerator poten¬ tiometer - r+r door. 1 X) )A==? & 2 ran:? <• nocots rir Installation - - - 8 Check that the carpet is undamaged. Position the carpet on the car floor pan. Tighten the accelerator pedal adjustment clip. Complete with Op. 7040A65 Passenger com¬ partment box lock , one , r r Complete with Op. 7040L50 Driver side foot rest - r r Complete with Op. 1056B79 Injection/ignition contro unit guard - r r Complete with Op. 7040L20 Tunnel trim - r r Complete with Op. 7040H36 Central trim lower element - r r Complete with Op. 7040L44 Rear compartment scuff strip - r r PA5106/03 10/1998 REPAIR PROCEDURES Front seats rC 7045 J Sub-group index - SUB-GROUP GRAPHIC INDEX Assembly drawings index Cmp Description 7045A Front seat assembly 7045B Front seat head restraint/arm rest 7045J Front seat movement 7045M Front seat handling Validity SUB-GROUP GRAPHIC INDEX Os 2 ( 1 3 4 Ref. Description Cmp 1 Front seat assembly 7045A 2 Front seat head restraint/arm rest 7045B 3 Front seat movement 7045J 4 Front seat handling 7045M PA5106/00 06/1998 1 REPAIR PROCEDURES Front seats 7045 rC J 7045A - Front seat assembly VIEW OF ASSEMBLY 1 r [ .) 6 1st 4 7 3 8 2 5 Ref. Description 1 FRONT SEAL ASSEMBLY 2 FRONT SEAT GUIDES 3 FRONT SEAT LUMBAR ADJUSTMENT LEVER/KNOB 4 DRIVER'S SEAT SQUAB LUMBAR ADJUST DEVICE 5 FRONT SEAT OUTER GUARD 6 FRONT SEAT SQUAB TRIM FRONT SEAT SUQUB PADDING 7 FRONT SEAT CUSHION TRIM 8 FRONT SEAT CUSHION PADDING Operations index Code Operation Validity 7045A10 L/h or r/h front seat (one) - r+r 2 PA5106/00 06/1998 REPAIR PROCEDURES Front seats rC 7045 J r-\ Code Validity Operation 7045A22 L/h or r/h front seat support/guide - r+r with seat removed 7045A23 Front seat mounts - r r 7045A25 Squab lumbar knob - r r 7045A38 Driver's seat squab lumbar adjustment device - repair with seat removed 7045A39 Front seat lumber device - r r 7045A43 Seat exterior guard - r r 7045A84 Trim of front seat squab - r r with seat removed 7045A85 Trim of front seat squab, Ih or rh, - r r 7045A86 Trim of front seat cushion, Ih or rh, removed - r r with seat 7045A87 Trim of front seat cushion, Ih or rh, r r 7045A88 Padding of front seat squab, Ih or rh - r r with seat removed 7045A89 Padding of front seat squab, Ih or rh 7045A90 L/h or r/h front seat cushion padding - repair with seat removed 7045A91 Seat padding of one front seat Ih or rh - r r 7045 A92 L/h or r/h front seat trim - r+r with seat removed 7045A93 Trim of one front seat rh or Ih -rr 7045A98 Front seat rear pouch panel, Ih or rh - r r WARNINGS OPERATIONS Use care when working on trim components and use the specified tools correctly in order to avoid damage.Always ensure that unwoven cloth is present between trim and padding.After fitting a trim section, carefully mould the trim onto the padding. 7045A10 - L/H OR R/H FRONT SEAT (ONE) - R+R PRECAUTIONS Removal 1. Unscrew bolt (1a) securing seat belt (1b) to the seat. 1b DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). I 1a i Move the seat fully forward. 1. Unscrew the rear seat anchorage bolts. PA5106/00 06/1998 3 REPAIR PROCEDURES Front seats 7045 rC J % - H Mkj Description 1.878.017.001 Stapler Complete with Op. 7045A98 Front seat rear pouch panel, Ih or rh - r r Complete with Op. 7045A25 Squab lumbar knob - r r Complete with Op. 7045A10 L/h or r/h front £>5 a Code 1b seat (one) - r+r 7045A39 - FRONT SEAT LUMBER DEVICE - R R Installation - Check the device components are undamaged. Fit the cable and connect it to the anchorage points on the chassis. 1. Use a riveting machine (1a) to secure the adjustment device to the chassis using new rivets (1b). Removal - Follow the Op. 7045A10 L/h or r/h front seat (one) - r+r Follow the Op. 7045A25 Squab lumbar knob rr Follow the Op. 7045A98 Front seat rear pouch panel, Ih or rh - r r Follow the Op. 7045A38 Driver's seat squab lumbar adjustment device - repair with seat removed Installation - Complete with Op. 7045A38 Driver’s seat squab lumbar adjustment device - repair with seat removed Complete with Op. 7045A98 Front seat rear pouch panel, Ih or rh - r r Complete with Op. 7045A25 Squab lumbar knob - r r Complete with Op. 7045A10 L/h or r/h front seat (one) 6 - r+r PA5106/00 06/1998 REPAIR PROCEDURES Front seats rC 7045 J 7045A43 - SEAT EXTERIOR GUARD - R R 1b 2 1a Removal Follow the Op. 7045M10 Front seat heating system switch - r+r 1-Use tool (1a) to remove switch cover panels (1b). E9 1a Description Code Blade 1.823.014.000 / 1a o 2. Unscrew bolts retaining the switch unit side cover. 3. Remove the outer guard. cz > ( A' 3 J 2 \ 2 2 n 1.Pull up plastic sections (1a) from seat frame (1b) retaining the left and right hand side trim.Pull away plastic section (1a) of the upper squab trim section. Take the trim off the front part of the seat. 2. Cut the fasteners shown. 3. Remove the trim. 1b Installation - - - Position the side cover and secure the five bolts securing the cover to the seat. Fit the switch cover panels. Check the unit is working properly at the bench. Complete with Op. 7045M10 Front seat heating system switch - r+r 7045A84 - TRIM OF FRONT SEAT SQUAB - R R WITH SEAT REMOVED Removal Follow the Op. 7045A25 Squab lumbar knob rr Follow the Op. 7045A98 Front seat rear pouch panel, Ih or rh - r r Follow the Op. 7045B10 L/h or r/h front seat head restraint - r+r I.Undo retaining tabs (1a) to remove head retaining pin fitting bushes (1b). 2. Cut the fasteners from the squab trim lower area. PA5106/00 06/1998 7 REPAIR PROCEDURES 0 Front seats 7045 2 3 7045A85 - TRIM OF FRONT SEAT SQUAB, LH OR RH, - R R Removal Follow the Op. 7045A10 L/h or r/h front seat (one) - r+r Follow the Op. 7045A25 Squab lumbar knob rr Follow the Op. 7045A98 Front seat rear pouch panel, Ih or rh - r r Follow the Op. 7045BIO L/h or r/h front seat head restraint - r+r Follow the Op. 7045A84 Trim of front seat squab - r r with seat removed Installation 1a 1a Complete with Op. 7045A84 Trim of front seat squab - r r with seat removed Complete with Op. 7045B10 L/h or r/h front seat head restraint - r+r Complete with Op. 7045A98 Front seat rear pouch panel, Ih or rh - r r Complete with Op. 7045A25 Squab lumbar knob - r r Complete with Op. 7045A10 L/h or r/h front seat (one) r+r - 7045A86 - TRIM OF FRONT SEAT CUSHION, LH OR RH, - R R WITH SEAT REMOVED 1b ,1a Removal Follow the Op. 7045M10 Front seat heating system switch - r+r - Follow the Op. 7045A43 Seat exterior guard - r r 1. Unscrew bolts (1a) retaining switch unit (1b) and move it to one side. Installation - Examine the trim to check it is in good condi¬ tion. Fit the trim and secure to the front part of the trim using new fasteners. 1b / ES Description Code Stapler 1.878.017.001 Fit the trim to the padding. Position the upper trim section. Position the side trim sections. Mould the trim by hand. Position the lower section and secure using new fasteners. ES Description Code Stapler 1.878.017.001 / % O 1a 1a Fit the head retaining pin bushes. Complete with Op. 7045B10 seat head restraint - r+r L/h or r/h front Complete with Op. 7045A98 Front seat rear pouch panel, Ih or rh - r r Complete with Op. 7045A25 Squab lumbar knob - r r 8 PA5106/00 06/1998 REPAIR PROCEDURES Front seats rC 7045 j I.Undo the side rods securing the trim at both sides. 1 2 ©o A L — - 1a W °Q no h W ° jfli r / on a 1b tiOMtftfH /H16-/ O 71 /<ÿ Fold down the seats. 1 . Cut the front and rear trim fasteners. 2. Raise the trim. tttmniMtV AUX/f 2 1 .o 3 1 o w Aon <.'«*€ l/> 3 3 I© *ÿ 1. Cut the rear fasteners retaining the trim to the padding. 2. Fold back the trim and cut the front and side fasteners retaining the trim to the padding. 3. Separate the trim from the padding. 2 'u p \ 2 \ l 2 ,// l y i.tumramv A & © O 3a seat 1-2 it 2 r K Installation Ira (fl I/O Installation - - a Check the motor is in good condition, connect the electrical connection and ensure it is working properly. Fit the motor and tighten both retaining bolts. Fit a new antivibration collar and connect the electrical wiring. Check the seat is working properly. Complete with Op. 7045A10 L/h or r/h front seat (one) - r+r - Check the motor is in good condition, connect the electrical connection and ensure it is - Fit the motor and tighten both retaining bolts. Fit a new antivibration collar and connect the electrical wiring. Check the seat is working properly. Complete with Op. 7045A10 L/h or r/h front seat (one) - r+r - working properly. 7045J49 - REDUCTION MECHA¬ NISM FOR FRONT SEAT CUSHION REAR LIFT MOTOR, LH OR RH R R Removal Follow the Op. 7045A10 L/h or r/h front seat (one) - r+r Follow the Op. 7045M10 Front seat heating system switch - r+r Follow the Op. 7045A43 Seat exterior guard - r r I.Cut collar (1a) and disconnect lift motor elec¬ trical connection (1b). PA5106/00 06/1998 19 REPAIR PROCEDURES 7045 2. Unscrew fastenings (2a) securing the drive gear unit to the guide and the guide to the seat frame. Recover washer (2b). 3. Take off the retaining ring on the vertical slide pin. 4. Remove guide/plate assembly (4a) by taking shaft (4b) out of its fitting on the plate and remove motor/drive gear unit (4c). 2b 2a 4a 0 3 o laO IV Check the unit is working properly at the bench using an appropriate electrical supply system. Complete with Op. 7045A43 Seat exterior guard -rr Complete with Op. 7045M10 Front seat heating system switch L/h or r/h front 7045J54 - REDUCTION MECHA¬ NISM FOR LIFTING FRONT PART OF CUSHION AND SLIDING FRONT SEAT, LH OR RH, - R R FOLLOWING ELEC¬ TRICAL CHECK - 4b 4c 1b - r+r Complete with Op. 7045A10 seat (one) - r+r Removal 2a $ Follow the Op. 7045A10 L/h or r/h front seat (one) - r+r I.Cut connection collar (1a) and disconnect lift and slide motor electrical connections (1b). 2. Unscrew fastenings securing the drive gear unit to the guide and the guide to the seat frame. 3. Take off the retaining ring on the vertical slide pin. 4. Remove guide/plate assembly (4a) together with motor/drive gear unit (4b) by withdrawing idler shaft (4c) from control shaft (4d). 4a 2a hi b 3 Position the motor/drive gear unit on a work bench. 1. Unscrew the bolts. 2. Remove the motor from the drive gear unit. 4J c as 0/ 0 « 0 o 1a [0 C| 2 \ a Front seats PfflD— CD J Oj e Id 1b X ,\i 2 li 1 0, ol Installation - - - 20 Position the motor and refit the guide and plate by connecting them together as a unit. Tighten the fasteners securing the drive gear unit to the guide and the guide to the seat Place the motor/drive gear unit on a work bench. I.Use a rubber mallet to remove the pinion from the control unit. 2. Unscrew bolts (2a) and remove motors (2b) from the drive gear unit. frame. Secure the retaining ring to the vertical slide pin. Fit the new collar and connect the lift motor electrical connection. PA5106/00 06/1998 REPAIR PROCEDURES Front seats Hf J 7045 1 2a m 3l R 2< 2b Installation - - - Check the motors and drive gear are in good condition. Fit the motor and tighten the retaining bolts. Fit the idler shaft. Position the control/motor assembly, then fit the plate/guide assembly and drive home using the rubber mallet. Tighten the fastenings securing the drive gear unit to the guide and the guide to the seat frame. Fit a seeger to the vertical slide pin. Fit a new collar and connect the motor supply connectors. Check the unit is working properly using an appropriate electrical supply system. Complete with Op. 7045A10 L/h or r/h front seat (one) - r+r PA5106/00 06/1998 21 REPAIR PROCEDURES Front seats 7045 rC j 7045M - Front seat handling VIEW OF ASSEMBLY 1 Ref. Description 1 FRONT SEAT HEATER SWITCH Operations index Code Operation Validity 7045M10 Front seat heating system switch - r+r WARNINGS OPERATIONS Use care when working on trim components and use the specified tools correctly in order to avoid damage. 7045M10 - FRONT SEAT HEATING SYSTEM SWITCH R +R PRECAUTIONS DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). 22 - Removal 1. Working from the lower part of the side cover, take the button out of its seat. 2. Disconnect the electrical connection from the button and remove the button. PA5106/00 06/1998 REPAIR PROCEDURES Front seats rC j IDescription 2 7045 Connector Left seat connection D70 \Description Connector Right seat connection D71 1 u (J Installation - - - Check the button is in good condition. Connect the connector to the switch and check it is working properly. Fit the button in its seat. With the ignition key in the stop position, connect the battery negative terminal. PA5106/00 06/1998 [[alHlCZJl, 23 REPAIR PROCEDURES 7045 24 Front seats rC J PA5106/00 06/1998 REPAIR PROCEDURES 0 Rear seats 7050 Sub-group index - SUB-GROUP GRAPHIC INDEX Assembly drawings index Cmp Description 7050A Rear seat assembly 7050B Rear seat head restraint/arm rest Validity SUB-GROUP GRAPHIC INDEX ,2 Ref. Description Cmp 1 Rear seat assembly 7050A 2 Rear seat head restraint/arm rest 7050B PA5106/00 06/1998 1 1 REPAIR PROCEDURES Rear seats 7050 W7 j 7050A - Rear seat assembly VIEW OF ASSEMBLY 4 2 ] D a u 0 5 (0. 3 Msmaimv/nw t-o Ref. Description 1 REAR SEAT ASSEMBLY 2 REAR SEAT SQUAB 3 REAR SEAT CUSHION 4 REAR SEAT SQUAB TRIM 5 REAR SEAT CUSHION TRIM A cnutm Operations index Code Operation Validity 7050A10 Rear seat - r+r 7050A19 Rear seat squab - r r 7050A20 One-piece rear seat cushion - r r 7050A24 Rear seat squab trim - r+r with squab removed 7050A27 Rear seat squab trim - r r 7050A28 Rear seat cushion trim - r+r with cushion removed 2 o, PA5106/00 06/1998 REPAIR PROCEDURES Rear seats rC 7050 J Code Operation 7050A29 Rear seat cushion trim - r r Validity WARNINGS Use care when working on trim components and use the specified tools correctly in order to avoid damage. Always check that unwoven cloth is present between trim and padding.After fitting a trim section, carefully mould the trim to fit the padding. 3 2 PRECAUTIONS DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). i 2 4 OPERATIONS 7050A10 - REAR SEAT - R + R \ 3)- ,7° 1 ipi i (CP Removal Follow the Op. 7050A20 One-piece rear seat cushion - r r Follow the Op. 7050A19 Rear seat squab - r r Installation Complete with Op. 7050A19 Rear seat squab rr Complete with Op. 7050A20 One-piece rear seat cushion - r r 7050A19 - REAR SEAT SQUAB R R Removal Follow the Op. 7050A20 One-piece rear seat cushion - r r 1. Unscrew the lower bolts retaining the squab to the body. 2. Move the rear seat belts aside. 3. Pull up the squab and release the upper retaining clips. 4. Remove the squab. PA5106/00 06/1998 Installation - - Check that the squab is undamaged. Fit the squab and ensure the fasteners fit prop¬ erly. Tighten both lower bolts retaining the squab to the body. Complete with Op. 7050A20 One-piece rear seat cushion - r r 7050A20 - ONE-PIECE REAR SEAT CUSHION - R R Removal 1. Raise the upper part of the cushion by releasing fasteners (1a) from their seats (1b). 2. Withdraw the cushion from the lower fasten¬ ings. 3. Remove the cushion from the passenger compartment. 3 REPAIR PROCEDURES Rear seats 7050 rC J .1 r. 3 3 2 _ l l ePHa 1b. 2 1a P N 2 1b Installation - - Check that the cushion is undamaged. Position the cushion and check that the fasteners are engaged and secured. 2 7050A24 - REAR SEAT SQUAB TRIM - R + R WITH SQUAB REMOVED Take the trim off the padding. 1. Cut the trim fasteners from the front part of the padding. 2. Remove the trim from the padding. 1 Removal Follow the Op. 7050B18 Rear seat arm rest - r+r I.Cut the fasteners retaining the trim to the padding. 2. Withdraw the metal wire in three sections from c the trim. 1 / 1 /0 0« /) 1 2 Installation - Position the trim and use the appropriate tool to clench from the front. H Description Code Stapler 1.878.017.001 Position the metal rods in the rear of the trim and clench from the rear using the appropriate tool. 4 PA5106/00 06/1998 REPAIR PROCEDURES Rear seats rC 7050 J H Description Code Stapler 1.878.017.001 '1 1 O / 1 Mould the trim on the padding by hand. Complete with Op. 7050B18 Rear seat arm rest - r+r 1 7050A27 - REAR SEAT SQUAB TRIM - R R /A Removal Follow the Op. 7050A20 One-piece rear seat cushion - r r Follow the Op. 7050A19 Rear seat squab - r r Follow the Op. 7050B18 Rear seat arm rest - TA 1 r+r Follow the Op. 7050A24 Rear seat squab trim - r+r with squab removed Installation 2 3 V Complete with Op. 7050A24 Rear seat squab trim - r+r with squab removed Complete with Op. 7050B18 Rear seat arm rest - r+r 2 1 Complete with Op. 7050A19 Rear seat squab rr Complete with Op. 7050A20 One-piece rear seat cushion - r r 1 2 7050A28 - REAR SEAT CUSHION TRIM - R + R WITH CUSHION REMOVED Removal . 1 Cut the fasteners retaining the trim to the frame. 2. Detach the trim metal wire and withdraw. 3. Remove the trim from the padding. 1 Q 3 7 1. Cut the trim fasteners from the upper part of the padding. 2. Remove the trim from the padding. 1 2 / > 1 \ 1, S-k A V 1 1 1 PA5106/00 06/1998 5 REPAIR PROCEDURES Rear seats 7050 rC J Installation - Fit the trim and clench from the front using the appropriate tool. 13 - Description Code Stapler 1.878.017.001 Refit the metal wire and fit the trim on the padding, taking care to mould the trim. Clench from the front using the appropriate tool. □ Description Code Stapler 1.878.017.001 Mould the trim onto the padding by hand. 7050A29 - REAR SEAT CUSHION TRIM - R R Removal - Follow the Op. 7050A20 One-piece rear seat cushion - r r Follow the Op. 7050A19 Rear seat squab - r r Follow the Op. 7050A10 Rear seat - r+r Follow the Op. 7050A28 Rear seat cushion trim - r+r with cushion removed Installation Complete with Op. 7050A28 Rear seat cushion trim - r+r with cushion removed Complete with Op. 7050A10 Rear seat - r+r Complete with Op. 7050A19 Rear seat squab rr Complete with Op. 7050A20 One-piece rear seat cushion - r r 6 PA5106/00 06/1998 REPAIR PROCEDURES Rear seats 7050 j 7050B - Rear seat head restraint/arm rest VIEW OF ASSEMBLY 1 2 U a? fy — 3 a 4 \ /?ef. Description 1 REAR SEAT HEAD RESTRAINT 2 REAR HEAD RESTRAINT TRIM 3 REAR SEAT ARM REST 4 REAR SEAT ARM REST TRIM Operations index Code Validity Operation 7050B18 Rear seat arm rest - r+r 7050B22 Rear seat arm rest trim - r+r with arm rest removed WARNINGS PRECAUTIONS Use care when working on trim components and use the specified tools correctly in order to avoid DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). damage. Always check that unwoven cloth is present between trim and padding.After fitting a trim section, carefully mould the trim to fit the padding. PA5106/00 06/1998 7 REPAIR PROCEDURES a Rear seats 7050 7050B18 - REAR SEAT ARM REST - R+R 7050B22 - REAR SEAT ARM REST TRIM - R + R WITH ARM REST REMOVED Removal Removal OPERATIONS Follow the Op. 7050A20 One-piece rear seat cushion - r r Follow the Op. 7050A19 Rear seat squab - r r 1. Unscrew the bolts retaining the brackets to the 1. Unscrew bolts (1a) retaining armrest brackets (1b) to the squab and remove. seat. 2. Remove the armrest from the seat. ■) J ■) d o V2 r O ■> J, 1b 1a 3 1 o' Kj o 5 © 1. Pull up the trim attachment flaps. 2. Remove the trim flap fasteners. 3. Take the trim off the padding. 1 7 5 J. 5 Installation - Fit the armrest. - Tighten the bolts retaining the bracket to the / 1 seat. Complete with Op. 7050A19 Rear seat squab rr Complete with Op. 7050A20 One-piece rear seat cushion - r r 1 3 2 1 Installation - - - - Check that the trim is undamaged. Fit the trim on the padding, taking care to mould the trim into place. Fit new fasteners to the inner trim flaps. Fit the trim attachment flaps, taking care to ensure that the trim is properly moulded. Tighten the bolts retaining the brackets to the squab. 8 11 PA5106/00 06/1998 REPAIR PROCEDURES a Mouldings on protections 7055 Sub-group index - SUB-GROUP GRAPHIC INDEX Assembly drawings index Cmp Description 7055A Exterior mouldings 7055 B Exterior protections Validity SUB-GROUP GRAPHIC INDEX 1 2 Ref. Description Cmp 1 Exterior mouldings 7055A 2 Exterior protections 7055B PA5106/00 06/1998 1 REPAIR PROCEDURES Mouldings on protections 7055 rC j 7055A - Exterior mouldings VIEW OF ASSEMBLY 1 /5ÿ 7 6 a V, / / / 2 7, 7 7 7 7 8 9 3 5 D 4 ■ /?ef. Description 1 ROOF PANEL MOULDING 2 WINDSCREEN BASE TRIM 3 RADIATOR SHIELD 4 FRONT GRILLE-SIDE ELEMENT 5 FRONT GRILLE-CENTRAL ELEMENT 6 FRIEZE 7 ORNAMENT 8 ORNAMENT 9 MOULDING ON RAIL t'Ai'W M A .CHMI* Operations index Code Operation Validity 7055A10 Moulding on roof panel (one), l/h or r/h - r+r 7055A18 Windscreen base trim - r+r 2 PA5106/00 06/1998 REPAIR PROCEDURES a Mouldings on protections Operation Code 7055 Validity 7055A38 L/h or r/h rail moulding (door sill) - r+r 7055A40 Radiator shield - r r 7055A41 Front grille(one) - r r 7055A43 Central front grille - r r 7055A50 Frieze, hinge cover or code (one) - r+r 7055A80 Rear ornament - r r 7055A84 Front ornament - r r WARNINGS Installation Use care when working on trim components and use the specified tools correctly in order to avoid damage. DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). OPERATIONS - Check that the clips are undamaged and fit properly into the moulding or body. - Check that the moulding is undamaged. - Fit the moulding to the roof panel. 7055A18 - WINDSCREEN BASE TRIM - R + R Removal Follow the Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r 1. Unscrew the bolts retaining the grille covering the base of the windscreen. 2. Lift the base cover to gain access to the washer pump water pipe. 3. Disconnect the washer pump pipe from the connector, then remove the cover together with the seal. 7055A10 - MOULDING ON ROOF PANEL (ONE), L/H OR R / H - R+R Removal 1. Prise the moulding away from the rear and central retaining clips. 2. Prise the moulding away from the front retaining clips. 3. Remove the moulding. 1 1 a 2 K; 3 1 3r 0 ( o #> ' // Installation - i 2 & PA5106/00 06/1998 - Fit the seal to the grille, then position the grille and seal on the car. Connect the windscreen washer pipe and check the sprays are working properly Tighten the grille retaining bolts. Complete with Op. 5050B34 Windscreen wiper arm/s complete with blade - r+r 3 REPAIR PROCEDURES 7055 a Mouldings on protections 7055A38 - L/H OR R/H RAIL MOULDING (DOOR SILL) - R + R 1b Removal - Place the car on a lift. Raise the lift. 1. Unscrew the bolts retaining the moulding to the body. 2. Undo the stud retaining the front wheel arch to the moulding. □ MkJDescription Blade tp Code 1.823.015.000 3. Detach moulding (3a) from fasteners (3b). cp 1a 7 3b 2 Installation - 3a Fit the shield. Tighten the retaining bolts to the bonnet. Close the bonnet lid. 7055A41 - FRONT GRILLE(ONE) - R R Removal - Installation - - Check that the rail moulding is undamaged. Position the moulding. Check that the fasteners are properly fitted in the pins on the car. Fit the moulding into the retainer on the rear wheel arch. Do up the stud retaining the moulding to the front wheel arch. Tighten the retaining bolts. Follow the Op. 7055A43 Central front grille - r r 1. Unscrew the grille retaining bolts. 2. Withdraw the grille towards the catch and remove /. 7055A40 - RADIATOR SHIELD R R 9 3 / Removal - Open the bonnet lid. 1. Unscrew bolts (1a) and remove radiator shield (1b). C 1 2 Installation - - 4 Refit the grille in its seat by pushing into the catch area and then pushing toward the lighting unit. Tighten the grille retaining bolts. Complete with Op. 7055A43 Central front grille -rr PA5106/00 06/1998 REPAIR PROCEDURES Mouldings on protections Hf 7055 j 7055A43 - CENTRAL FRONT GRILLE - R R 2 Removal - Open the bonnet lid. 1. Unscrew the griile retaining bolts. 2. Remove the central grille. % r 1 L 4Z d/ÿ & r :r Installation - Clean the panel surface using heptane. 1. Place adhesive tape over the new wording in order to ensure the wording component centre lines are aligned. Z* 1 1 5 § T Installation - Refit the grille in its seat. Tighten the grille retaining bolts. Close the bonnet lid. 7055A50 - FRIEZE, HINGE COVER OR CODE (ONE) - R+R Removal 1 . Before removing the wording, it is advisable to indicate the position in which it was fitted. To do this, use adhesive tape to create fitting refer¬ ence marks. 1 1. Remove the protective backing film and apply the wording. Locate with reference to the marks made previously. 2. Remove the adhesive tape. 2 1. Slightly heat the wording using a suitable blower. 2. Remove the wording using a plastic spatula. /ÿS PA5106/00 06/1998 5 REPAIR PROCEDURES 7055 7055A80 - REAR ORNAMENT R R Installation - - Removal I.Open the boot lid and remove the trim retaining studs. - 1 - 1 ?! o m Mouldings on protections V \ -1 0 7055A84 - FRONT ORNAMENT R R Removal - o Ensure the lock barrel and crest are undamaged. Fit the retaining clip into its seat. Fit the lock barrel into its seat until the groove engages with the retaining clips. Fit the lock barrel assembly and secure using two new self-tapping screws. Connect the catch link. Test the lock barrel to ensure it works properly. Refit the inner trim and secure by means of studs. V Open the bonnet lid. 1. Unscrew nuts retaining shield frame (1b) and remove together with the crest. 2. Remove crest retaining clips (2a), then detach crest (2b) from the frame. 2b 1. Lower the interior trim and disconnect the link from the lock barrel. 1b ,1 <5 2a „o; 1a I.Turn crest (1a) and prise out both plugs (1b) protecting the retaining bolts. 2. Use a drift to unscrew both self-tapping screws (2a) securing crest (2b) and remove. Installation - - 1a VI £ < n coinw Operations index Code Validity Operation 7055B10 Front bumpers - r+r PA5106/00 06/1998 BULB) 7 REPAIR PROCEDURES 7055 Code Mouldings on protections rC J Operation Validity 7055B14 Front bumpers, removed - strip - includes r+r parts 7055B18 Rear bumpers - r+r 7055B26 Cover (one) on bumpers - r+r 7055B28 Lh or rh reflector(one) on rear bumpers - r r 7055B39 Front additional wheel arch half (one), Ih or rh. front element - r r 7055B41 Front supplementary wheel arch half (one), Ih or rh, rear element r r 7055B42 Supplementary wheel arch (one) - r+r 7055B43 Rear supplementary wheel arch (one) - r+r 7055B54 Under-engine guard - r r 7055B70 Gasket and front wheel arch border - r r 7055B72 Gasket on rear wheel arch border - r r 7055B78 Absorbing buffer between rear bumpers and body - r r WARNINGS Use care when working on trim components and use the specified tools correctly in order to avoid damage. Take care to avoid any damage to body paintwork. PRECAUTIONS DISCONNECT THE BATTERY (before working on the electrical system (connectors, electrical compo¬ nents, wiring etc.). OPERATIONS 7055B10 - FRONT BUMPERS R+R Removal Follow the Op. 7055B39 Front additional wheel arch half (one), Ih or rh, front element - r r - Follow the Op. 7055A41 Front grille (one) - r r Follow the Op. 7055A43 Central front grille - r r - Disconnect the battery negative terminal. 1. Unscrew the bolts retaining the bumper to the beam. 2. Unscrew the bolts retaining the bumper to the body. 3. Disconnect the fog lamp electrical connection. IDescription 3 Data not yet available Connector D50 Lower the lift. 4. Unscrew the upper bolts securing the bumper to the body. 5. Remove the front bumper. 8 PA5106/00 06/1998 REPAIR PROCEDURES a Mouldings on protections MU! 7055 'v A 4 // 5 ,Y 71 c., WLJ fl 3 1 3 2 i, K i?a: Installation - - - Check that the bumper is undamaged. Fit the front bumper. Tighten the upper bolts retaining the bumper to the body. Raise the lift. Tighten the bolts retaining the bumper to the body and to the lower beam. Take care to keep it aligned with the wings. Connect the fog lamp electrical connection. Connect the battery negative terminal. Complete with Op. 705SA43 Central front grille -rr Complete with Op. 7055A41 Front grille(one) rr Complete with Op. 7055B39 Front additional wheel arch half (one), Ih or rh, front element - r r 7055B14 - FRONT BUMPERS, REMOVED - STRIP - INCLUDES R + R PARTS Removal - S Follow the Op. 5540D14 L/h or r/h fog lamp bulb (one) - r+r 1. Unscrew both retaining bolts (1a) and prise up retaining clip (1b) from the air intake - left handand right hand. Remove air intake (1c). PA5106/00 06/1998 1C o, 1a 'o •5 / 1b I.Use tool (1a) to prise out clips (1b) retaining the lower bumper grille. 2. Remove the grille. 9 REPAIR PROCEDURES 7055 n 1a a Mouldings on protections Description Code Blade 1.823.015.000 7055B18 - REAR BUMPERS R +R Removal - 2 H o 1b 1a □ 1. Unscrew retaining bolts (1a) and remove left and right reinforcements (1b) retaining the bumper to the wing. Follow the Op. 5530B54 Battery cover - r+r Follow the Op. 5540A94 L/h or r/h number plate light (one) - r+r Follow the Op. 5530B10 Battery - r+r Follow the Op. 5530B52 Battery cradle - r r Follow the Op. 7025B41 Boot lid lock Follow the Op. 7025B66 Boot compartment seal - r+r Follow the Op. 7040B22 Luggage compart¬ ment/load platform moulding - r+r Follow the Op. 7040B20 Back trim for luggage compartment/load platform - arrange Load platform Follow the Op. 7040B10 (luggage platform) trim - r+r Follow the Op. 7040B13 Load compartment/ load platform right side trim - r r Follow the Op. 7040B12 Load compartment/ load platform left side trim - r r 1. Unscrew the bolt retaining the rear wheel arch to the bumper.Carry out the same operation on both sides. 2. Move the wheel arch aside. \ 2 1b o O T :<§>o 1 1a 1. Working from the right hand side, unscrew retaining bolts (1a) and remove fuse carrier bracket (1b). Installation - - Check the condition of all components removed. Fit right and left reinforcements retaining the bumper to the wing. Fit the lower bumper grille, then fit new retaining clips. Tighten both retaining bolts and fit the right and left air intake retaining clip. Complete with Op. 5540D14 L/h or r/h fog lamp bulb (one) - r+r J==\ a. ra k-ÿ1b □ 1a rmmmfmv/nw 10 . >\ PA5106/00 06/1998 REPAIR PROCEDURES Mouldings on protections rC j 1. Working from the luggage compartment, unscrew the bolts retaining the bumper to the body. 7055 Complete with Op. 7025B66 ment seal - r+r Complete with Op. 7025B66 ment seal - r+r Boot compart¬ Boot compart¬ - Complete with Op. 5530B52 Battery cradle r r Complete with Op. 5530B10 Battery r+r Complete with Op. 5540A94 L/h or r/h number plate light (one) - r+r Complete with Op. 5530B54 Battery cover r+r - 105 - - 1 7055B26 - COVER (ONE) ON BUMPERS - R+R Removal I.Use cutter (1a) to remove cover (1b) from its seat. □ 1a 1. Unscrew the bumper retaining bolts. 2. Remove the rear bumper. . c Blade 1.823.014.000 □ a f Code 2. Release the retaining device and remove the cover. k \ Description Take care not to damage the bumper paint¬ work K ccS- 2 sf- iVh s Wt7/ r 2 & 1a 1 □ 1b y' Installation - Check that the bumper is undamaged. Fit the bumper. Ensure the number plate light wires pass through the holes in the bumper. Tighten the bolts retaining the bumper to the body. Ensure the bumper is aligned with the rear wing. Tighten the nuts retaining the fuse carrier bracket located on the right hand side of the luggage compartment. Fit the wheel arch protections and tighten the retaining bolts. Complete with Op. 7040B12 Load compart¬ ment/load platform left side trim - r r Complete with Op. 7040B13 Load compart¬ ment/load platform right side trim - r r Complete with Op. 7040B10 Load platform (luggage platform) trim - r+r Complete with Op. 7040B20 Back trim for luggage compartment/load platform - arrange Complete with Op. 7040B22 Luggage compart¬ ment/load platform moulding - r+r PA5106/00 06/1998 Installation - Check that the lid is undamaged. Fit the lid in its seat. 7055B28 - LH OR RH REFLECTOR (ONE) ON REAR BUMPERS - R R Removal 1. Release the inner retainer by pressing the reflector outward. 2. Remove the reflector. 11 REPAIR PROCEDURES Mouldings on protections 7055 j 7055B41 - FRONT SUPPLEMEN¬ TARY WHEEL ARCH HALF (ONE), LH OR RH, REAR ELEMENT R R Removal - 1 2 Place the car on a lift. Raise the car. 1. Unscrew the bolts retaining the rear wheel arch half to the body. 2. Undo the retaining stud. 3. Remove the rear wheel arch half. Installation - Check that the reflector is undamaged. Position the reflector in its seat and press home. 7055B39 - FRONT ADDITIONAL WHEEL ARCH HALF (ONE), LH OR RH, FRONT ELEMENT - R R vV3 2 o Removal Place the car on a lift. - Raise the car. 1. Unscrew the bolts retaining the front wheel arch half to the body. 2. Undo the fastening stud. 3. Remove the front wheel arch half. - - wl&l - K! riL i Refit the wheel arch half. Do up the connection stud. Tighten the retaining bolts to the body. Remove the car from the lift. Follow the Op. 7055B39 Front additional wheel arch half (one), Ih or rh, front element - r r Follow the Op. 7055B41 Front supplementary wheel arch half (one), Ih or rh, rear element r r ° Installation o Complete with Op. 7055B41 Front supplemen¬ tary wheel arch half (one), Ih or rh, rear element rr Complete with Op. 7055B39 Front additional wheel arch half (one), Ih or rh, front element r r O - Installation - .c Removal o o - O' 7055B42 - SUPPLEMENTARY WHEEL ARCH (ONE) - R+R 1 - o 1 Installation 3 i 3>o D O O Refit the wheel arch half. Do up the fastening stud. Tighten the retaining bolts to the body. Lower the car. Remove the car from the lift. 7055B43 - REAR SUPPLEMEN¬ TARY WHEEL ARCH (ONE) R+R Removal - - 12 Follow the Op. 4450B13 Rear wheels(2) r r Raise the car. PA5106/00 06/1998 r\ REPAIR PROCEDURES a Mouldings on protections 1. Unscrew the bolts retaining the wheel arch to the body. 2. Remove wheel arch (2a) by withdrawing from rear connector (2b) with the rail moulding. 7055 Installation - Fit the under-engine protection/guard and secure using the appropriate bolts. 7055B70 - GASKET AND FRONT WHEEL ARCH BORDER - R R Removal - 2a Follow the Op. 7055B42 Supplementary wheel arch (one) - r+r 1. Remove seal around the edge of the wing. 1 tM O 1 O :m o “2b Installation - Refit the wheel arch. Check it is undamaged and take care to ensure it is fitted to the rail moulding. Tightening the retaining bolts to the body. Lower the car. Complete with Op. 4450B13 Rear wheels(2) r r 7055B54 - UNDER-ENGINE GUARD - R R 0 o O tatwmmv/ow/.. tt. . Installation - Removal - O Place the car on a lift. 1. Unscrew bolts (1a) and remove under-engine protection/guard (1b). Check the seal is in one piece. Fit the seal around the edge of the wing. Complete with Op. 7055B42 Supplementary wheel arch (one) - r+r 7055B72 - GASKET ON REAR WHEEL ARCH BORDER - R R Removal - o o Move the wheel arch protection aside. 1. Remove the seal from the wheel arch. »1a - i r T, rf'/ 1b PA5106/00 06/1998 13 REPAIR PROCEDURES Mouldings on protections 7055 rC J 7 2 1 e O \v ; 1 0 □ Installation Refit the seal. Fit the wheel arch protection. - 7055B78 - ABSORBING BUFFER BETWEEN REAR BUMPERS AND BODY - R R Follow the Op. 5530B54 Battery cover - r+r Follow the Op. 5540A94 L/h or r/h number plate light (one) - r+r Follow the Op. 5530B10 Battery - r+r Follow the Op. 5530B52 Battery cradle r r Follow the Op. 7025B66 Boot compartment - - - seal - r+r Follow the Op. 7040B22 Luggage compart¬ ment/load platform moulding - r+r Follow the Op. 7040B20 Back trim for luggage compartment/load platform - arrange Load platform Follow the Op. 7040B10 (luggage platform) trim r+r - Follow the Op. 7040B13 Load compartment/ load platform right side trim r r Follow the Op. 7040B12 Load compartment/ load platform left side trim - r r Follow the Op. 7055B18 Rear bumpers - r+r 1. Use cutter (1a) to remove studs (1b). - - Check the absorption block is in good conditon. Refit the block. Refit the retaining studs. Complete with Op. 7055B18 Rear bumpers - r+r Complete with Op. 7040B12 Load compart¬ Complete with Op. 7040B13 Load compart¬ ment/load platform left side trim - r r ment/load platform right side trim - r r Removal - 1b 1a O Installation - © - Complete with Op. 7040B10 Load platform (luggage platform) trim - r+r Complete with Op. 7040B20 Back trim for luggage compartment/load platform - arrange Complete with Op. 7040B22 Luggage compart¬ ment/load platform moulding r+r Complete with Op. 7025B66 Boot compart¬ - ment seal - r+r Complete with Op. 5530B52 Battery cradle - r r Complete with Op. 5530B10 Battery r+r Complete with Op. 5540A94 L/h or r/h number - plate light (one) - r+r Complete with Op. 5530B54 Battery cover - r+r - H Description Code 1a Blade 1.823.015.000 2. Remove the impact absorption block. 14 PA5106/00 06/1998 REPAIR PROCEDURES 0 Safety belts and accessories 7065 Sub-group index - SUB-GROUP GRAPHIC INDEX Assembly drawings index Cmp Description 7065A Front safety belts 7065B Rear safety belts 7065C Accessories and decorations Validity SUB-GROUP GRAPHIC INDEX 3 2 1 Ref. Description Cmp 1 Front safety belts 7065A 2 Rear safety belts 7065B 3 Accessories and decorations 7065C PA5106/00 06/1998 1 REPAIR PROCEDURES 7065 Safety belts and accessories rC J 7065A - Front safety belts VIEW OF ASSEMBLY .3 40\ r*\ 1 2 4 Ref. Description 1 FRONT SAFETY BELT 2 FRONT SEAT BELT LINK 3 FRONT SAFETY BELT HEIGHT ADJUSTMENT 4 FRONT BELT PRETENSIONER ECU LEAD/S Operations index Code Operation Validity 7065A12 Front seat belt (one). Ih or rh, with pretensioner on wheel - r r 7065A14 L/h or r/h front safety belt (one) - r+r 7065A18 L/h or r/h front safety belt height regulator - r+r 2 PA5106/00 06/1998 REPAIR PROCEDURES rC Safety belts and accessories J WARNINGS Front seat belts with preten¬ sioners. The front seat belts with pyrotechnic pretensioners form an integral part of the AIR BAG system. When carrying out operations involving the preten¬ sioners, take great care to observe the safety rules described for the Air Bag system (5580C) - with the following exceptions. SAFETY RULES FOR HANDLING PRETEN¬ SIONERS The front seat belts with pyrotechnic pretensioners are an integral part of the AIR BAG system When carrying out operations involving the preten¬ sioners, take great care to observe the safety rules described for the Air Bag system (5580C) - with the following exceptions. The following rules MUST be observed to ensure the safety of operators and to prevent damage to the seat belt and pretensioner unit. - Do not move the pretensioner by the pipe. - Do not move the the pretensioner by the belt. - Do not tamper with or carry out repairs on the pretensioner. Send all defective pretensioners to the manufacturer. - Do not subject the pretensioners to percussion, drilling, machining or heating due to welding. - Do not allow the unit to drop or subject to impact. Pretensioners that have been dropped from a height greater than 1 metre must not be used but sent back to the manufacturer. - When repairs to the car require temporary removal of the unit, place it in a locked steel cabinet that meets legal requirements for the storage of pyrotechnic charges. - Do not expose the device to naked flames, fluids, solvents or lubricants and do not expose to temperatures higher than 110°C.The gas generator may ignite spontaneously at tempera¬ tures higher than 180°C. - When handling a device that has been activated, use gloves and protective goggles. - If the device has been activated, ALWAYS wait at least 30 minutes after activation before carrying out any work on the device. - Wash your hands with soap and water after handling the device. In the case of exceptional atmospheric events (e.g. floods, high tides etc.), if water or mud levels rise high enough to reach device compo¬ nents, the device must be replaced.The preten¬ sioner does not require any maintenance and must not be lubricated under any circumstances. Unit efficiency will be affected if any attempt is made to alter its original condition.Units shipped by road must be carried in the luggage compart¬ - - ment. - If a pretensioner does not go off during an acci¬ dent, it should be considered still active. Preten¬ sioners that fail to explode due to defects, because they are out of warranty or for other reasons and therefore require replacement must be changed (complete unit) at the appropriate centre using the procedure described for Air Bag modules (See assembly See assembly drawing 5580C Air bag system 5580C BAG). WORKING ON THE BODY Do not subject the area around the pretensioner (60 - 70 cm in radius) to high impact loads while working on the body (e.g. use of a hammer). Remove the unit if necessaiy. When using radiant lamps in the area surrounding the pretensioner during painting operations - or when carrying out welding or brasing work remove the inertia reel - pretensioner unit. OPERATIONS 7065A12 - FRONT SEAT BELT (ONE), LH OR RH, WITH PRETENSIONER ON WHEEL - R R WARNING: before removing and refitting preten¬ sioners the following operations must be carried out: - Turn the key to STOP and remove. - Disconnect the battery leads and insulate. - Wait for 10 minutes before continuing. - OBSERVE ALL SPECIFIED SAFETY RULES (see 7065A - Precautions) Removal Follow the Op. 7040H36 Central trim lower element - r r Follow the Op. 7040H38 Central pillar upper element - r r Follow the Op. 7040H34 Central pillar trim - r r 1. Unscrew the upper nut retaining the seat belt height adjustment device. 2. Unscrew bolts (2a) retaining the bracket (2b). 3. Disconnect the pretensioner device electrical connection. 3 PA5106/00 06/1998 7065 \ Description Connector Driver’s seat belt pre-tensioner Q20 3 REPAIR PROCEDURES Safety belts and accessories 7065 3 iDescription Connector Front passenger seat belt pre¬ tensioner 021 rC j 3bO 3a 4. Unscrew the reel retaining bolt. 5. Remove the seat belt with the pretensioner. Replace the pretensioner in the special cabinet. Place it carefully on a free surface. 5a 5 1 5b 2b S2, 4 L-*' 5 02 2a ?D i 4 5 Removal Handle the pretensioner with extreme care.Ensure the battery is disconnected. 2. Tighten the bolt to the specified torque. 2 Check the belt slides freely. Complete with Op. 7040H34 Central pillar trim -rr Complete with Op. 7040H38 Central pillar upper element - r r Complete with Op. 7040H36 Central trim lower element - r r 7065A14 - L/H OR R/H FRONT SAFETY BELT (ONE) - R + R Installation 1. Refit the pretensioner. o 1 Mounting Component 0 Value (daNm) Screw FRONT SEAT BELT REEL 7/ 4 Follow the Op. 7045A10 L/h or r/h front seat (one) - r+r 1. Remove the protective cap. 2. Unscrew bolt (2a) retaining the link to the seat. - Cut the collars retaining the seat belt unfastened warning light wiring.Carry out this operation only on the driver's seat. 3. Remove the seat belt anchorage link. 16“ 3. Fit the seat belt gear unit (3a) and tighten nut (3b) to the specified torque. 4. Connect the electrical connection. 5. Fit retaining bracket (5a) and tighten both retaining bolts (5b). 4 PA5106/00 06/1998 r*> REPAIR PROCEDURES 0 Safety belts and accessories 7065 i 3 L 2 G o 2 or «?n 1 1. Unscrew the height adjustment device retaining bolts. 2. Remove the device. Installation - - Refit the anchorage link. Fit the electrical wiring and connect the elec¬ trical connector. Ensure the warning light is working properly. Tighten the link retaining bolt to torque. Fit the protective cap. Complete with Op. 7045A10 L/h or r/h front seat (one) - r+r \ 7065A18 - L/H OR R/H FRONT SAFETY BELT HEIGHT REGU¬ LATOR - R + R /5£v o 1 Removal Follow the Op. 7040H36 Central trim lower element - r r Follow the Op. 7040H38 Central pillar upper element - r r Follow the Op. 7040H34 Central pillar trim - r r 1. Unscrew the upper nut retaining the seat belt to the height adjustment device. 2. Move the belt to one side. 21 w 0 0 Installation - Fit the height adjustment device. Tighten the retaining bolts to the specified - Tighten the upper nut securing the seat belt to the height adjustment device to the specified torque. torque. Complete with Op. 7040H34 Central pillar trim -rr Complete with Op. 7040H38 Central pillar upper element - r r Complete with Op. 7040H36 Central trim lower element - r r PA5106/00 06/1998 5 REPAIR PROCEDURES 7065 Safety belts and accessories rC J 7065B - Rear safety belts VIEW OF ASSEMBLY ft 1 2 Ref. Description 1 REAR SAFETY BELT 2 CENTRAL REAR SAFETY BELT LINK Operations index Code Operation Validity 7065B10 L/h or r/h rear safety belt (one) - r+r 7065B14 L/h or r/h rear safety belt anchorage link - r+r 7065B18 Central rear safety belt - r+r 7065B22 Central safety belt anchorage link - r+r 7065B40 Bracket for rear seat belt wheel (one) Ih or rh - r r WARNINGS Use care when working on trim components and use the specified tools correctly in order to avoid damage. 6 PA5106/00 06/1998 REPAIR PROCEDURES a Safety belts and accessories PRECAUTIONS If the seat belt has been subjected to great stress, e.g. following an accident, it must be replaced together with its anchorages and retaining bolts. Even if the seat belt does not show signs of visible defects, it may have lost its resistent properties. 7065 72 £ 1 OPERATIONS 7065B10 - L/H OR R/H REAR SAFETY BELT (ONE) - R + R - Carry out op. 7050A20 One-piece rear seat cushion - r r - Carry out op. 7050A19 Rear seat squab - r r Carry out op. 7040H42 Rear pillar trim - r r Carry out op. 7040 H 84 1. Unscrew the lower belt retaining bolt. 2. Unscrew the reel retaining bolt. 3. Remove the rear safety belt. M i B Complete with Op. 7040H84 Parcel rack plus speaker - r r Complete with Op. 7040H42 Rear pillar trim - r r Complete with Op. 7050A19 Rear seat squab rr Complete with Op. 7050A20 One-piece rear seat cushion - r r u A • r& 3-4 6 Do not attempt to remove the plate from the glass because the glass could be damaged. Installation 1 . Remove any traces of adhesive from the plate. 2. Thoroughly degrease the mating surfaces between plate and glass using disposable paper and heptane. 3. Remove any adhesive traces from the wind¬ screen glass. 4. Thoroughly degrease mating surfaces between glass and plate using disposable paper and heptane. 5. Apply a sufficiently long strip of double-sided adhesive tape to the plate. r*\ PA5106/00 06/1998 13 REPAIR PROCEDURES 7065 Safety belts and accessories a r\ r r 14 PA5106/00 06/1998 REPAIR PROCEDURES Body panels - replacement and repair 7090 J Sub-group index - -SYMBOLS - PROCESSING SYMBOLS SUB-GROUP GRAPHIC INDEX - WARNINGS Assembly drawings index Cmp Description 7090A Body panel replacement 7090G Replacement elements Validity SUB-GROUP GRAPHIC INDEX £ V' m f jfih 1 (c| // 7/ B (cl 2 Ref. Description Cmp 1 Body panel replacement 7090A 2 Replacement elements 7090G r*\ PA5106/03 10/1998 1 REPAIR PROCEDURES 0 Body panels - replacement and repair 7090 WARNINGS The graphic index and the description of the sym¬ bols appearing in the repair procedures are given below. SYMBOLS 8 9 4 3 2 t+> 10 5 6 7 12 13 14 19 20 21 • 15 16 17 22 23 24 0 18 25 '/ £ 1. Cut with hack-sawing machine 2. Cut with circular saw 3. Clean with rotary brush 4. Remove spot welds with spot weld remover 5. Remove spot welds with drill. Drilling for MIG welding 6. Chiselling metal panel. Drilling for MIG welding 7. Application of electro-weldable protection 8 Application of thick electro-weldable protection 9 Centring components 10. Measurement 11. Fixing components 1 2. Fixing threaded rivets 1 3. Checking alignment gaps 14. Straightening edges with profiled stake and hammer 1 5. Removing weld spots with chisel and hammer 1 6. Removing treatment with pneumatic knife 1 7. Spot welding 18. MIG welding 1 9. Welding with oxyacetylene torch 20. Grinding 21. Application of anti-corrosion protection 22. Application of sealants 23. Application of underbody protections 24. Application of paints 25. Application of wax-based protection 26. Application of foam products K PROCESSING SYMBOLS The symbols are given below of the work tasks which are described in the repair procedures with an example of application. In the descriptions of the procedures, beside the progressive number of the steps of the procedure relating to welding tasks, there may be numbers in brackets which indicate the number of spot welds to be made or to be filled by MIG welding. Cut made by hack saw or pneumatic chisel A & \N.. 3 kC • » ..VOXAUf n 2 PA5106/03 10/1998 REPAIR PROCEDURES repair Body panels - replacement and El Brazing Spot welding X % 7090 TOM! PS § / 0 V V MIG fill welding Spot welding (three panels) ®®®®®® -I II / r 0 r Jl 1=&SQ) r/ \ Sealing welding Continuous - sectional MIG jnrmnnnl E \ E In * / 3. 3 PA5106/03 10/1998 REPAIR PROCEDURES Body panels - replacement and repair 7090 7090A - rC J Body panel replacement VIEW OF ASSEMBLY 4 3 2 1 X x\v-- f M: m 6 5 i I *- a XsN mV 8 7 4-v t. W ."/EL LiH Wb 0 // §# \\ ///& Ref Description 1 BONNET LID 2 BOOT LID 3 FRONT SIDE DOOR 4 REAR SIDE DOOR 5 FRONT WING 6 LEFT REAR WING 7 RIGHT REAR WING 8 ROOF PANEL Operations index Code Operation Validity 7090A10 Bonnet lid - r+r and adaptation for replacement 7090A14 Boot lid - r+r and adaptation for replacement 7090A26 L/h or r/h front side door (one) - r+r and adaptation _ for replacement _ 7090A34 L/h or r/h rear side door (one) - r+r and adaptation for _replacement _ 7090A50 L/h or r/h front wing (one) - r+r and adaptation for _replacement _ _ 7090A55 Left hand rear wing -r + r and adapt for replacement 7090A56 Right hand rear wing -r + r and adapt for replacement 7090A58 Roof panel - r+r and adaptation for replacement 4 PA5106/03 10/1998 REPAIR PROCEDURES El Body panels - replacement and repair 7090 OPERATIONS t 7090A10 - BONNET LID - R + R AND ADAPTATION FOR REPLACEMENT ■ V-1 ii Removal - - <-ÿ Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (e.g. gauges). Straighten the body if necessary. Remove the bonnet lid from the car. 2 2 c 7? 7A / \rivÿ 1. Seal the bonnet lid in the areas indicated in the figure (use specified procedure). Paint the bonnet lid (use specified procedure). §1 1 tStOOCOHV 79021 » J\ Installation Fit the part on the stand and fit the catch. 1. Fit the part on the car provisionally and secure without tightening the retaining bolts. Check it is properly adjusted. 2. Remove the bonnet lid from its seat by unscrewing the bolts indicated. Note: Remove the catch from the bonnet lid. - - xm \\ l\ Refit the bonnet lid to the car. 7090A14 - BOOT LID - R+R AND ADAPTATION FOR REPLACE¬ MENT Removal - - PA5106/03 10/1998 Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (e.g. gauges). Straighten the body if necessary. Remove the bonnet lid from the car. 5 REPAIR PROCEDURES Body panels 7090 - El replacement and repair r*s 1 6%?- g|g •«5)| 2) A !! ft iv >XS $ 77, 7/\ 1 1 Refit the bonnet lid to the car. Installation Fit the part to a stand and fit the catch and buffer blocks. 1 . Fit the part to the car and secure without tight¬ ening the retaining bolts. - Adjust boot lid position. 2. Remove the boot lid from its seat by unscrewing the bolts indicated. Note: Remove the catch and buffer blocks from the boot lid. - 7090A26 - L/H OR R/H FRONT SIDE DOOR (ONE) - R + R AND ADAPTATION FOR REPLACE¬ MENT Removal - - Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (e.g. gauges). Straighten the body if necessary. Remove the front side door from the car. 1 EEE35 rs \ it' >0' fo' mg. 2 I.Seal the boot lid in the areas shown in the figure. Paint the boot lid (use the specified procedure). . iMmcorti/noi? to. Installation - 6 Fit the part on a stand and fit the door limiter, catch and handle. 1. Fit the door to the car and secure without tight¬ ening the retaining bolts. PA5106/03 10/1998 rs REPAIR PROCEDURES a Body panels - replacement and repair 7090 Adjust door position. Fit shims between the hinge and pillar if necessary to ensure the door is adjusted properly 2. Remove the door from the car by unscrewing the retaining bolts. Remove the catch, door limiter and handle from the door. - Note: t i 1 >i o A ; Oh 2 or 9 o 0C 777 /\\ I.Seal the front door in the area indicated in the figure. Paint the front door (use the specified cycle). Refit the front side door to the car. 7090A34 - L/H OR R/H REAR SIDE DOOR (ONE) - R+R AND ADAPTATION FOR REPLACE¬ MENT Removal - Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (e.g. gauges). - Straighten the body if necessary. Remove the rear side door from the car. IN 7 Pre¬ installation - PA5106/03 10/1998 Fit the part on a stand and fit the door limiter, catch and handle. 1 . Fit the door to the car and secure without tight¬ ening the retaining bolts. 7 REPAIR PROCEDURES Body panels - replacement and repair 7090 rC J - Adjust door position. Note: Fit shims between the hinge and pillar if necessary to ensure the door is adjusted properly 2. Remove the door from the car by unscrewing the retaining bolts. - Remove the catch, door limiter and handle from the door. t I I j m \ 1 2 \ % / 1 . Seal the rear door in the area indicated in the figure. Paint the rear door (use the specified cycle). 1 U 1 1 Refit the rear side door to the car. 7090A50 - L/H OR R/H FRONT WING (ONE) - R+R AND ADAP¬ TATION FOR REPLACEMENT Removal - - Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (ref¬ erence rigs, templates or gauges). Straighten the body if necessary. j#’ / L tMoautn rnnr _t» nr _ASOUOII 1. Lift the bonnet lid. 2. Open the front door. 3. Protect the area beneath the windscreen pillar using adhesive tape. 4. Remove the PVC treatment between front pillar and wing using a vibrating cutter and appro¬ priate blade. 8 PA5106I03 10/1998 REPAIR PROCEDURES El Body panels - replacement and repair 7090 5. Heat and then use an appropriate blade to cut the sealant between front pillar and wing. t J '/ 1 fA A 4 1b /0 5 'll 1b / V 1b / 2 Check the wing in accordance with the speci¬ fied procedure. 1 . Restore the sealant in the area indicated. 2. Reapply plastic foam to the upper wing insert. 1. Unscrew the upper wing retaining bolts. 2. Unscrew the wing side retaining bolt. 3. Unscrew the lower wing retaining bolts. 4. Remove the wing from the car. 2 ✓rV 3* 1 SP® y 3 ;!• a JL !l 0 3 Installation 5Il Clean off residues of old sealant, foam and PVC using a vibrating cutter and appropriate blade. 1. Position wing ( 1 a) to the car and secure provi¬ sionally using retaining bolts (1b). Lower the bonnet lid and close the front door. Check the door is aligned and that the gap around the edge is even. - PA5106/03 10/1998 2 \ . I ,T| 1 . Position the wing on the car and screw in the retaining bolts without tightening. 2. Align the wing and check the edges between wing and door (2a) and bonnet lid (2b). 3. Permitted wing adjustment movements are indi¬ cated by arrows. 4. Fully tighten the wing retaining bolts. 9 REPAIR PROCEDURES 7090 t I 4 /> '/ 3=1 -T— El Body panels - replacement and repair //- 2b ■i A 1 •«3, 'O 2a 4* Vi iq 3\ ?T} 4 4 1. Apply sealant to the area indicated (use the specified cycle). 2. Reapply PVC treatment to the areas indicated (use the specified cycle). 1 . Use a circular saw to follow the dotted cutting lines shown in the figure. 2. Use an air saw to follow the dotted cutting lines shown in the figure. 3. Cross-sections of key areas as a guide to allow the operator to adjust cutting position and depth in order to avoid damage to the underlying panels. 4. Drill out the spots shown in the figure. 5. Remove the car's rear wing. //f 2 */i 2 Z / 19 <5a II 3 /< / A I ftJK. 7090A55 - LEFT HAND REAR WING - R + R AND ADAPT FOR REPLACEMENT Removal - - 10 Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (ref¬ erence rigs, templates or gauges). Straighten the body if necessary. =71 2 / 4 >5 m 3 Use a vibrating cutter with appropriate blade to remove P.V.C. from the cut end of the rear wing on the car. Use a rotary brush to remove paint to gain access to the spot welds. PA5106/03 10/1998 REPAIR PROCEDURES a Body panels - replacement and repair 1-Use a chamfering machine to remove the spot welds shown in the figure. Drill out any weld spots not accessible to the chamfering machine. 2. Use a chisel and mallet to remove spots ground previously. 7090 1. Cut the wing at the bench. Take care to leave a sufficiently wide section of steel to attach the new part to. 2. Use a rotary brush to remove the corrosionproofing from around the inner and outer edge of the part. 3. Drill out equidistant holes along the lower edge. Apply electric weld paint finish to the sections to be welded. 2 2 .1 2 r~h i fl 2 t Jm "~lkli 1 wm 2 j 3 1 1 . Make equidistant holes along the edge of the beam beneath the back window. Straighten the door sill compartment flaps using a mallet and profiled stake. Use a grinding wheel to remove the spot weld residues. Use a rotary brush to clean the treated areas. 2. Apply the electroweldable paint finish. 1 .0 2 /7 / Installation 1. Position the part on the car and secure using self-locking grippers. 2. Fit the door sealing strip, catch striker and rear door. 3. Fit the sealing strip and boot lid. Check alignment. 4. Use a circular saw to cut both panel sections in order to achieve a perfect joint line. - Remove any excess sheet steel and adjustment components from the part. / o m ®7 4 2 S' MB a 4/&M Si 2 w mp1, 2 2 PA5106/03 10/1998 1 n 11 REPAIR PROCEDURES Body panels 7090 - replacement and repair 1. Fit the wing to the car and secure using self¬ locking clips. 2. Use a spot welder to weld the areas shown in the figure. 3. Use a MIG welder to weld the upper wing pillar. 4. Use a MIG welder to fill the holes made previ¬ ously. 2® (9) 2 ‘(7) 2-0) 2 0(2) 3 v EJK2*(4) r*C J 1. Apply rust-proofing to newly welded areas. Seal the joint lines between the part and the car. 2. Apply sound-deadening panels. Apply paint. 3. Apply wax oil inside the rear wing. lira m 2 1 % I ■2*(2) _2*j3)-i ; 1 2® (25) 1 / mi m4 2.(6) -(5) 2 .(9) ■ •2* (8) 3 2 *(8) Use a profiled stake and mallet to correct any deformations in panel 1. Use a grinding wheel to level the weld and remove. 1 / X 7 7090A56 - RIGHT HAND REAR WING - R + R AND ADAPT FOR REPLACEMENT Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (ref¬ erence rigs, templates or gauges). Straighten the body if necessary. Note: For removal and refitting Refer to op.. 7090A55 Left hand rear wing - r + r and adapt for replacement 1 ■ 1 12 PA5106/03 10/1998 REPAIR PROCEDURES a Body panels - replacement and repair 7090 1c 2 O' m 1b 'rnr.C) 9m 7090A58 - ROOF PANEL - R+R AND ADAPTATION FOR REPLACEMENT Removal - - Move all fouling parts. Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (ref¬ erence rigs, templates or gauges). Straighten the body if necessary. b \ -==z" / / u 1a□ L& I.Use a chamfering machine to crop weld points on the front and rear edges. 2. Drill out weld spots on the side edges. 3. Use an oxyacetylene torch and wire brush to remove the braze welds at the corners of the roof. Use a chisel and mallet to remove spots ground previously. 4. Remove the roof panel from the car. 0 3 1 4 3 i N; 2\ s\ hr s\ PI 2 3 .v j tMcooor* v?oo&_ M... AUuoiBiir 1. Use a vibrating cutter with suitable blade to cut the sealant (1a) between reinforcements (1b) of roof panel (1c). 2. Remove the paint from around the edge of the roof panel using a rotary brush to reveal weld points. PA5106/03 10/1998 \ 1. Straighten the roof panel seat flaps using a mallet and profiled stake. Use a grinding wheel to remove the spot weld residues. Use a rotary brush to clean treated areas. Apply the electroweldable paint finish. 13 REPAIR PROCEDURES a Body panels - replacement and repair 7090 1. Reapply the seal between roof panel and rein¬ forcements. 1 'Zl J i \' 0 3 A As,. Installation 1-Use a rotary brush to remove the corrosion¬ proofing from around the inner and outer edge of the part. - Apply the electric weld paint finish to the affected parts. 1. Position the part correctly using self-locking grippers. 2. Fit front doors (2a) and rear doors (2b). Check alignment and gaps around the edges. Use a sliding gauge to check windscreen com¬ partment and back window compartment diag¬ onals. 3. Carry out some spot welds on the roof panel. Remove the front and rear doors. t• t 1 «-ÿ MS 3 1 ib 2b r \ tcor* v root? _ $O_AUUM* TIT ,2a wr»«»_ip. At Use a spot welder to weld the roof panel in windscreen compartment area (1a) and back window compartment area (1b). 2. Use a spot welder to weld the roof panel in the area of right side panel (2a) and left side panel 3. Use an oxyacetylene torch to hard-solder the roof panel corners. 14 PA5106/03 10/1998 A REPAIR PROCEDURES 0 Body panels - replacement and repair 7090 ft El 3 2a «(2i) % ojh K °JA o\ 1 ■1a (22) 2b ‘(2D Z hJi r Refit all fouling parts. /p Correct any deformations in the panel using a profiled stake and mallet. 1 . Use a grinding wheel to level the braze welds in the areas shown in the figure. 2. Use a rotary brush to clean the newly-welded areas. sS~ 2 Mm 1 2\o\ 2 1 •2 /C 1. Apply rust- proofing to newly welded areas. Apply sealant in the area of contact between roof panel and car border. Apply paint. Apply wax. PA5106103 10/1998 15 REPAIR PROCEDURES Body panels 7090 - replacement and repair j 7090G - Replacement elements VIEW OF ASSEMBLY ---- 2 1 - tyy y 25 :::: • / i t I te> 7 6 JiU 4> r.; 12 11 o \ N <$5s 13 17 wÿ-3c m -it ÿ i e> r< m. l! IMOOOOr* V 70027 Ref. Description 1 HEADLAMP SEAT 2 HEADLAMP SEAT CONNECTION BEAM 3 SIDE CONNECTION BEAM 4 TOTAL FRONT SIDE 5 PARTIAL FRONT SIDE 6 FRONT WING TOP INSERT 7 FRONT WING TOP INSERT 8 FRONT PILLAR 9 FRONT PILLAR/F.DOOR HI NGE( REINFORCEMENT) 10 CENTRAL PILLAR 11 CENTRAL PILLAR R.DOORHINGE REINFORCEMENT 12 DOOR SILL ASSEMBLY 13 PART OF FRONT DOOR SILL 16 1H@ L '"‘f\ÿ==ÿ= SO O — \\ 1701 M Ilf PA5106/03 10/1998 REPAIR PROCEDURES a Body panels - replacement and repair Ref. Description 14 PART OF FRONT DOOR SILL 15 FRONT DOOR SILL REINFORCEMENT 16 CROSSMEMBER UNDER THE REARSCREEN 17 REAR OUTER WHEEL ARCH 18 REAR TRIM (STRUCTURAL ELEMENTS) 19 PART OF REAR DOOR RAIL 20 BOOT/LOAD COMPARTMENT FLOOR PAN 7090 Operations index Code Operation Validity 7090G05 Headlamp housing one Ih or rh.foliowing other _repairs,-r r and adapt for replacement _ 7090G06 Headlamp housing connection beam,following other _repairs,-r r and adapt for replacement _ 7090G08 Side connection beam, following other repairs,-r r and _adapt for replacement _ 7090G10 Total front side one Ih or rh, following other repairs, r _r and adapt for replacement _ 7090G12 Partial side panel (1) Ih or rh - level 2 replacement 7090G16 Front wing top insert one Ih or rh.following another _repair,-r r and adapt for replacement _ 7090G19 Front wing buffer insert with light unit seat (one) Ih or rh (following) other intervention) - r r and adapt for _replacement 7090G30 Front pillar one Ih or rh.following another repair,-r r _and adapt for replacement 7090G32 Front door hinge (one) on front pillar, Ih or rh - r r __ _ 7090G40 Central pillar, following another repair, r r and adapt _for replacement 7090G42 Rear door hinge (one) on central pillar, Ih or rh - r r _ 7090G50 Door sill one Ih or rh.following another repair,- r r and _adapt for replacement 7090G52 Part of front door sill one Ih or rh, following another _repair, r r and adapt for replacement _ 7090G54 Part of front door sill one Ih or rh, following amother _repair, -r r and adapt for replacement _ 7090G56 Door cill reinforcement - replace _ 7090G64 Upper rear window beam - replace 7090G72 Outer rear wheel arch (one), Ih or rh(following _another operation) r+r and adapt for replacement 7090G76 Rear trim structural parts (following other operation) _-r+r and adapt for replacement _ /ÿS PA5106/03 10/1998 17 REPAIR PROCEDURES 7090 Body panels - replacement and repair rT J Validity Operation Code 7090G85 Partial rear floor rail (one), Ih or rh (following other intervention) - r r and adapt for replacement with rear trim removed _ 7090G94 Load platform floor complete with rails - following _other intervention r r for replacement _ OPERATIONS 7090G05 - HEADLAMP HOUSING ONE LH OR RH, FOL¬ LOWING OTHER REPAIRS,-R R AND ADAPT FOR REPLACE¬ MENT 1 Removal - - Follow the Op. 7090G06 Headlamp housing connection beam.following other repairs,-r r and adapt for replacement Move all fouling parts. Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (ref¬ erence rigs, templates or gauges). If necessary, straighten the body before cutting the part. 1 V \ ill ft a t \ ij G. Use a grinding wheel to remove the weld spot residues on the body. 1. Apply the electroweldable paint finish. / A £ ID, P 4 /, 1 '/vW- l\! IMOOOOf* V70017 _ OCSUOtM tr Use a rotary brush to clean the areas in order to expose the weld spots. 1. Drill out the spot welds shown in the figure. 2. Remove the headlamp housings. a \ tr G 1. Make equidistant holes as shown in the figure. Remove the corrosion-proofing from around the inner and outer edge of the part. 2. Apply electroweldable paint finish to the edges in contact with the car. 18 PA5106/03 10/1998 REPAIR PROCEDURES 0 Body panels - replacement and repair 7090 1 . Use a grinding wheel to level weld residues and remove. V: 2 w 'Si 1 <=> 0° „ 0 V O NN!!. -1 m I 1 ItJI "3“ rt A. tr 2 1 a\ Q Installation 1. Fit the part correctly and secure with self¬ locking clips. 2. Use a spot welder to weld the areas shown in the figure. 3. use a MIG welder to fill the holes made previ¬ ously. t<-ÿ \ 1. Apply rust-proofing to newly welded areas. 2. Seal the joint lines between the part and the car. Apply paint. 3. Apply wax oil inside the holes shown in the figure. [S * ix2-(5) I 0 si? a ill 1 h ,%2'W 3-(U 'cT a \ ti . OdUOit 7 1MOOOOP*V7aB27 .JO PA5106/03 10/1998 If 19 REPAIR PROCEDURES a Body panels - replacement and repair 7090 1. Unscrew bolt (1a) securing the upper radiator attachment and bolt (1b) retaining the inter¬ cooler sleeve bracket. 2. Unscrew retaining bolts (2a) shown in the figure, then remove headlamp housing connec¬ tion beam (2b). 1 1 \ N 2a * m 2b a 1a \ Qk 2a I 3 3 with Op. 7090G06 Headlamp housing connection beam,following other repairs,-r r and adapt for replacement Complete 7090G06 - HEADLAMP HOUSING CONNECTION BEAM,FOLLOWING OTHER REPAIRS,-R RAND ADAPT FOR REPLACEMENT /I O Installation 1. Provisionally position part (1a) on the car and screw in retaining bolts (1b) without tightening. 2. Fit the bonnet lid catch in its seat. 1b Removal - Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (ref¬ erence rigs, templates or gauges). Straighten the body if necessary before carrying out the following procedure. / £ r/ 1 f/ <0 fr c Q vS? 1a 2 A T 20 IM 00 00J* V TOOJf SO .0 OHU 1. Lower the bonnet lid. Check it is properly aligned and that the gap around the edge is even. Remove the catch and headlamp housing con¬ nection beam from the car. PA5106/03 10/1998 1~\ REPAIR PROCEDURES 51 Body panels - replacement and repair 7090 1. Use a pneumatic saw to cut along the lines shown in the figure. 2. Remove the section of the side panel connec¬ tion beam cut previously. 1 / r Y| © 'V l Paint the headlamp housing beam in accord¬ ance with the specified cycle. 7090G08 - SIDE CONNECTION BEAM, FOLLOWING OTHER REPAIRS,-R RAND ADAPT FOR REPLACEMENT 1 J iFJ?, Jj lip / 77 7» © °liV\! ct 2 1 Use a rotary brush to clean the areas to be ground in order to expose the weld spots. 1. Drill out the weld spots exposed previously. 2. Use a scalpel and mallet to remove the side panel connection beam cut edges. Removal - - - Follow the Op. 7090G06 Headlamp housing connection beam,following other repairs,-r r and adapt for replacement Move all fouling parts. Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (ref¬ erence rigs, templates or gauges). If necessary, straighten the body before cutting the part. 1 iifi 1 2 ¥ 47 1 II 1 2 Straighten the panel edges using a mallet and profiled stake. Use a grinding wheel to remove the spot weld residues. 1.Apply the electroweldable paint finish. PA5106103 10/1998 21 REPAIR PROCEDURES Body panels 7090 - replacement and repair j t Uw o A \ fifes 1 L 0 11 areas. Check the welded parts are correctly positioned. PA5106/03 10/1998 REPAIR PROCEDURES a Body panels - replacement and repair 7090 Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (ref¬ erence rigs, templates or gauges). If necessary, straighten the body before cutting the part. V mA 1 r MOB I 11 (S' f t /• .0 N7- 1 5' - 1. Spread rust-proofing inside the beam. Apply paint. Apply wax. K \/ JLlt 'i II m I.Use a pneumatic saw to cut along the lines shown in the figure. 2. Cross-section of key area as a guide to allow the operator to adjust cutting position and depth in order to avoid damage to the underlying panels. 3. Remove the front side panel cut edge. T 1 Headlamp Complete with Op. 7090G06 housing connection beam,following other repairs,-r r and adapt for replacement 7090G10 - TOTAL FRONT SIDE ONE LH OR RH, FOLLOWING OTHER REPAIRS, R R AND ADAPT FOR REPLACEMENT m O 1 fBdS Lo, i } 3 % J- o Removal /ÿS Follow the Op. 7090G08 Side connection beam, following other repairs,-r r and adapt for replacement . Follow the Op. 7090G30 Front pillar one Ih or rh,following another repair,-r r and adapt for replacement PA5106/03 10/1998 1. Drill out the weld spots. 2. Use a chamfering machine to remove the spot welds. 3. Remove the front side panel cut edge. 23 REPAIR PROCEDURES Body panels 7090 vo ft 1 • - replacement and repair rC J JML 2 2 3 “ 1— - 'T'fr?- • 1 V r 31 PS 2 5ÿ, -K«l J 2 ;0 » 1 0 GtOUOiltit Installation 1 . Position the front side panel correctly on the car using a template and self-locking clips. 2. Position the front side panel connection beam. Check the parts are properly aligned. 2 1. Make equidistant holes as shown in the figure. Straighten the panel edges using a mallet and profiled stake. Use a grinding wheel to remove the spot weld t residues. 2. Apply electric weld paint finish to newly-treated edges. 1 2 1 Yifevÿir1 ■PI J @ 0— >• [O Sit I % // 2ÿm < 1 2 H o « convntnr.. »__ o touottur Remove the side panel connection beam. 1. Use a spot welder to weld the areas shown in the figure. 2. Use a spot welder to weld the areas shown in the figure. 1. Make a hole as shown in the figure. Use a rotary brush to remove the corrosion¬ proofing from the areas shown in the figure. 2. Apply electric weld paint finish to the panel edges shown in the figure. 24 PA5106/03 10/1998 REPAIR PROCEDURES Body panels rC replacement and repair - J 7090 ' 2 $ o -4" Complete with Op. 7090G30 Front pillar one Ih or rh.following another repair,-r r and adapt for replacement Complete with Op. 7090G08 Side connection beam, following other repairs,-r r and adapt for replacement 7090G12 - PARTIAL SIDE PANEL (1) LH OR RH - LEVEL 2 REPLACEMENT 1. Use a circular saw to cut along the lines shown in the figure. 2. Cross-sections of key areas as a guide to allow the operator to adjust cutting position and depth in order to avoid damage to the underlying panels. 3. Use a rotary brush to clean the areas to be ground to expose the weld spots. Removal - Follow the Op. 7090G08 Side connection beam, following other repairs,-r r and adapt for replacement Follow the Op. 7090G16 Front wing top insert one Ih or rh,following another repair,-r r and adapt for replacement Remove all fouling parts. Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (ref¬ erence rigs, templates or gauges). If necessary, straighten the body before cutting o 1 3 to the part. 2 o o 1. Drill out the spot welds shown in the figure. 2. Remove the side panel section from its seat. 26 PA5106/03 10/1998 REPAIR PROCEDURES El Body panels - replacement and repair 7090 1 2 o 1 r o o 2 # f/ ,oy 0 1 1 . Make equidistant holes as shown in the figure. Straighten the body edges using a mallet and profiled stake. Use a grinding wheel to remove the spot weld residues. 2. Apply electric weld paint finish to the newlytreated edges. 2 Installation 1 . Lay the inner reinforcement on the car and posi¬ tion correctly using a template and self-locking clips. - Check the parts are properly aligned. 2. Use a circular saw to trim the panel and remove excess parts. t I : § $ 2 •(22) L. (( 2a tMOOOOH v TOUT ,JO (T2-(2) _ 1 . Drill out equidistant holes on the part as shown in the figure. Use a grinding wheel to remove rustproofing from around the inner and outer edge of the part. 2. Apply electroweldable paint finish to the mating 1 . Correct any deformations in the panel using a profiled stake and mallet. Use a grinding wheel to level weld residues and remove. Use a rotary brush to clean the newly-welded areas. Check the welded parts are correctly positioned. edges. 30 PA5106/03 10/1998 REPAIR PROCEDURES m Body panels - replacement and repair JSi s \\ i 7090 7090G19 - FRONT WING BUFFER INSERT WITH LIGHT UNIT SEAT (ONE) LH OR RH (FOLLOWING) OTHER INTER¬ VENTION) - R R AND ADAPT FOR REPLACEMENT Removal « - 0 %\ - 1 Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (ref¬ erence rigs, templates or gauges). If necessary, straighten the body before cutting the part. iff Apply rustproofing to the newly welded areas. 1. Seal the joint lines between part and car using sealant. Apply paint. 2. Reapply foam to the area shown in the figure. 5' 3/jl: o 1 K> \ 1 9 2 1 . Use a circular saw to follow the dotted cutting lines shown in the figure. 2. Cross-sections of key area as a guide to allow the operator to adjust cutting position and depth in order to avoid damage to the underlying panels. 3. Use a chamfering machine to crop the spot welds shown in the figure. 4. Drill out the spot welds shown in the figure. 5. Remove the upper partial insert from the car. A PA5106/03 10/1998 31 REPAIR PROCEDURES Body panels - replacement and repair 7090 rC j Installation 1 . Lay the part in its seat and secure using selflocking grippers. 2. Refit front wing (2a) and bonnet lid (2b). Check alignment and ensure the gap around the edge is even. - Remove the front wing and the bonnet lid. -1 4 V, \ .4 «1 £ 2 \ (Ti 3 0 2b v- O r\T5 1 Straighten the upper wing insert seat panel edges using a mallet and profiled stake. Use a grinding wheel to remove the spot weld residues. Use a rotary brush to clean the treated areas. 1. Apply electric weld paint finish to the areas shown in the figure. 2a 1. Use a circular saw to cut both parts by laying them on top of one another. 2. Remove parts (2a) and cut ends (2b). 2b \ 2a 8. 1 V-/ HJ 6 1 V 2b (• a & ii O / u>:k I Vl/ T Opl! Ca V I KU w [( 9 I MJ I 1. Drill out equidistant holes on the part as shown in the figure. Use a grinding wheel to remove rustproofing from around the inner and outer edge of the part. 32 PA5106/03 10/1998 REPAIR PROCEDURES s Body panels - replacement and repair 7090 2. Apply electroweldable paint finish to the mating edges. Eta lot 1 o 1 Q; 2 U 7) C5 to 3 A !// 2 1 s: 2.(5) 2.(2) 2 ( 7/ -1 2 1. Correct any deformations in the panel using a profiled stake and mallet. Use a grinding wheel to level weld residues and remove. Use a rotary brush to clean the newly-welded areas. Check the welded parts are correctly positioned. 1 . Position the wing partial upper insert in its seat and secure using self-locking clips. 2. Use a spot welder to weld the areas shown in the figure. 3. Use a MIG welder to seam weld the area shown in the figure. 4. Use a MIG welder to fill the holes made previ¬ ously. \ t ?/.( .1 ; 1 3 .1 4 :f/7 2« [12) A _ 0 yV Apply rustproofing to the newly welded areas. 1 . Seal the joint lines between part and car using X fX sealant. Apply paint. 2. Reapply foam to the area shown in the figure. O, ■N 1 . Position the headlamp seat correctly using self¬ locking clips. 2. Use a spot welder to weld the areas shown in the figure. 3. use a MIG welder to fill the holes on the part made previously. PA5106/03 10/1998 33 REPAIR PROCEDURES m Body panels - replacement and repair 7090 2. Cross-sections of key areas as a guide to allow the operator to adjust cutting position and depth in order to avoid damage to the underlying panels. 3. Remove the front pillar cut edges from the car. 1 07 f\ ■f/c t: U'°j 22 -f/r m 1 sz&ftGs h 2 cr0 2 f 2 i 7090G30 - FRONT PILLAR ONE LH OR RH, FOLLOWING ANOTHER REPAIR,-R R AND ADAPT FOR REPLACEMENT Removal - - Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (ref¬ erence rigs, templates or gauges). Straighten the body if necessary. WL 1 1 . Use a chamfering machine to remove the spot welds shown in the figure. 2. Drill out the spot welds shown in the figure. 3. Use a scalpel and mallet to remove spots ground previously and remove panel cut edges. / w ,0 N}; W ixoooo fKVToar _ so_. ojouott w Remove the PVC treatment from the door sill pillar using a vibrating cutter and appropriate blade. 1-Use a circular saw to follow the dotted cutting lines shown in the figure. 34 PA5106/03 10/1998 REPAIR PROCEDURES a Body panels ___ 0 D oD • a 1 \; > replacement and repair 1 2 - 3ÿ - 2 3 oo /1 7090 loo I © A 1 iJOj fi i<3 t 0 o 3 1 2 !l 2 2 3 Straighten the body edges using a mallet and profiled stake. Use a grinding wheel to remove the spot weld residues. / TJ Installation 1-Tack pillar reinforcement (1a) to the car using Parker screws (1b). 1 . Apply the electroweldabie paint finish. t • <ÿ % S' 1 / ■■I 0° 1 A oD (9 j mI I.Cut the front pillar at the bench. Take care to leave a sufficiently wide steel edge to attach the new part to. 2. Make equidistant holes on the front pillar and part as shown in the figure. Use a rotary brush to remove the corrosion¬ proofing from around the entire edge. 3. Apply electroweldable paint finish to the edges in contact with the car. PA5106/03 10/1998 e of /cm. 1 (0 1 k/ÿfTE 1 // i •1. Position the front pillar on the car and secure using self- locking clips. 2. Use the wing retaining nut as a reference point when locating the pillar. 3. Position the reinforcement on the car using self¬ locking clips. 4. Tack both parts using Parker screws. 35 REPAIR PROCEDURES Body panels - replacement and repair 7090 2. Trim off any excess from the panel. 3. Remove the parts. Remove the self-locking grippers. a f • «ÿ /A 3 — qacQÿ/y 2 ) ' h'm! 4 2 (HU ( ITTr W. 1 Oj — 4 o mk IS Q 3 2- \ I ! LV 4 1. Refit the front wing. Use a gauge to check windscreen seat diago¬ nals, door compartment and component align¬ ment. 2. Position the lower wing bracket and mark its correct position. t i 1 1 . Use the holes made previously to position the pillar reinforcement to the car and secure. 2. use a MIG welder to fill the holes made previ¬ ously in the door sill reinforcement. 3. Use a spot welder to make a few spot welds around the edge of the part. 4. Apply hard solder between the pillar and wind¬ screen surround. t <-*ÿ • «-ÿ i 1 3«(2j in ML 9 & Q M Ii 1 u 2 s7/ 2 tMOoooHtvnan to 3« (7) \/\ _ Remove the front wing and lower wing retaining bracket. 1 . Use a circular saw to cut both panel sections in order to achieve a perfect joint line. 36 A 3* (4) 2 -(2) PA5106/03 10H 998 REPAIR PROCEDURES 0 Body panels - replacement and repair 1 . Position the front pillar and secure to the car. 2. Use a MIG welder to weld the holes made pre¬ viously. 3. Use a MIG welder to seam weld the pillar and door sill edges. 4. Use a spot welder to weld the points indicated. 5. Position the wing retaining bracket, using the marks made previously as a reference. 6. Use a MIG welder to fill the holes made previ¬ ously. t• i // t I >• //* // / r /Jan- [mi 4 \ 4 -(2), 3*(5) A v I \ \ Jj ( c YT >|>2-(20) «-ÿ 4 •(6) 7090 1 (1 5-(8) & u_> 4 ©(20) 2- (10) <*ll 5 1 Correct any deformations in the panel using a profiled stake and mallet. I.Use a grinding wheel to level the weld and remove. 6- (4) ■ l, 3 ss; 2- (5) //A 1. Fit the reinforcement to the car. 2. Use a MIG welder to fill the holes made previ¬ ously. 3. Use a spot welder to weld the points indicated. 4. Position the car lift bracket at the height shown in the figure. 5. Use a welding machine to fill the holes made previously. © 7 / TTTT r ( / / © 1 \ ft II 1 Jk Apply rust-proofing to newly welded areas. 1. Seal the joint lines between the part and the car. 2. Apply foam through the hole indicated in the figure. Apply paint. 3. Apply wax oil inside the front pillar. PA5106/03 10/1998 37 REPAIR PROCEDURES m Body panels - replacement and repair 7090 Installation 1. Fit spacers (sizes shown in the figure) along the door surround compartment. t l ♦+•*> 1 lit-3 -1 2 I0 3 0 77 V ( -a r°8 JJ ,v #1/ 3 - Complete with Op. 70S0G32 Front door hinge (one) on front pillar, Ih or rh - r r 7090G32 - FRONT DOOR HINGE (ONE) ON FRONT PILLAR, LH OR RH - R R Removal Complete operation Follow the Op. 7090G30 Front pillar one Ih or rh.following another repair,-r r and adapt for replacement , then refit as follows: Fit the catch to the door. 1. Bring the door complete with hinges up to the door. Note: New doors are supplied already fitted with hinges. - Secure hinges inside the pillar using self-locking clips. 2. Close the rear door. - Check alignment and gaps around the edges. - Check the dimensions shown in the figure. 3. Use a MIG welder to make some spot welds as shown in the figure, after removing the cataphoretic treatment from the hinges. - \ \ It 1 5mm NT •c 5 mm •&r- ]3r3 / 5mm 2 38 r / PA5106/03 10/1998 REPAIR PROCEDURES a Body panels - replacement and repair 1 . Fit the front wing provisionally to the car. Check alignment and gaps around the edges. Then check the dimensions. Remove the front wing and the door. I.Use a grinding wheel to level the weld and remove. t l y 7090 »/ '1, © £\ \ / 1 r*s P I.Use a MIG welder to complete the seam weld around the edges of the hinges. Remove the self- locking clips from inside the pillar. 2. Use a MIG welder to seam weld the areas shown in the figure. / 3 II i pm' Q 1 2 0 ./ ) ©, 1. Apply rust-proofing to newly welded areas. Apply paint. 2. Apply wax oil inside the rear wing. v, 2 iLJ Q 1 LO P 2 © /ÿs PA5106/03 10/1998 39 REPAIR PROCEDURES Body panels 7090 - replacement and repair rC J 7090G40 - CENTRAL PILLAR, FOLLOWING ANOTHER REPAIR, R R AND ADAPT FOR REPLACEMENT 0 Removal Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (ref¬ erence rigs, templates or gauges). Straighten the body if necessary. - - 'Q, 2 / ai /J & 1 or 1 . Remove the PVC treatment from the door sill using a pneumatic knife and appropriate blade. 2. Use a rotary brush to clean the panel edges in order to expose the spot welds. 40 So I.Use a circular saw to follow the cutting lines shown in the figure. 2. Use a pneumatic saw to follow the dotted cut¬ ting lines shown in the figure. 3. Cross-sections of key areas as a guide to allow the operator to adjust cutting position and depth in order to avoid damage to the underlying panels. 4. Use a chamfering machine to crop weld points around the edge of the pillar. 5. Drill out spot welds in the areas shown in the figure. Use a chisel and mallet to remove spots ground previously. 6. Remove the pillar PA5106/03 10/1998 r»\ REPAIR PROCEDURES Body panels - replacement and repair r*C j 2 3 6— (o 2 o D /“ÿs in. jjr 7090 1 2 3 izr.l z 5 ! 1 4 2 1 ixoocoFf>vrota> to 1 . Use a chamfering machine to remove the spot welds shown in the figure. Use a chisel and mallet to remove spots ground previously. Trim the cut edges of the central pillar. Use a chisel and mallet to remove spots ground previously. 2. Remove the interior trim. 1 IMCOOOF6V 70027 ooovosctif to Straighten the car edges using a mallet and pro¬ filed stake. Use a grinding wheel to remove the spot weld residues. Use a rotary brush to clean treated areas. 1. Apply electric weld paint finish around the newly-treated edges. WP 1 tHCOCOMV T0D27 tO _ OOiUOtC.tif I.Cut the central pillar and reinforcement at the bench. Take care to leave a sufficiently wide section of steel to attach the new part to. 2. Use a drill to make holes at the points indicated. PA5106/03 10/1998 41 REPAIR PROCEDURES Body panels 7090 - El replacement and repair Use a rotary brush to remove the corrosionproofing from around the entire edge. 3. Apply electrogalvanised paint on the newlytreated eges. t i \ i-1 % 50mm // 1 3 3 3 3b 3- 1 3 i 3 2 3 _ (o T1 L70mm 1 O I 2 50mm 50mm 1 1 2 Installation 2 2 2 1. Position the central pillar on the car and secure using self-locking clips. 2. Check that the part overlaps the edge of the car by about 50 mm. 3. Use a circular saw to cut the panel eges (3a), then remove the excess parts in order to achieve a perfect joint line. Leave about 70mm from the central pillar reinforcement cut edge (3b). 3a 3a 1 . Fit the pillar reinforcement correctly to the car using self-locking clips. 2. Check the part overlaps the edge of the car by about 50 mm. 3. Use a pneumatic saw to trim the panels and remove excess parts. t 2 mm 1 (PJ it hi_J37 q/Dl Q V 0 \ a 3) I.Tack the reinforcement and central pillar to the car by applying a few spot welds. 2. Fit the front door. Check alignment and gaps around the edges, then remove the door. 42 PA5106/03 10/1998 r*\ REPAIR PROCEDURES 0 Body panels - replacement and repair 7090 t i t i <+ • <-*• ■1 W' //, > 2 q, 4-(2) 4 *{2) Ui ' U O 2 Q 3- (14) a MIG welder to seam weld the edge shown in the figure. 2. use a MIG welder to fill the holes made previ¬ ously. Use a grinding wheel to level the welds made previously Apply rust-proofing to newly treated areas. I.Use 2. 3 -(e) 2 1. Position the internal reinforcement on the car correctly and secure using self-locking clips. 2. use a MIG welder to fill the holes made previ¬ ously. 3. Use a spot welder to weld the areas shown in the figure. t 8 1 CD QUELIT?/ Cl 1% 7/ y fn V), \u\ 3 ©(27) ro 2 3 © (27) a J 0©/ ' 1 ll ia 2 1. Fit the central pillar correctly using self-locking clips. 2. Use a MIG welder to seam weld the upper edge and door sill. 3. Use a MIG welder to fill the holes made previ¬ ously. 4. Use a spot welder to apply a few spot welds to the areas shown in the figure. PA5106/03 10/1998 2 17 Correct any deformations in the panel using a profiled stake and mallet. I.Use a grinding wheel to level the weld and remove. 43 REPAIR PROCEDURES Body panels - replacement and repair 7090 Use a rotary brush to clean the newly-welded areas. HT J 7090G42 - REAR DOOR HINGE (ONE) ON CENTRAL PILLAR, LH OR RH - R R Removal - fl LI Complete operation 7090G40 Central pillar, following another repair, r r and adapt for replacement , then refit as follows: \ X -1 Q E ■f/ {il 1. Apply rust-proofing to newly welded areas. 2. Seal the joint lines between the part and the car. Apply paint. 3. Apply wax oil inside the door sill rail. Installation 1. Fit spacers (sizes shown in the figure) along the door surround compartment. t 1 & 1 1 ,1 a >2 a 3 J16mm id] 2 1 b' - f MOOOOF* V 7X3037 44 X IMOOCOJ* V ... » a 42usat« Fit the catch to the door. 1. Bring the door complete with hinges up to the door. Note: New doors are supplied already fitted with hinges. - Secure hinges inside the pillar using self-locking clips 2. Close the front door. - Check alignment and gaps around the edges. PA5106/03 10/1998 r REPAIR PROC si Body panels - replace Check the dimensions shown in the figure. t i 5mm V' ,1 2 5mm 5mm •c’ 5mm DC 1. Use a MIG welder to make some spot welds as shown in the figure, after removing the cataphoretic treatment from the hinges. y 1 /I O D x 7 i 1 \ Fit the rear wing provisionally to the car. I.Use a MIG welder to complete the seam weld around the edges of the hinges. 2. Use a MIG welder to seam weld the areas shown in the figure. /ÿS PA51 06/03 10/1998 REPAIR PROCEDUR 7090 Body panels - replacement a 1 . Remo expos and ap 2. Use a reveal N Ilk i 2-K M 1 7090G50 - DOOR SILL ONE LH OR RH,FOLLOWING ANOTHER REPAIR,- R R AND ADAPT FOR REPLACEMENT Removal - - Check if any of the connected are parts deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (ref¬ erence rigs, templates or gauges). Straighten the body if necessary. I.Use a welds 2. Use a out th the fig lower Open 3. Use a shown Use a previo 4. Remo 1 \ 46 3 REPAIR PROCEDURES a Body panels - replacement and repair 1. Straighten the door sill seating edges using a mallet and profiled stake. Use a grinding wheel to remove the spot weld residues. Use a rotary brush to clean the treated areas. Apply the electroweldable paint finish. 7090 \\ ) N \\l ft ; 1 1d Of £1 VI / /I 07331 QOQ 1 1a I.Use a rotary brush to remove the corrosion¬ proofing from around the inner and outer edge of the door sill (1a), car lift brackets (1b) and lower bracket (1c). 2. Make equidistant holes as shown in the figure. Apply electrogalvanised paint to the edges in contact with the car. Installation 1. Fit the part in its seat after rough-grinding and securing using self-locking clips. 2. Refit front door (2a), rear door (2b) and front wing (2c). 3. Position lower wing bracket (3a) and mark its exact position (3b). Check alignment and gaps around the edges, then remove the parts positioned previously. 2 t 1a <+ •*> • ; h-JzQnun 2 2a % 2 ' '2\ \ 1c 2b' 1 ss35 3b-ÿ" 3a 2c I.Use a circular saw to cut part (1a) by laying it in place with front pillar (1b), central pillar (1c) and door sill end section (1d). Trim the cut edges and remove the part. PA5106/03 10/1998 1. Position the front car lift bracket at the distance shown in the figure. 2. Use a spot welder to weld the points indicated. 3. Position the rear car lift bracket at the distance shown in the figure. 4. Use a spot welder to weld the points indicated. 5. Fit the lower wing retaining bracket in the posi¬ tioned marked previously. 6. Use a spot welder to weld the points indicated. 47 REPAIR PROCEDURES Body panels - replacement and repair 7090 t i m ■ -*-*> ? UL 1Jÿv/g .4 ‘(4) 2*(4) 1 TM \ i. 300mm 5 250mm 1 6 -(4) Apply rust-proofing to newly welded areas. 1. Seal the joint lines between the part and the car. Apply paint. 2. Apply wax oil inside the door sill rail. Position the part on the car and secure using self- locking grippers. 1 . Use a spot welder to weld the points indicated. 2. Use a MIG welder to seam weld the pillars. 3. Use a MIG welder to fill the holes made previ¬ ously. 1 1 iLJi 2 Prism ®(12)T7ÿ 2 4 3- (4) / A -1®(21) il lo/o 3 -(5) 3-(4) 3- (30) 3- (4) 2 Correct any deformations in the panel using a profiled stake and mallet. Crimp the reference tabs. I.Use a grinding wheel to level the weld and remove. Use a rotary brush to clean the newly-welded areas. 1 2 7090G52 - PART OF FRONT DOOR SILL ONE LH OR RH, FOLLOWING ANOTHER REPAIR, R R AND ADAPT FOR REPLACEMENT Removal - - 48 Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (ref¬ erence rigs, templates or gauges). Straighten the body if necessary. PA5106/03 10/1998 REPAIR PROCEDURES Body panels rC - replacement and repair 7090 J II \ \\\ 5 , \ fr- I D 1\ T / !' A 3 3 4 tMoaeonvTOKf 1. Remove the PVC treatment from the door sill to expose the spot welds using a vibrating cutter and appropriate blade. 2. Use a rotary brush to clean the panel edges to reveal the spot welds. to Straighten the door sill seating edges using a mallet and profiled stake. Use a grinding wheel to remove the spot weld residues. Use a rotary brush to clean the treated areas. 1. Apply the electroweldable paint finish to edges in contact with the part. 4 T PJ; 0 9, k 7 1 2 a chamfering machine to crop the spot welds shown in the figure. 2. Use a drill fitted with an appropriate bit to drill out the spot welds in the areas shown in the figure. 3. Use a circular saw to follow the cutting lines shown in the figure. 4. Cross-sections of key areas as a guide to allow the operator to adjust cutting position and depth in order to avoid damage to the underlying panels. Use a chisel and mallet to remove spots ground previously. 5. Remove the door sill from the car. I.Use PA5106/03 10/1998 Installation 1 .Trim the part, then position in its seat and secure the part door sill using self-locking clips. 2. Refit the front door. - Check alignment and ensure the surrounding gap is even, then remove the door. 49 REPAIR PROCEDURES a Body panels - replacement and repair 7090 t % 50mm 0 0 1 o 2 A 2 1 1 . Use a circular saw to cut the part by laying it in place. 2. Remove part (2a) and trim off any excess (2b). TJ ! 1 jfc >),: 1r 1. Position the part on the car and secure using self- locking grippers. 2. Use a spot welder to weld the points indicated. 3. use a MIG welder to seam weld (3a) the areas shown in the figure, then carry on welding to fill (3b) the holes made previously. ESS T 2® (14) h' 2b 2b 2a 1. Drill out equidistant holes as shown in the figure. Use a rotary brush to remove the corrosion¬ proofing from around the inner and outer edge of the part. 2. Apply electrogalvanised paint to the edges in contact with the car, as shown in the figure. 50 1 3a 3b* (a) 3a Correct any deformations in the panel using a profiled stake and mallet. I.Use a grinding wheel to level the weld and remove. Use a rotary brush to clean the newly-welded areas. PA5106/03 10/1998 REPAIR PROCEDURES a Body panels - replacement and repair A 7090 ■w T W A M V m / 1 1.Apply rust-proofing to newly welded areas. 2. Seal the joint lines between the part and the car. Apply paint. 3. Apply wax oil inside the door sill rail. K T 2 h T 1 1 . Use a rotary brush to clean the panel edges to reveal the spot welds. 2. Use a chamfering machine to crop the spot welds shown in the figure. 3. Drill out the spot welds shown in the figure. 4. Use a circular saw to follow the cutting lines shown in the figure. 5. Cross-sections of key areas as a guide to allow the operator to adjust cutting position and depth in order to avoid damage to the underlying panels. Use a chisel and mallet to remove spots ground previously. 6. Remove the door sill from the car. .V'. 5 \*\\ 3 7090G54 - PART OF FRONT DOOR SILL ONE LH OR RH, FOLLOWING AMOTHER REPAIR, -R R AND ADAPT FOR REPLACEMENT I) 4 1 6 3 4 2 __ OUUOJBlIf Removal - - Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (ref¬ erence rigs, templates or gauges). Straighten the body if necessary. PA5106/03 10/1998 Straighten the door sill seating edges using a mallet and profiled stake. Use a grinding wheel to remove the spot weld residues. Use a rotary brush to clean the treated areas. 1. Apply the electric weld paint finish to panel edges in contact with the part. 51 REPAIR PROCEDURES Body panels 7090 - m replacement and repair '©I v. 1 o' 1 lv o\’\ 0 A 7 / i&t 2b 2b 2a 1 1. Drill out equidistant holes as shown in the Installation 1. Fit the part in its seat after rough-grinding and securing using self-locking clips. 2. Refit the rear door. - Check alignment and ensure the surrounding gap is even, then remove the door. t I figure. Use a rotary brush to remove the corrosionproofing from around the inner and outer edge of the part. 2. Apply electroweldable paint to the edges in contact with the car, as shown in the figure. IS 2 2 t 1 mcooomvnmj . to _ on 1. Use a circular saw to cut the part by laying it in place. 2. Remove part (2a) and trim off any excess (2b). 52 1 50 mm 1 . Position the part on the car and secure using self- locking grippers. 2. Use a spot welder to weld the points indicated. 3. use a MIG welder to seam weld (3a) the areas shown in the figure and then fill (3b) the holes made previously. PA5106/03 10/1998 REPAIR PROCEDURES 0 Body panels - replacement and repair 7090 // // 3a 1 1 IV 2®(6) I \ 3b-(5) rv 2 Jj 3 3a Correct any deformations in the panel using a profiled stake and mallet. I.Use a grinding wheel to level the weld and remove. Use a rotary brush to clean the newly-welded areas. 7090G56 - DOOR CILL REIN¬ FORCEMENT - REPLACE Removal - // - Follow the Op. 7090G50 Door sill one Ih or rh.following another repair,- r r and adapt for replacement Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (ref¬ erence rigs, templates or gauges). Straighten the body if necessary. \ 1 1. Apply rust-proofing to newly welded areas. 2. Seal the joint lines between the part and the car. Apply paint. 3. Apply wax oil inside the door sill rail. 'SS iv tMUeOMM M._9UUOtBnr Use a rotary brush to clean the areas to be ground to expose the weld spots. 1. Drill out the spot welds shown in the figure. 2. Use a chamfering machine to crop the spot welds shown in the figure. 3. Use a circular saw to follow the cutting lines shown in the figure. PA5106/03 10/1998 53 REPAIR PROCEDURES 7090 4. Cross-section of key area as a guide to allow the operator to adjust cutting position and depth in order to avoid damage to the underlying panels. 5. Remove the door sill frame. / Apply electric weld paint finish to the panel edges beneath the overlapping section of the cut edges. / 4 3b k 0 0 2 m t'j m 15 3a\ T tJ CD 3 a Body panels - replacement and repair 2 / 1 /: m W) /ÿ> a € CD o 0 IDm zkSffiNQj) 1 13* 0000 F* V TOK 7 90 OMUOIttlf 1. Drill out equidistant holes as shown in the figure. Straighten the panel edges using a mallet and profiled stake. Use a grinding wheel to remove the spot weld residues. 2. Apply electric weld paint finish to the panel edges shown in the figure. Use a rotary brush to remove the corrosion¬ proofing from around the inner and outer edge of the part. 1. Apply electric weld paint finish to the panel edges shown in the figure. 1 I 'o IQ mm 513 1 2 1 IMOOOOf* Installation .oa 1. Fit the part in its seat after rough-grinding and secure using self- locking clips. - Check alignment and ensure the gap around the edge is even. 2. Use a circular saw to cut the part by laying it in place, cut along the cutting line shown in the figure. 3. Remove part (3a) and trim off any excess (3b). 54 1 - Fit the part to the car and secure using self¬ locking clips. Check the part is properly aligned and ensure the surrounding gap is even. 2. Use a spot welder to weld the areas shown in the figure. 3. use a MIG welder to seam weld (3a) and fill (3b) the holes made previously. PA5106/03 10/1998 ns REPAIR PROCEDURES Body panels - replacement and repair rC j 7090 t• <-ÿ K ; / T 2*(3) 1 0 AG 6/ \ 2» (6) 3a 3b-(e) 0 1 2®(4) III Is ) K c- by v icIcXg. 3b -(4) Correct any deformations in the panel using a profiled stake and mallet. 1 Use a grinding wheel to level the weld spots and remove any residue. Use a rotary brush to clean the newly-welded areas. ! I 2 / CD $ o // Use a rotary brush to remove the corrosion¬ proofing from around the inner and outer edge of the part. 1. Apply electroweldable paint finish to the edges ~~~ 2- (37) "s' Correct any deformations in the panel using a profiled stake and mallet. 1. Use a grinding wheel to level weld residues and remove. in contact with the car. 56 PA5106/03 10/1998 REPAIR PROCEDURES a a, Body panels - replacement and repair 7090 7090G72 - OUTER REAR WHEEL ARCH (ONE), LH OR RH(FOLLOWING ANOTHER OPERA¬ TION) R + R AND ADAPT FOR REPLACEMENT ( IK Removal - n - 1 1. Apply rust-proofing to newly welded areas. 2. Apply sealant to the areas indicated in the figure. Apply paint. 3. Apply wax oil inside the back window base beam. Follow the Op. 7090A55 Left hand rear wing r + r and adapt for replacement Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (ref¬ erence rigs, templates or gauges). Straighten the body if necessary. f •<5), jal x i S)K A# 7090 - 2 -(12) - 2 4 (5) TXOOOOPfi Vtoov to I.Use a circular saw to cut along cutting lines marked previously. 2. Trim the cut edge from the car. 3. Apply electric weld paint finish to the area beneath the cut edge. Position the part on the car and secure using self-locking grippers. Check alignment. 1 . Use a circular saw to cut both panel edges in order to obtain a perfect join. 2. Remove part (2a) and any excess sheet steel (2b). t i 1 ,2 b (T >>0 0 1 S3 2a Vv "0T 3 2 -1 V 3 ja 1 . Position the part on the car and secure using self-locking grippers. Check the part is properly aligned. 2. Use a spot welder to weld the roof panel in the areas shown in the figure. 3. Use a MIG welder to seam weld the upper panel edge. 4. Use a MIG welder to fill the holes made previ¬ ously. 2b 1. Position the part on the car and secure using self-locking grippers. Check alignment. 2. Use a spot welder to weld the roof panel in the areas shown in the figure. 3. Use a MIG welder to seam weld the upper panel edge and the door sill rail. 4. Use a MIG welder to fill the holes made previ¬ ously. PA5106/03 10/1998 59 REPAIR PROCEDURES 0 Body panels - replacement and repair 7090 t ' \ ; 3— - 2® (2) fr i .I ii 111/ /i-2®(3) •S'* 2 -(13) 4ÿ / ?•(-) IM 3 2 *(5) fÿT(5) \4 ) fc V 4-(5)'<2l Correct any deformations in the panel using a profiled stake and mallet. I.Use a grinding wheel to level the weld and remove. U & m 0ÿ2 3 Complete with Op. 7090A55 Left hand rear wing r + r and adapt for replacement - 7090G76 - REAR TRIM STRUC¬ TURAL PARTS (FOLLOWING OTHER OPERATION) - R+R AND ADAPT FOR REPLACE¬ MENT Removal - $5n K1 - 1 w Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (ref¬ erence rigs, templates or gauges). Straighten the body if necessary. r-ÿi 1 tMoooopnvnar to 1.Apply rust- proofing to newly welded areas. 2. Seal the areas indicated in the figure. Apply paint. 3. Apply wax oil protection through the hole indi¬ cated. 777s? i t 1. Drill out weld spots (1a) and weld spots (1b). 2. Use an air saw to follow the dotted cutting lines shown in the figure. 60 PA5106/03 10/1998 REPAIR PROCEDURES Body panels - replacement and repair rC 7090 J 3. Cross-sections of key areas as a guide to allow the operator to adjust cutting position and depth in order to avoid damage to the underlying panels. 4. Remove the rear trim from the car. & f/Q 3 i 1a 2 Jrt i m ?—1b 3 1 . Straighten the edges using a mallet and profiled 3 3 2 4 Use a vibrating cutter with appropriate blade to remove P.V.C. from the cut end of the car rear trim. Use a rotary brush to remove paint to gain access to the spot welds. 1 . Use a chamfering machine to remove the spot welds shown in the figure. Drill out any weld spots not accessible to the chamfering machine. 2. Drill out equidistant holes on the rail edges. Use a chisel and mallet to remove spots ground previously. 3. Remove the cut edge of the rear trim from the car. stake. Use a grinding wheel to remove the spot weld residues. Apply the electroweldable paint finish. O' \ 7 1 1. Drill out equidistant holes along the edges of the reinforcement and the lower edge of the rear trim. 2. Use a grinding wheel to remove the corrosion¬ proofing (2b) from around the edge of the part (2a). Apply electric weld paint finish to the edges in contact with the car. PA5106/03 10/1998 61 REPAIR PROCEDUR Body panels - replacement a 7090 2a 3 1 2b 1 Jh to/ ilm 2b ___ y 1®(1 2b cfc 2b 2a Installation 1 . Position the part properly on the car and secure using self-locking clips. 2. Tack the part by carrying out some spot welds. Remove the self-locking grippers. 3. Provisionally position rear bumper (3a), gasket (3b) and boot lid (3c). Check alignment and ensure the gap around the edge is even. Mi 1 . Correc profile Use a newly t 1 3b 3c ' © l 2 d) 3a 'tr; 2 1 2 1. Use a spot welder to weld the areas shown in the figure. 2. use a MIG welder to fill the holes made previously on the rear trim and rail edges. ' 3. Fit the reinforcement in its seat. .4. Use a MIG welder to fill the holes made previ¬ b:7 ously. a :r 469'!.“ 62 9d.t of d2>n : ' iitq .ij?v Apply 1 . Seal th Apply Reapp REPAIR PROCEDURES Body panels - replacement and repair HT 7090 j 1 i t i Vh tl ■ J Use a rotary brush to clean the newly-welded areas to reveal the weld spots. I.Use a circular saw to follow the cutting lines shown in the figure. 2. Cross-sections of key areas as a guide to allow the operator to adjust cutting position and depth in order to avoid damage to the underlying panels. 3. Drill out spot welds in the areas shown in the figure. Use a scalpel and mallet to remove spots ground 7090G85 - PARTIAL REAR FLOOR RAIL (ONE), LH OR RH (FOLLOWING OTHER INTER¬ VENTION) - R R AND ADAPT FOR REPLACEMENT WITH REAR TRIM REMOVED previously. 4. Remove the rear floor pan rail section. Removal - - Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (ref¬ erence rigs, templates or gauges). Straighten the body if necessary. '/ 1 A / .4 V, 2 "s'j 3 3 - U Straighten the body edges using a malleÿand profiled stake. Use a grinding wheel to remote the spot weld residues. 1.Apply the electric weld paint finish to the areas shown in the figure. PA5106/03 10/1998 63 REPAIR PROCEDURES 7090 Body panels - replacement and repair _ rC J rÿ. fr '/ J \o( A / o 5. >. 2b 1 o .J O 2a 1 2b I.Cut the part at the bench. Take care to leave a sufficiently wide section of steel to attach the new part to. 2. Use a drill to make equidistant holes as shown in the figure. Use a rotary brush to remove the corrosion¬ proofing from the edges in contact with the car. 3. Apply electric weld paint finish to the newlytreated panel edges. T7 Position the floor pan rail on the car and secure using self-locking clips. I.Use a MIG welder to fill the holes made previ¬ ously. 2. Use a MIG welder to seam weld the areas shown in the figure. 3. Use a spot welder to weld the areas shown in the figure. '/ 39rr A ,1 2 o° 1"(2) 3 °o P / o © O o lb ■1-(6) !** • 5S 3 Installation 0 3 1. Lay the floor pan rail on the car and lock using self- locking clips. Check the parts are properly aligned. 2, Use a circular saw to follow the cutting lines (2a) and trim the panel to remove any excess (2b). 64 lYÿ\ *(9) .o, \ 3 *(15) \\ \ 3 -(6) u Correct any deformations in the panel using a profiled stake and mallet. 1 . Use a rotary brush to level the weld and remove. PA5106/03 10/1998 REPAIR PROCEDURES Body panels - replacement and repair rC j 1 o 7090 7090G94 - LOAD PLATFORM FLOOR COMPLETE WITH RAILS - FOLLOWING OTHER INTER¬ VENTION R R FOR REPLACE¬ MENT Removal o - - Check if any of the connected parts are deformed by checking body alignment dimen¬ sions. Use appropriate measurement tools (ref¬ erence rigs, templates or gauges). Straighten the body if necessary. 1 A r\ rs 1. Apply rust-proofing to newly welded areas. 2. Seal the joint lines between the part and the car using sealant. Reapply the PVC treatment. 3. Apply sound-deadening panels. Paint the load compartment floor (according to the specified cycle). 4. Apply wax. S 1 V 'K. Q~ N A / 1 O. 2 o 4ÿÿ$ m i) m \ 1. Use an air saw to follow the dotted cutting lines shown in the figure. 2. Cross-sections of key areas as a guide to allow the operator to adjust cutting position and depth in order to avoid damage to the underlying panels. 3. Remove the central part of the floor pan. cr 3%/ .4.1’ . PA5106/03 10/1998 : o. eeU.g' ibiuoiic HI.'-T bn6 (efei .yiSi 65 REPAIR PROCEDURES Body* panels - replacement and repair 7090 H9Qb*j or rC J iniar 9irj6bi$wo;:D0‘ i • P OV 4ÿ 7, u, TjST-j 2 3 3 2 4 :4 5 5 lit- 2 5b 5a 5a 5b Straighten the car edges using a mallet and pro¬ filed stake. Use a grinding wheel to remove the spot weld residues. 1. Apply the electroweldable paint finish. 2 1. Use an pneumatic saw to cut along dotted cut¬ ting lines (1a), use as a reference to cut rear suspension attachment hole (1b). j 2. Use a drill to remove the weld spots shown in : f the figure. k Dl h L- ,5rs-- V V ,/ IT 1a t 1 'ÿ T-" 1 & 7] RJ 1b ISO ie>i n°ÿ'dked V Si? rns P.'/’/fJIOS aÿhamferihg machinÿto ! 2. Use a chamfering machine to remove the spot welds shown in the figure. 3. Use a scalpel and mallet to remove weld spots and remove the upper rear beam. 4. Use a drill to remove the weld spots shown in the figure. 5. Use a scalpel and mallet to trim the cut edges of floor pan (5a) and rail reinforcement (5b). 66 PA5106/03 10/1998 REPAIR PROCEDURES Body panels r-C - replacement and,rep£jr J r\ "y * Apply the electroweldable paint finish to edges 3. in contact with the car. I.Cut the part at the bench. Take care to leave a sufficiently wide section of steel to attach the new part to. 2b 3 2b 3 1 ,1 2a 'o >; 2a \ r\ \ 3 1. Position the load compartment floor pan on the car and secure using self-locking clips or Parker Installation 1. Position the rail reinforcements and secure using self- locking clips. 2. Use a spot welder to weld the areas shown in the figure. screws. Check the panel laid on correctly in the joint area. 2. Use the rear suspension attachment holes with a template as reference. 3. Use a scribe to mark the ideal cutting line. Remove the load compartment floor pane from the car. t _ ' i t i sP 3 7 3 v>i % m ) //Q :/! 1 Ik / 1 2 sp 134.0303?* V TOCC7 7$ 30 0HUC3B 1* 1. Position the load platform floor pan on the car and secure using self-locking clips or Parker screws. ion ijecomr*v.TOB27„sa._ 1.Working at the bench, cut the load compartment floor pan following the line traced previously. 2. Use a drill to make equidistant holes (2a) along the edge of the load compartment floor pan. Then make equidistant holes (2b) round the outside of the upper rear beam. Use a rotary brush to remove the corrosion¬ proofing from around the entire inner and outer edge of the part. PA5106/03 10/1998 tOQ3 9f1t ns' o! ..m gniiefmerto s eaU aril rr nworla abtew t3'is- ~ b.-a iaqisoa s er:U £ =>io;. t' ?.ioqa 1' oi ■.-da is9 1 isqqu 9/lt 9vorri9i jqa b!9w 9rt: -vomai ot lii s • /• ' r ‘Of.. :30l. ons saU.£ .9iugit erlt 9fit mm ot tslis/n bns ,9q!6c - 9al! 3 n9/n90iotni9i l/ei brie \ad) r 67 mmm PROCEDURES E paitel&s* replacement and repair fr'; U3 t D // xCO Sc 2 IT ii '.ZZV tJ*00C0r*V7003T V so 1 . Use a spot welder to weld the areas shown in the figure. 2. Use a MIG welder to seam weld along the line shown in the figure. I.Use a spot welder to weld the rear wing and wheel arch area of the load compartment floor pan from both sides. m D ii. y // me \ZZv m c □3) . - 1 (7) 1*(7) .o ~3> So l.use a MIG welder to fill the holes made previ¬ ously around the edge of the load platform floor pan. L_1®(3) © © - 1 (12) 1 . Position the upper rear beam. 2. Use a MIG welder to fill the holes made previ- i -.o ously. 2. Use a MIG welder to seam weld the edge in contact with the floor pan rails. o. 68 PA5106/03 10/1998 . REPAIR PROCEDURES Body panels - replacement and) repafr N 43 ? l|5 //a M k % mBBw y; Sg 2-(4) 2-(4) 2-d2) 2 b c 1 <£L> Correct any deformations in the panel using a profiled stake and mallet. 1 . Use a grinding wheel to level weld residues and remove. g JJ ?5 / v 1 - • ;r. i t&m Apply rust-proofing to newly welded areas. •£ 1. Seal the joint lines between the part and the car using sealant. Reapply the PVC treatment. 2. Apply sound-deadening panels. - Paint the load compartment floor (according to the specified cycle). 3. Apply wax. PA5106/03 10/1998 Sl% •! •> ft ■■be erli ;• •4 .J„ o-'i* - -ft ir.i ' a aaU .£ 'cr> 69 REPAIR PROCEDURES 7090 Body panels - replacement and repair a rs r*\ 70 PA5106/03 10/1998