Body Repair Manual PDF

Body Repair
Manual
Carrosserie reparatiehandboek
Manuel de réparation
de carrosserie
Karosseriereparaturanleitung
Manuale delle operazioni di

riparazione della carrozzeria
Manual de reparaciones
de carrocería
Manual de reparações
da carroçaria
INTRODUCTION
GENERAL INFORMATION
INFORMATION
SUSPENSION
RESTRAINT SYSTEMS
BODY
MGF
PANEL REPAIRS
BODY REPAIR
MANUAL
Publication Part No. RCL 0090ENG

Published by Rover Technical Communication
 1996 Rover Group Limited
INTRODUCTION
INTRODUCTION REPAIRS AND REPLACEMENTS
How to use this Manual When replacement parts are required it is essential
that only Rover recommended parts are used.
This Body Repair Manual is designed to provide the
experienced Body Shop technician with the Attention is particularly drawn to the following points
information required to carry out efficient and concerning repairs and the fitting of replacement
cost-effective repairs. parts and accessories.
To assist in the use of this Manual the section title is Safety features and corrosion prevention treatments
given at the top and the relevant sub-section at the embodied in the car may be impaired if other than
bottom of each page. Rover recommended parts are fitted. In certain
territories, legislation prohibits the fitting of parts not
The individual items comprising operations are to be to the manufacturer’s specification. Torque wrench
followed in the sequence in which they appear, see setting figures given in this Manual must be used.
BODY and SRS sections. Items numbers in the Locking devices, where specified, must be fitted. If
illustration are referred to in the text. Adjustment and the efficiency of a locking device is impaired during
repair operations include reference to Service Tool removal it must be renewed.
numbers. Each adjustment or repair operation is
given its Service Repair Operation number. Owners purchasing accessories while travelling
abroad should ensure that the accessory and its
The repair operations cover replacement of the fitted location on the car conform to legal
relevant welded panels and panel assemblies on the requirements.
vehicle, see PANEL REPAIRS . Each operation
details special points to observe when replacing a The Terms of the vehicle Warranty may be
welded panel, together with cross-reference to the invalidated by the fitting of other than Rover
relevant trim items to be removed and replaced for recommended parts.
access.
All Rover recommended parts have the full backing
WARNINGS, CAUTIONS and NOTES have the of the vehicle Warranty.
following meanings:
Rover Dealers are obliged to supply only Rover
WARNING: Procedures which must be recommended parts.
followed precisely to avoid the possibility
of injury.
CAUTION: Calls attention to procedures

which must be followed to avoid damage
to components.
NOTE: Gives helpful information.
References
References to the LH or RH side given in this

Manual are made when viewing the vehicle from the
rear.
Dimensions
The dimensions quoted are to design engineering

specification with Service limits where applicable.
INTRODUCTION 1
INTRODUCTION
SPECIFICATION
Rover are constantly seeking to improve the

specification, design and production of their vehicles
and alterations take place accordingly. While every
effort has been made to ensure the accuracy of this
Manual, it should not be regarded as an infallible
guide to current specifications of any particular
vehicle.
This Manual does not constitute an offer for sale of

any particular vehicle. Rover Dealers are not agents
of Rover and have no authority to bind the
manufacturer by any expressed or implied
undertaking or representation.
2 INTRODUCTION
GENERAL INFORMATION
A= Model Change
VEHICLE IDENTIFICATION NUMBER
D= Assembly Plant
Location 6 figures= Serial number
The Vehicle Identification Number (VIN) is stamped

on a plate attached to the RH side of the spare Paint and Trim colour codes
wheel compartment, and behind the LH lower corner
of the windscreen. The VIN number is also stamped 3-letter codes identifying the original Paint and Trim
on the RH side front, upper suspension mounting colours are stamped on the VIN plate
plate. Example given below:
Paint
KMN
K= Basic colour
M= Mark identifier
N= Colour/Shade name
Trim
LQP
L= Basic colour
Vehicle identification number Q= Mark identifier
S A R R D W B G/T B/M/J A D 000001 P= Colour/Shade name
S= Geographic area
A= Country IDENTIFICATION NUMBER LOCATIONS
R= Manufacturer Engine number
RD= Marque/Model 1.8 ’K’ Series Engine: Stamped on the front face of
the cylinder block adjacent to the gearbox.
W= Body/Trim Level
B= Body Style (2 door convertible) Gearbox number
G/T=Engine Type Manual Gearbox: Stamped on a label attached to

(G- K 1.8 MPi) (T- K 1.8 VVC) the front face of the clutch housing.
B/M/J/X= Steering and Transmission Body number

(B- RHD Man) (M- LHD Man)
(J- RHD CVT) (X- LHD CVT) The body number is stamped on a plate attached to
the centre cross member, under the LH side seat.
VEHICLE IDENTIFICATION NUMBER 1

GENERAL INFORMATION
SAFETY INSTRUCTIONS
Brake hydraulics
Jacking
WARNING: It is imperative that the correct
Use recommended jacking points. See brake fittings are used and that threads of
INFORMATION, Lifting and towing. components are compatible.
Never rely on a jack as the sole means of support Always use two spanners when slackening or
when working beneath the vehicle. Use additional tightening brake pipe or hose connections. Ensure
safety supports beneath the vehicle. that hoses run in a natural curve and are not kinked
or twisted. Fit brake pipes securely in their retaining
Do not leave tools, lifting equipment, spilt oil, etc. clips and ensure that the pipe run cannot contact a
around or on the work bench area. potential chafing point.
Precautions against damage Containers used for hydraulic fluid must be kept
absolutely clean. Do not store hydraulic fluid in an
Always fit wing and seat covers before commencing unsealed container, it will absorb water and in this
work. Avoid spilling brake fluid or battery acid on condition would be dangerous to use. Do not allow
paintwork. Wash off with water immediately if this hydraulic fluid to be contaminated with mineral oil, or
occurs. use a container which has previously contained
mineral oil. Do not re-use fluid from the system.
Disconnect the battery earth lead before starting Always use clean brake fluid or a recommended
work. See Electrical precautions. alternative to clean hydraulic components. Fit a
blanking cap to an hydraulic union and a plug to its
Always use the recommended service tool or a socket after removal to prevent the ingress of dirt.
satisfactory equivalent where specified. Absolute cleanliness must be observed with
hydraulic components.
PRECAUTIONS 1
GENERAL INFORMATION
FUEL HANDLING PRECAUTIONS Fuel tank draining
General WARNING: Petrol/gasoline must not be

extracted or drained from any vehicle
The following information provides basic precautions whilst it is standing over a pit.
which must be observed if petrol (gasoline) is to be Draining or extraction of petrol/gasoline from a
handled safely. It also outlines other areas of risk vehicle fuel tank must be carried out in a well
which must not be ignored. This information is ventilated area.
issued for basic guidance only, and if in doubt The receptacle used to contain the
appropriate enquiries should be made of your local petrol/gasoline must be more than adequate for
Fire Officer. the full amount of fuel to be extracted or drained.
The receptacle should be clearly marked with its
Petrol - Gasoline contents, and placed in a safe storage area
which meets the requirements of local authority
Petrol/gasoline vapour is highly flammable and in regulations.
confined spaces is also explosive and toxic.
CAUTION: When petrol/gasoline has been
When petrol/gasoline evaporates it produces 150 extracted or drained from a fuel tank the
times its own volume in vapour which when diluted precautions governing naked lights and
with air becomes a readily ignitable mixture. The ignition sources should be maintained.
vapour is heavier than air and will always fall to the
lowest level. It can readily be distributed throughout Fuel tank removal
a workshop by air currents; consequently, even a
small spillage of petrol/ gasoline is potentially very When the fuel line is secured to the fuel tank outlet
dangerous. by a spring steel clip, the clip must be released
before the fuel line is disconnected or the fuel tank is
Always have a fire extinguisher containing FOAM, removed. This procedure will avoid the possibility of
CO2, GAS or POWDER close at hand when residual petrol fumes in the fuel tank being ignited
handling or draining fuel or when dismantling fuel when the clip is released.
systems and in other areas where fuel containers
are stored. As an added precaution, fuel tanks should have a
’PETROL (GASOLINE) VAPOUR’ warning label
Always disconnect the vehicle battery before attached to them as soon as they are removed from
carrying out dismantling or draining work on a fuel the vehicle.
system.
Whenever petrol/gasoline is being handled, drained

or stored or when fuel systems are being
dismantled, all forms of ignition must be
extinguished or removed; any leadlamps must be
flameproof and kept clear of spillage.
WARNING: No one should be permitted to

repair components associated with
petrol/gasoline without first having
specialist training.
FUEL HANDLING PRECAUTIONS 1

GENERAL INFORMATION
Fuel tank repairs QUICK FIT FUEL HOSE CONNECTORS
Under no circumstances should a repair to any fuel

tank involving heat treatment be carried out without WARNING: Hose connections between the
first rendering the tank SAFE, by using one of the fuel pump outlet union and the fuel rail
following methods: contain fuel under pressure, which MUST
be relieved prior to disconnection of hoses. See
a. STEAMING: With the filler cap and tank unit Workshop Manual, FUEL DELIVERY SYSTEM,
removed, empty the tank. Steam the tank for at least Repairs.
two hours with low pressure steam. Position the tank
so that condensation can drain away freely, ensuring
that any sediment and sludge not volatized by the
steam is washed out during the steaming process.
b. BOILING: With the filler cap and tank unit

removed, empty the tank. Immerse the tank
completely in boiling water containing an effective
alkaline degreasing agent or a detergent, with the
water filling and also surrounding the tank for at least
two hours.
After steaming or boiling, a signed and dated label to

this effect should be attached to the tank.
Body and chassis repairs
When a body or chassis repairs involve the use of

heat, all fuel pipes which run in the vicinity of the
repair area must be removed, and the tank outlet
plugged, BEFORE HEAT IS APPLIED. If the repair
is in the vicinity of the fuel tank, the tank must be
removed.
Plastic fuel pipes are particularly susceptible to heat,

even at relatively low temperature, and can be
melted by heat conducted from some distance away.
Fuel lines or tanks must not be removed whilst the

vehicle is over an inspection pit.
2 FUEL HANDLING PRECAUTIONS

GENERAL INFORMATION
ELECTRICAL PRECAUTIONS Having confirmed a component to be faulty switch

off the ignition and disconnect the battery. Remove
General the component and support the disconnected
harness. When replacing the component keep oily
The following guidelines are intended to ensure the hands away from electrical connection areas and
safety of the operator whilst preventing damage to push connectors home until any locking tabs fully
the electrical and electronic components fitted to the engage.
vehicle. Where necessary, specific precautions are
detailed in the relevant sections of this Manual which Battery disconnecting
should be referred to prior to commencing repair
operations. Before disconnecting the battery, switch off all
electrical equipment. If the radio is to be serviced,
Equipment - Prior to commencing any test ensure the security code has been deactivated.
procedure on the vehicle ensure that the relevant
test equipment is working correctly and any harness CAUTION: To prevent damage to electrical
or connectors are in good condition, this particularly components ALWAYS disconnect the
applies to mains lead and plugs. battery when working on the vehicle
electrical system. The earth lead must be
WARNING: Before commencing work on disconnected first and reconnected last.
an ignition system all high tension Always ensure that battery leads are routed
terminals, adapters and diagnostic correctly and are not close to any potential
equipment for testing should be inspected to chafing points.
ensure that they are adequately insulated and
shielded to prevent accidental personal contacts Battery charging
and minimise the risk of shock. Wearers of
surgically implanted pacemaker devices should Recharge the battery out of the vehicle and keep the
not be in close proximity to ignition circuits or top well ventilated. While being charged or
diagnostic equipment. discharged, and for approximately fifteen minutes
afterwards, batteries emit hydrogen gas. This gas is
Polarity - Never reverse connect the vehicle battery inflammable.
and always observe the correct polarity when
connecting test equipment. Always ensure any battery charging area is well
ventilated and that every precautions is taken to
High Voltage Circuits - Whenever disconnecting live avoid naked flames and sparks.
ht circuits always use insulated pliers and never
allow the open end of the ht lead to come into
contact with other components particularly ECU’s.
Exercise caution when measuring the voltage on the
coil terminals while the engine is running, high
voltage spikes can occur on these terminals.
Connectors and Harness - The engine compartment

of a vehicle is a particularly hostile environment for
electrical components and connectors. Always
ensure these items are dry and oil free before
disconnecting and connecting test equipment. Never
force connectors apart either by using tools or by
pulling on the wiring harness. Always ensure locking
tabs are disengaged before removal and not
orientation to enable correct reconnection. Ensure
that any protective covers and substances are
replaced if disturbed.
ELECTRICAL PRECAUTIONS 1
GENERAL INFORMATION
Disciplines
Switch off ignition prior to making any connection or

disconnection in the system as electrical surge
caused by disconnecting ’live’ connections can
damage electronic components.
Ensure hands and work surfaces are clean and free

of grease, swarf, etc. as grease collects dirt which
can cause tracking or high-resistance contacts.
When handling printed circuit boards, treat them as

you would a disc - hold by the edges only; note that
some electronic components are susceptible to body
static.
Connectors should never be subjected to forced

removal or refit, especially inter-board connectors,
damaged contacts will cause short- circuit and
open-circuit conditions.
Prior to commencing test, and periodically during

test, touch a good earth, i.e. cigar lighter socket, to
discharge body static as some electronic
components are vulnerable to static electricity.
Grease for electrical connectors
All under bonnet and under body connectors are

protected against corrosion by the application of a
special grease on production. Should connectors be
disturbed in service or repaired or replaced, a
grease of this type, available in 150 gm tubes under
Part No. BAU 5811, should again be applied.
NOTE: The use of other greases must be

avoided as they can migrate into relays,
switches etc. contaminating the contacts
and leading to intermittent operation or failure.
2 ELECTRICAL PRECAUTIONS
GENERAL INFORMATION
BODY REPAIRS Body repairs often involve the removal of

mechanical and electrical units and associated
General wiring. Where necessary, refer to the relevant
section of the Workshop Manual for removal and
Body shells are of monocoque construction. Front refitting instructions. Body trim and SRS sections
and rear sections of the shell are designed as with remove and refit operations are also included in
’energy absorbing’ zones. This means they are this Manual.
designed to deform progressively when subjected to
impact in order to minimise the likelihood of injury to
vehicle occupants. Body Components
It is essential that design dimensions and strength Taking into consideration the differences in body
are restored in accident rectification. It is important styles, steering and suspension systems and engine
that neither structural weakness nor excessive local and transmission layouts, the location of the
stiffness are introduced into the vehicle during body following components as applicable to a particular
repair. vehicle is critical:
Repairs usually involve a combination of operations • Front suspension upper damper mountings.
ranging from straightening procedures to renewal of • Front suspension or sub frame mountings.
individual panels or panel assemblies. The repairer • Engine mounting on RH and LH valances.
will determine the repair method and this decision • Rear suspension upper damper mountings.
will take into account a balance of economics • Rear suspension mountings or lower pivots.
between labour and material costs and the • Steering rack mountings.
availability of repair facilities in both equipment and
skills. It may also involve considerations of vehicles’ Additional points which can be used to check
downtime, replacement vehicle availability and alignment and assembly are:
repair turn-around time.
• Inner holes in crossmember - side - main floor.
It is expected that a repairer will select the best and • Holes in front longitudinals.
most economic repair method possible, making use • Holes in extension - side member - front.
of the facilities available. The instructions given are • Holes in rear longitudinals.
intended to assist a skilled body repairer by • Holes in rear lower panels or extension rear floor.
expanding approved procedures for panel • Petrol tank mountings.
replacement. The objective is to restore the vehicle
to a safe running condition by carrying out a repair Apertures for windscreen, backlight, bonnet and
which is close as feasible to original standards. The doors can best be checked by offering up an
result will not advertise to the experienced eye the undamaged component as a gauge.
fact that the vehicle has been damaged, although
the repair will not necessarily be identical in all Follow basic alignment measurements for relevant
respects to original factory build. Commercial model. See INFORMATION, General data.
bodyshop repair facilities cannot always duplicate
methods of construction used during production.
Operations covered in this Manual do not include

reference to testing the vehicle after repair. It is
essential that work is inspected and suspension
geometry checked after completion. A road test of
the vehicle should be carried out, particularly where
safety-related items are concerned.
Where major units have been disconnected or

removed it is necessary to ensure that fluid levels
are checked and topped up where necessary. It is
also necessary to ensure that the repaired vehicle is
in a roadworthy condition in respect of tyre
pressures, lights, washers fluid etc.
REPAIRS 1
INFORMATION
JACKING, SUPPORTING AND TOWING
1. Central jacking point - front 6. RH sill reinforced bracket - rear

2. Central jacking point - rear 7. Subframe longitudinal members - front
3. RH sill reinforced bracket - front 8. Subframe longitudinal members - rear
4. LH sill reinforced bracket - front 9. Front towing eyes
5. LH sill reinforced bracket - rear
The correct lifting, jacking and towing procedures WARNING: In accordance with normal
MUST be followed when carrying out body repairs, workshop practice, and to avoid the
paying particular attention to the following points: possibility of damage or personal injury,
work must not be carried out on or under a
• Locate trolley jack pads properly before lifting vehicle when it is supported solely on a jack.
and lower the jack fully before withdrawal. Place safety supports under the sill reinforced
• Locate the lifting heads of wheel-free lifts jacking areas (3, 4, 5 or 6). Ensure that the head
correctly, with rubber or a similar protective of the stand is either flat or has only a shallow
material between lifting head and underbody. recess, to avoid damage to adjacent bodywork.
LIFTING AND TOWING 1

INFORMATION
WARNING: Do not position a jack, jack WHEEL-FREE LIFT

stand or wheel free support under the
suspension attachment points. If crossbeams are available, locate the pads under
the sill reinforced jacking brackets (3, 4) and (5, 6).
CAUTION: When lifting the side of the
vehicle with a workshop jack, ensure that If longitudinal beams are available, locate the beams
the jack head is positioned under the under the subframe longitudinals with lifting pads at
reinforced area of the sill, as shown. the front and rear positions (7 and 8). Raise the lift a
few inches and ensure the vehicle is firmly
supported. Raise the lift to full height and inspect the
lifting points for security.
RECOVERY
It is recommended that a recovery trailer or two

wheel car ambulance be used. In an emergency, the
car may be towed on its own wheels using the front
lashing/towing eyes (9).
SUSPENDED TOW: Cannot be carried out without

incurring damage. If additional damage is immaterial
because of existing crash damage, lifting chains can
WORKSHOP JACK be attached to the towing eyes.
Front: Locate the jack head under the central Before towing commences, release the handbrake,
location bracket(1). place the gear lever in neutral and the ignition switch
Position safety supports under both front sill at ’I’. Do not tow at a greater speed than 30 mph, 50
reinforced brackets (3 and 4). km/h. On no account should the vehicle be towed
with the rear wheels on the ground if the
Rear: Locate the jack head under the central transmission is faulty, the transmission fluid level is
location bracket (2). low, or the towing distance exceeds 30 miles or 50
Position safety supports under both rear sill km.
reinforced brackets (5 and 6).
TRANSPORTER OR TRAILER LASHING: Use the
Side Front: Position the safety support under the sill front towing eyes, and specific lashing points for rear
reinforced bracket (3 or 4) and locate jack head of car. DO NOT secure lashing hooks or trailer
under front subframe longitudinal member (7). fixings to other parts of the car.
Side Rear: Position the safety support under the sill

reinforced bracket (5 or 6) and locate jack head
under rear subframe longitudinal member (8).
2 LIFTING AND TOWING

INFORMATION
TOWING
The rear lashing/towing eye, must only be used for

towing a light vehicle.
Use the front lashing/towing eyes (9) for towing the

vehicle on all four wheels from the front.
WARNING: To ensure that the steering

does not lock when the vehicle is being
towed, it is essential that the ignition key
is turned to position ’I’, and remains there while
the vehicle is moving.
Ensure the following precautions are observed:
Do not tow if the gearbox or a drive shaft is
faulty.
Do not tow if a wheel or drive shafts are touching
the body or frame.
Ensure the gear lever is in neutral and the
handbrake is released.
Remember that greater effort than normal will be
necessary to apply the brakes if the vehicle is
being towed without the engine running.
Automatic gearbox models
When a car with automatic gearbox is to be towed

on four wheels from the front, the following
precautions must be observed:
The gearbox fluid level must be correct before

starting to tow.
The selector must be at ’N’.
The car must not be towed at speeds greater than

30 m.p.h., 50 km/h or for distances which exceed 30
miles, 50 km.
CAUTION: A front suspended tow must

not be attempted as serious damage will
be caused to the automatic transmission.
NOTE: A vehicle fitted with an automatic

gearbox cannot be started by towing or
pushing.
LIFTING AND TOWING 3

INFORMATION
STEERING
Front wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . Toe-out 0fl 10’ – 3’ - each wheel

Front wheel camber . . . . . . . . . . . . . . . . . . . . . . . . . . Negative 0fl 30’ – 30’
Front wheel caster . . . . . . . . . . . . . . . . . . . . . . . . . . . Positive 5fl 0’ – 55’
King pin inclination . . . . . . . . . . . . . . . . . . . . . . . . . . . 11fl 40’
Steering angle of inner wheel to outer wheel . . . . . . . Outer wheel 29fl 12’
Inner wheel 34fl 42’
Overall steering ratio

Manual steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.8 : 1
Power steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.1 : 1
Rear suspension geometry

Rear wheel alignment . . . . . . . . . . . . . . . . . . . . . . . . Toe-in 0fl 10’ to – 3’ - each wheel
Rear wheel camber . . . . . . . . . . . . . . . . . . . . . . . . . . Negative 1fl 0’ – 30’
NOTE: Steering and suspension geometry settings are for a vehicle at kerbside weight.
DIMENSIONS
Overall length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.913 m 12 ft 10 in

Overall width (includes mirrors) . . . . . . . . . . . . . . . . . 1.753m 5 ft 9 in
Overall height
Cabriolet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.268 m 4 ft 2 in
Hard Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.273 m 4 ft 2 in
Ground clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 mm 4 • in
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.376 m 7 ft 9 … in
Turning circle, kerb to kerb . . . . . . . . . . . . . . . . . . . . 10.54 m 34 ft 7 in
Track
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.394 m 4 ft 6 • in
Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.394 m 4 ft 6 • in
WEIGHTS
1.8 MPi
Cabriolet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050 kg 2315 lb
Hard Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1068 kg 2355 lb
1.8 VVC
Cabriolet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1060 kg 2337 lb
Hard Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1078 kg 2377 lb
Maximum gross weight . . . . . . . . . . . . . . . . . . . . . . . 1320 kg 2910 lb
GENERAL DATA 1
INFORMATION
ELECTRONIC CONTROL UNITS
1. ABS5 ECU (front compartment at RH) 5. Relay module (behind ECM)

2. Anti-theft alarm ECU (behind heater controls) 6. EPAS ECU - RHD (behind glove box)
3. Diagnostic control unit (below anti-theft ECU) 7. EPAS ECU - LHD (behind glove box)
4. Engine control unit (ECM) (on rear bulkead at
LH of engine compartment)
The electronic control units fitted to Rover vehicles

make it advisable to follow suitable precautions prior
to carrying out welding repair operations. Harsh
conditions of heat and vibration may be generated
during these operations which could cause damage
to the units. See GENERAL INFORMATION,
Electrical precautions.
In particular, it is essential to follow the appropriate

precautions when disconnecting or removing the
SRS diagnostic unit. See RESTRAINT SYSTEMS,
Precautions.
Equipment - Prior to commencing any test

procedure on the vehicle, ensure that the relevant
test equipment is working correctly and any harness
or connectors are in good condition. This particularly
applies to electronic control units.
COMPONENT LOCATIONS 1
INFORMATION
TRANSVERSE DIMENSIONS
Location Dimension Reference
Front bumper mounting inner hole right hand to left hand 992mm 1
Rear bumper mounting inner hole right hand to left hand 497mm 2
Front suspension damper mount right hand to left hand 961.5mm 3
All dimensions taken at centre line of set screw, set screw hole or jig hole.
BODY DIMENSIONS 1
INFORMATION
Transverse Dimensions - continued
Front subframe forward mount inner hole right hand to left hand 1020mm 4
Front subframe rear mount inner hole right hand to left hand 586mm 5
Floor longitudinal reinforcement to dash side jig hole right hand to left 970mm 6
hand
Main floor lower reinforcement plunge hole right hand to left hand 838mm 7
Main floor drain hole right hand to jig hole left hand 1100mm 8
2 BODY DIMENSIONS
INFORMATION
Transverse Dimensions - continued
Floor longitudinal jig hole right hand to left hand 660mm 9

Rear subframe front mounting centre hole right hand to left hand 1190mm 10
Rear suspension damper mount right hand to left hand 1002mm 11
Rear subframe rear mounting inner hole right hand to left hand 570mm 12
Luggage floor longitudinal jig hole right hand to left hand 644mm 13
BODY DIMENSIONS 3
INFORMATION
DIAGONAL DIMENSIONS
Front subframe forward inner mounting hole to opposite side subframe 1041mm 1
rear mounting inner hole
Front subframe inner mounting hole to opposite side rear subframe 1906.2mm 2
centre mounting hole
Main floor lower reinforcement plunge hole to opposite side front 1040mm 3
subframe rear mounting inner hole
Main floor lower reinforcement plunge hole to opposite side rear 1372.5mm 4
subframe forward mount centre hole
Rear subframe forward mount centre hole to opposite side rear inner 1086.4mm 5
mounting hole
All dimensions taken at centre line of set screw, set screw hole or jig hole. Diagonal dimensions are taken in the
horizontal plane.
4 BODY DIMENSIONS
INFORMATION
This page is intentionally left blank
BODY DIMENSIONS 5
INFORMATION
LONGITUDINAL DIMENSIONS
6 BODY DIMENSIONS
INFORMATION
Front bulkhead centre crossmember paint drain hole to datum line -441.7mm 1
Front subframe front mounting inner hole to datum line -527.5mm 2
Front subframe rear mounting inner hole to datum line 135.3mm 3
Floor longitudinal jig hole to datum line 300mm 3a
Front suspension damper mount to datum line -96.3mm 4
Longitudinal reinforcement to dash side jig hole to datum line 339mm 5
Main floor lower reinforcement plunge hole to datum line 895mm 6
Main floor drain hole/jig hole to datum line 1550mm 7
Rear subframe front mounting centre hole to datum line 1822mm 8
Rear suspension damper mount to datum line 2274.5mm 9
Rear subframe rear mounting inner hole to datum line 2459.3mm 10
Luggage floor longitudinal jig hole to datum line 2800mm 11
BODY DIMENSIONS 7
INFORMATION
VERTICAL DIMENSIONS
8 BODY DIMENSIONS
INFORMATION
Front bulkhead centre crossmember paint drain hole to datum line 154mm 1
Front subframe front mounting inner hole to datum line -28mm 2
Front bumper mounting inner hole to datum line 102.5mm 2a
Front subframe rear mounting inner hole to datum line -152.8mm 3
Floor longitudinal jig hole to datum line -152.8mm 4
Front suspension damper mount to datum line 338.2mm 5
Longitudinal reinforcement to dash side jig hole to datum line -145mm 5a
Main floor lower reinforcement jig hole to datum line -143.5mm 6
Main floor rear drain hole/jig hole to datum line -118mm 7
Rear subframe front mounting centre hole to datum line -14mm 8
Rear subframe rear mounting inner hole to datum line 106mm 9
Luggage floor longitudinal jig hole to datum line 78mm 10
Rear suspension damper mount to datum line 337mm 11
Rear bumper mounting inner hole to datum line 153mm 12
BODY DIMENSIONS 9
INFORMATION
BODY REPAIRS Inspection
Straightening Every accident produces individual variations in

damage. Each repair is influenced by the extent of
Whenever possible, structural members should be the damage and the facilities and equipment
cold straightened under tension. Do not attempt to available for its rectification.
straighten with a single pull but rework the damaged
area using a series of pulls, releasing tension Most accident damage can be visually inspected
between each stage and using the opportunity to and the approximate extent of damage assessed.
check alignment. Sometimes deformation will extend beyond the
directly damaged area, and the severity of this must
Body Jig be accurately established so that steps can be taken
to restore critical body components to their original
Unless damage is limited to cosmetic panels, all dimensions. An initial check can be carried out by
repair work to body members must be carried out on means of drop checks or, preferably, trammels.
a body jig, to ensure that impact damage has not Gauges are available which will accurately check for
spread into more remote parts of the structure. body twist.
Mounting on a jig will also ensure that the
straightening and panel replacement procedures do Where repairs necessitate renewal of a critical body
not cause further distortion. component it is recommended that a body jig is
used.
If original dimensions cannot be satisfactorily
restored by these methods, damaged structural
members should be replaced. Damaged areas
should be cut away using a high speed saw, NOT an
oxy-acetylene torch.
As a rule, body dimensions are symmetrical about

the centre line. A good initial check for distortion is
therefore to measure diagonally and to investigate
apparent differences in dimensions.
10 BODY DIMENSIONS
INFORMATION
APPROVED MATERIALS
Description Make Part Number
SEALERS:
Bolted Panel Sealer 3M 08572
Drip-Chek Clear 3M 08401
Drip-Chek Heavy 3M 08531
Flexseal Polyurethane Seam Sealer 3M 08684/89/94
Polyurethane Sealer (sachet) 3M 08703/83/88
Weld Thru’ Seam Sealer 3M 08625
Super Seam Sealer 3M 08537
Sprayable Sealer 3M 08800/23
Windscreen Sealer 3M 08509
Betafill Clinch & Brushable Sealer Gurit-Essex 10211/15/20
Polyurethane Seam Sealer PPG 6500
Polyurethane Seam Sealer Teroson 92
Terostat Preformed Strip Teroson V11
Terostat 1k PU Seam Sealer Teroson -
Terostat Sprayable Seam Sealer Teroson 9320
Terolan Light Seam Sealer Teroson -
Terolan Special Brushable Seam Sealer Teroson -
Clinch Joint & Underbody Coating Gurit-Essex 10101/7
Leak-Chek Clear Putty Kent Industries 10075
Promatch Bolted Panel Sealer Unipart UBS111
Promatch Sealing Compound Unipart UBS605/6/7
Body Caulking 3M 08568
Sealing Compound Wurth 890100/1-6
ADHESIVES:
Automotive Structural Adhesive 3M 08120
Aerosol Auto Adhesive (Trim) 3M 08080
Fast Tack Adhesive 3M 08030/34
Spray 80 Adhesive 3M 08090
Structural Two-Part Epoxy Ciba-Geigy XB5106/7
Evo-Stik Multi-Purpose Clear Adhesive Evode -
SEALING AND CORROSION PROTECTION 1

INFORMATION
Description Make Part Number
UNDERBODY COATINGS:
Crodapol Brushable Underbody Sealer Croda PV75
Underbody Wax Croda PW61
Tectacote Underbody Wax Dinol 205
Body Schutz 3M 08861
Spray Schutz 3M 08877
Terotex Underseal CP02 Teroson 9320
Promatch Underbody Schutz Unipart UBS410
Promatch Underbody Wax Unipart PW61
Stonechip Coating (Textured) 3M 08868/78/79
Stonechip Coating (Smooth) 3M 08158/60/088-
86
Bodygard (Aerosol) 3M 08158/9
WAX COATINGS:
Astrolan Engine Bay Wax & Cosmetic Wax Astors DA3241/3
Engine Bay & Cosmetic Wax/Lacquer Croda PW197
Engine Bay Cosmetic Wax/Lacquer Dinol 4010
Inner Cavity Wax (Transparent) 3M 08909/19/29
Inner Cavity Wax (Amber) 3M 08901/11/21
Cavity Wax Croda PW57
Promatch Cavity Wax Unipart UBS508
WELD-THROUGH PRIMERS:
Weld Thru’ Coating 3M 05913
Zinc Rich Primer ICI P-565634
Zinc Spray 3M 09113
GENERAL MATERIALS:
Waterproof Cloth Tape 3M Y387/Y3998
Flexible Parts Repair Material (FRPM) 3M 05900
Cleaner & Wax Remover 3M 08984
Water Shedder Repair (Aerosol) Teroson -
Waterproof Tape Unipart GWS121
Urethane Butyl Tape Unipart BHM605
2 SEALING AND CORROSION PROTECTION

INFORMATION
MATERIALS APPLICATIONS
1. Between panels - bolted 6. Panel edges - bonded

2. Panel edges - bolted 7. Clinch joints (type a)
3. Between panels - spot welded 8. Clinch joints (type b)
4. Panel edges - spot welded 9. Clinch joints (type c)
5. Between panels - bonded 10. Gaps between panels (type a)
11. Gaps between panels (type b)

INFORMATION
Material/Joint Type Description Method
ICI P565 634, 3M 09113 - between bolted panels, spot welded panels Zinc rich primers Brush or spray
and type (a) clinch joints
Terostat V11 - between bolted panels Preformed strip Hand
Kent Industries 10075 - between bolted panels Seam sealer Applicator

gun/by hand
3M 08401, 08572, 08684, 08689, 08694, 08703, 08783, 08788 - PPG Seam sealers Applicator
6500, Teroson 92, Teroson Light, Terostat 9320, Unipart UBS 605/6/7, gun/by hand
Wurth 890100/1/2/3/4/5/6 - bolted panel edges
Ciba-Geigy XBS 106/7 - between spot welded panels Structural adhesive Applicator gun
Kent Industries 10075, 3M 08401 and 08684, PPG 6500, Teroson 92, Seam sealers (light) Hand
Terolan Light, Terostat 9320, Terostat 1k PU SE20, Unipart UBS applicator gun
605/6/7, Wurth 890100/1/2/3/4/5/6 - spot welded and bonded panel
edges
Ciba-Geigy XBS 106/7, 3M 8120 - between bonded panels and type Structural Caulking gun
(a) clinch joints adhesives
PPG 6500, Teroson 92, Teroson Light, Teroson 9320, Unipart UBS Semi-structural Caulking gun
605/6/7, Wurth 890100/1/2/3/4/5/6 - between bonded panels adhesives
Gurit-Essex 10211, 10215, 10220, 3M 08531, 08537, 08703, 08783, Seam sealers Caulking gun
08788 - clinch joints type (b)
Kent Industries 10075, 3M 08401, 08531, Terolan Light - clinch joints Seam sealers (light) Hand
type (c) applicator,
caulking gun
Kent Industries 10075, 3M 8401, 8684, 8689, PPG 6500, Terolan Light, Seam sealers (light) Hand
Terostat 1k PU SE20, Unipart UBS 605/6/7, Wurth 890100/1/2/3/4/5/6 - applicator gun
gaps between panels type (a)

INFORMATION
Material/Joint Type Description Method
Kent Industries Putty and 10075, 3M 08401, 08531, 08568, 08684, Seam sealer heavy Applicator gun,
08689, 08694, PPG 6500, Teroson 92, Terolan Light, Terostat 1k PU tube or hand
applicator
SE20, 9320, Unipart UBS 605/6/7, Wurth 890100/1/2/3/4/5/6 - gaps
between panels type (b)
Gurit-Essex 10101, 10707, 3M 08537, Teroson Brushable Sealer - Brushable sealers Brush
overlap joints (e.g. wheel arch and floor pan seams)
Croda PW57, 3M 08901, 08909, 08911, 08919, 08921, 08929, Unipart Cavity waxes Wax injection
UBS 508 - box sections and cavities equipment
Astors 3241/3, Croda PW197, Dinol 4010 - engine compartment Engine bay Spray gun or
cosmetic wax & brush
lacquer
Croda PW61, Dinol 205 Unipart PW61 - Underbody Underbody wax Spray gun or
brush
Croda PV75, 3M8861, 8877, Terotex CP02 9320 Underseal, Unipart Underbody sealer Schutz gun or
UBS 410 - underbody coat aerosol
3M Y397, YS3998, Unipart GS121 - panel apertures Waterproof tape Hand
3M 08509 - dry glazing Windscreen sealer Applicator gun
Unipart BHM 605 - direct glazing Urethane butyl tape Caulking gun
3M 05900 Flexible Parts Repair Material - rubber-modified Flexible parts repair Palette knife or
polypropylene parts (e.g. Pocan) material (two-pack) spreader
3M 08158, 08159, 08160, 08868, 08878, 08879, 08886 - stone Stone chip Schutz gun
chip-prone areas (e.g. sill panels) protective coatings
Evode Evo-Stik, 3M 8030, 8034, 8080, 8090 - trim parts Impact adhesive Brush or
aerosol
3M 08984 - Cleaning Adhesive cleaner Hand/clean

and wax remover cloth

INFORMATION
APPLICATION EQUIPMENT
Suitable application equipment is available from the following manufacturers and suppliers:
3M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automotive Trades Group

3M UK Plc
3M House
PO Box 1
Market Place
Bracknell
Berks. RG12 1JU
Tel. (01344) 858611
Cooper Pegler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Burgess Hill

Sussex RH15 9LA
Tel. (014 446) 42526
SATA Spray Equipment . . . . . . . . . . . . . . . . . . . . . Minden Industrial Ltd.

16 Greyfriars Road
Moreton Hall
Bury St. Edmunds
Suffolk IP32 3DX
Tel. (01284) 760791
SATA Schutz Gun Model UBE SATA HKD1 Wax Injection Injection Equipment
The SATA Schutz Gun is approved for the This equipment is approved for carrying out cavity
retreatment of vehicle underbody areas with wax re-treatment on Rover vehicles. The SATA
protective coatings as supplied in 1 litre, HKD1 set comprises a high quality forged gun with
purpose-designed ’one-way’ containers. The screw 1-litre pressure feed container, a flexible nylon
thread fitting (female on the gun) is standard to most lance, a straight 1100mm steel lance and hooked-
Schutz-type packs. wand lance. A quick-change coupling is provided as
a standard fitting to allow lances to be easily
Full operating details are supplied with the interchanged. Each lance has an integral, machined
equipment. nozzle with specialised spray characteristics to suit
the type of box section to be treated.
NOTE: Always clean gun after use with Specifications of Model UBE:
appropriate solvent to maintain efficiency.
Air consumption: 7cu.ft/min (200 litres/min) @ 45psi
Weight: 23.3oz (220 grams)

INFORMATION
3M Body Schutz Pistol Spraygun 08004 3M Applicator Gun 08190.
A pistol type spraygun constructed from case and For the application of 3M Structural Adhesive 08120.
machined light alloy and designed for use with 3M
screw fit Body Schutz containers.
3M Inner Cavity Wax Applicator Gun
NOTE: Always clean gun after use with
appropriate solvent to maintain efficiency. This equipment accepts 1-litre canisters and has a
750mm flexible tube.
3M Caulking Gun 8002
The approved system is available from all 3M
A lightweight, robust metal skeleton gun designed to refinishing factors.
accept 325mm (13Æ) cartridge for dispensing
sealants etc. This gun provides rapid cartridge
insertion and loading, with a quick-release lever for Cooper Pegler Falcon Junior Pneumatic Gun
accurate control of material ejection and shut-off. (Airless)
Intended primarily for applying transit wax, this

3M Pneumatic Cartridge Gun 08012 pneumatic sprayer has a 5-litre container with
integral hand pump. It provides an effective means
Air line-fed gun for applying 3M cartridge products. of wax spraying without the need for compressed air
Excellent for ease of application to obtain a smooth or additional services.
bead. Regulator valve for additional control.
A selection of nozzles, lances, hose lengths and a
trigger valve assembly with integral filter allows
3M Pneumatic Applicator Guns flexibility in use. Additional applications include
general maintenance, wax injection and paint
Air line-fed gun for application of 3M sachet sealers application. Heavy-bodied materials may also be
(Part Number 08006 for 200ml and 310ml sachet applied. All parts are fully replaceable and a wide
applications, and Part Number 08007 for all size range of nozzle configurations is available.
sachets including 600ml).
Also available: Heavy Duty Manual Gun 08013.

INFORMATION
MATERIALS GUIDE 3M Super Seam Sealer 08537
A brushable sealer which is designed to simulate the

3M Automotive Structural Adhesive 08120 original factory-applied sealer on all overlap joints on
floor panels, wheel arches, boot and load space
A two-part epoxy structural adhesive, twin cartridge seams, and petrol filler cap areas. Petrol, oil and
with ’Automix’ dispensing. For doorskin application water resistant.
and for bonding panels and stiffeners. Supplied in
two-pack form for use in small trigger-type gun (Part Supplied in 1 litre tins.
Number 08190).
NOTE: Brush on in ONE direction only for
best results.
3M Bolted Panel Sealer 08572
WARNING: Must be stored under normal
Preformed strip 20mm x 2mm. Permanently flexible conditions for highly flammable materials.
with good adhesion for sealing wing to body joints
and other bolted or riveted panels.
3M Flexseal 08684, 08689, 08694
Supplied in 4.6 metre reels.
A high solids, non-shrinking polyurethane sealer for
use in either a hand-operated gun or a pneumatic
3M Body Caulking 08568 applicator gun. Offers firm adhesion and sealing.
Water, oil and petrol resistant. Available in black,
Thumbing compound in preformed strips 6mm x white or grey.
300mm long. For sealing all large openings and
cracks. Non-hardening, does not dry out or crack. Supplied in 310ml cartridges.
Can be overpainted immediately.
3M Polyurethane Sachet Sealer 08703, 08783,
Supplied in packs of 60 strips. 08788
Similar to Flexseal polyurethane but available in

3M Drip-Chek Sealer Heavy 08531 collapsible aluminium foil sachets giving many
advantages over conventional cartridge packs.
For use on vertical seams and cracks up to 3mm Available in black, white or grey and in 310ml or
wide to give a firm but flexible seal which does not 600ml sachet sizes.
harden or shrink. Self-levelling but will not deform on
vertical surfaces. May be tooled or smoothed with a
wet finger. 3M Windscreen Sealer 08509
Supplied in 150ml tubes. Non-hardening sealant for sealing dry-glazed

weatherstrip windscreens. Applied to joint using the
applicator gun.
3M Drip-Chek Clear 08401
Supplied in 310ml cartridges.
Sealer with good flow qualities similar to Drip-Chek
Heavy but of clear consistency. Can achieve almost
invisible spot sealing over finished paintwork. May
be painted over or mixed with paint colour to give
self-coloured sealing medium.
Supplied in 150ml tubes.

INFORMATION
3M Spray Schutz 08877, Body Schutz 08861 3M Zinc Spray 09113
Quick-drying, flexible rubberised coatings which dry Anti-corrosive coating for joints and seams in spot
to a black textured finish. welding applications.
Supplied in 400g aerosol (Spray Schutz) and 1-litre Supplied in 500ml aerosol packs.
cartridges to fit Schutz spray gun.
3M Weld Thru’ Sealer 08625

3M Flexible Parts Repair Material 05900
Anti-corrosive protection between spot welded
a two-part, rapid-curing system for repairing minor panels. Brush application.
damage to plastic bumpers, air dams, valances etc.
Drying time 30 minutes. Supplied in 1-litre canisters.
Supplied in two-part 10fl.oz. kit.

3M Inner Cavity Wax 08901/29
3M Waterproof Cloth Tape Y3998 (equivalent to For providing a protective wax coating on inner
Unipart GWS121) panels. Supplied in 1-litre canister or 500ml aerosol
packs.
A black waterproof tape for sealing door panel
apertures and body box section access holes. Long
life, moisture-resistant adhesive will withstand 3M Bodygard 08158/9, 08588/9
immersion in water.
A rubber-based coating for stone chip protection on
Supplied in 50 metre rolls in a choice of widths. panels. Quick-drying, paintable and low bake
compatible.
3M Adhesive Cleaner and Wax Remover 08984 Supplied in 1-litre canister or aerosols in a choice of
white or grey.
For surface preparation prior to application of most
types of adhesives, coatings and sealant materials,
and for removal of tar, silicone polish, wax, grease
and oil. Non-staining. May also be used for removing
disc pad adhesive from sander backing pads.
Supplied in 1-litre canisters.

FRONT SUSPENSION
HYDRAGAS SYSTEM PROCEDURES AND TRIM Adjust - Trim height

HEIGHT ADJUSTMENT
CAUTION: To minimise problems caused
Check - Trim height by contamination of the hydragas system,
it is important that all equipment is
1. Allow vehicle to stand in an unladen condition maintained in a clean condition. Only clean
on a level surface. filtered fluid must be used in filling/pressurising
2. Place steering in a straight ahead position. equipment.
CAUTION: Do not check or adjust

suspension trim height immediately after a
road test. Allow vehicle to stand for at
least two hours to allow vehicle temperature to
equalise with air temperature.
3. Bounce the vehicle at both ends a number of

times and allow it to settle.
4. Roll vehicle forward 1 m to relieve suspension
stresses.
5. Push down on front of vehicle and release,
allow suspension to return unassisted. Do not
apply handbrake.
6. Measure both front trim heights, hub centre to

top centre of the front wheel arch
front trim height = 368 ± 10 mm.
Service tool 18G 703 V
CAUTION: Fluid in the suspension system
is under very high pressure. Any repair or
1. Filler cap
adjustment can only be carried out using
2. Fluid level sight glass
specialist equipment.
3. Pressure gauge
4. Vacuum gauge
5. Control valves
6. Pump operating lever
7. Connector
ADJUSTMENTS 1
FRONT SUSPENSION
18G 703V Hydragas Unit Valve Setting When pressure check is completed, unscrew the
connector T-bar and release pressure in unit by
opening valve ’A’, before removing connector from
VALVES A B C D E displacer.
Pressure check - - - 0 0 Fit underbonnet closing panel. See BODY, Exterior
Drain 0 - - 0 0 fittings.
Evacuation 0 0 0 - -
Fill - 0 0 - 0
Pressurising - - - 0 0 NOTE: Temperature will affect the
suspension height. Trim height
specification is correct at a nominal
O = Valve Open temperature of 17°C. Setting trim heights at
- = Valve closed temperatures above or below 17°C will cause the
suspension trim height to be incorrect and
should be compensated for, by the factor of 0.6
mm per 1°C, When temperatures are above or
below this figure.
TO DEPRESSURISE OR DRAIN - Close valves

’A’,’B’ and ’C’. Open valves ’D’ and ’E’. slowly open
valve ’A’ until pressure reads zero and movement of
fluid in tube has stopped.
TO EVACUATE - Open valves ’A’,’B’ and ’C’ . Close

valves ’D’ and ’E’. Ensure the tubular pump is in the
evacuation position, i.e. Turn pump handle
anti-clockwise, lift and turn clockwise again to lock.
Operate pump slowly until 27 inches Hg is obtained

TO ADJUST and movement of fluid in the tube has stopped.
Remove underbonnet closing panel. See BODY,
Exterior fittings. TO FILL DISPLACERS - Close valves ’A’ and ’D’.
Open valves ’B’,’C’ and ’E’. Slowly open valve ’E’
Fit connector of tool 18G 703V to displacer valve and wait until vacuum gauge has settled at zero.
with the connector T-bar valve unscrewed. Any air
which may have entered the tube during this TO PRESSURISE - Close valves ’A’,’B’ and ’C’.
operation should be carefully bled out by opening Open valves ’D’ and ’E’. Lower pump handle to
the bleed valve in the connector body and slowly pressurising position and pump to required pressure
pumping then close the bleed valve. or trim height.
Ensure the service tool is 1/4 full of hydralastic fluid The vehicle should periodically bounced while
before use. pumping up to settle the displacer valves and avoid
excessive pressure.
Close valves ’A’,’B’ and ’C’. Open valves ’D’ and ’E’.
Operate the pump until approx 100 psi is registered Drive the vehicle for a minimum of 2 miles to settle
on the gauge. screw in connector T-bar, and read the suspension before resetting the trim height.
pressure of displacer on gauge. Check trim height
and adjust by increasing the fluid pressure to raise,
or lower by slowly opening valve ’A’ and reducing
pressure until the correct pressure or trim height is
reached.
2 ADJUSTMENTS
FRONT SUSPENSION
HYDRAGAS UNIT TESTING
Test 18G 703V, 18G 1743
If the trim height is low and there is no detectable

fluid leak from the hydragas system, a leakage of
nitrogen from one or more of the hydragas units is
indicated.
1. Depressurise and evacuate the hydragas unit

on the low side of the car.
2. Disconnect the connecting pipe from the

suspect hydragas unit and fit the tool 18G 1743
to the unit. Pressurise the hydragas unit using
tool 18G 703V and note the readings on the
servicing unit pressure gauge. The gauge
readings should rise rapidly to 2172 kN/m2 ±
3% (240 lbf/in2 ± 20lb/in2), (this is the nominal
nitrogen pressure) and then rise gradually at
each operation of the servicing unit pump . If
the gauge reading continues to rise rapidly at
each operation of the servicing unit pump after
the nitrogen nominal pressure is reached, the
unit is defective and must be renewed.
3. If a NEW Hydragas unit is fitted to the vehicle,

evacuate it.
4. Adjust the pressure to give the correct trim

height.
ADJUSTMENTS 3
RESTRAINT SYSTEMS
COMPONENT LOCATION
NOTE: LHD type is symmetrical to RHD type.
1. Driver’s airbag module * 6. Fuse/relay box

2. SRS warning light 7. Passenger’s airbag module (optional) *
3. Diagnostic control unit * 8. Seat belt pre-tensioners *
4. Rotary coupler * 9. Diagnostic socket
5. SRS harness (YELLOW) *
* Components to be renewed following system deployment.
Following deployment of the Supplementary Restraint System (SRS), under any circumstances, the above
components marked with an asterisk must be renewed.
Impacts which do not deploy airbags, check for structural damage in the area of impact, paying particular attention
to bumper armatures, longitudinals, crash cans and bracketry.
DESCRIPTION AND OPERATION 1

RESTRAINT SYSTEMS
DESCRIPTION
The airbag Supplementary Restraint System (SRS)

is a safety device which, when deployed in the event
of a severe frontal impact, provides additional
protection to the driver’s face and upper torso. The
airbag is designed to inflate when the vehicle is
exceeding a set speed and receives a frontal impact
within the area shown.
2 DESCRIPTION AND OPERATION

RESTRAINT SYSTEMS
OPERATION
Diagnostic Control Unit Sequence of operation:
CAUTION: The diagnostic control unit is a 1. The main sensor and the safing sensor are
non-serviceable component and no activated.
attempt should be made to repair or 2. Power is supplied to the airbag igniter by the
modify the unit. battery or the back-up circuit.
3. The airbag deploys.
The diagnostic control unit which is mounted within
the passenger compartment performs two functions: It takes approximately 0.1 seconds from the
beginning of the airbag deployment until it is
1. It monitors the airbag system for faults; completely deflated.
2. It provides a fire signal to the airbag(s) in the
event of a crash.
System check
The warning lamp illuminates to inform the driver of
any airbag system faults. The warning light, located in instrument pack
illuminates when the electrical circuits are switched
The diagnostic control unit comprises of the on whilst the system performs a self diagnosis test. If
following circuits which control the airbag system: the system finds no fault during self diagnosis the
light will extinguish after approximately 5 seconds
1. The crash sensor determines the severity of and remain extinguished.
any impact and can discriminate between
rough road conditions and an actual crash. In the event of a fault in the system, the warning light
2. The safing sensor is wired in series with the will illuminate continuously or fail to illuminate during
crash sensor. The fire signal from the crash the self diagnosis test.
sensor therefore, passes through the safing
sensor which confirms a crash is taking place. Fault finding diagnosis
3. The regulator circuit maintains stability of the
system in the event of battery voltage drop. Faults in the SRS system can be identified by
4. The back-up power supply provides power to connecting TestBook into the diagnostic socket,
the system in the event of the battery being located on the passenger compartment fuse box.
damaged or disconnected during the impact.
5. Internal diagnostics continually monitor the
SRS system.
The fire signal from the diagnostic control unit

passes via the airbag harness to the airbag modules
and pretensioners. Grains of Nitrocellulose and
Nitroglycerine inside the airbag module, ignite and
combine in a chemical reaction to form a large
amount of Nitrogen gas leading to inflation of the
airbag in approximately 30 milli-seconds.
As the occupant moves forward into the airbag it

immediately deflates to provide progressive
deceleration and reduce the risk of injuries.
DESCRIPTION AND OPERATION 3

RESTRAINT SYSTEMS
PRECAUTIONS General
Making the system safe
• Remove key from starter switch, disconnect both

battery leads, earth lead first, wait 10 minutes to
allow the SRS back-up circuit to fully discharge. • Carefully inspect any SRS part before you install
it. Do not install any part that shows signs of
being dropped or improperly handled, such as
dents, cracks or deformation:
- Airbag assembly - Pretensioners

- Rotary coupler - SRS Harness
- Diagnostic control unit (DCU).
• The DCU is a shock sensitive device and must

be handled with extreme care.
• Because the crash sensor is incorporated inside
the DCU it is imperative that the bolts securing
the DCU and its bracket are tightened to their
correct torque.
• Never install a part that shows signs of being
dropped or improperly handled.
• Do not install used SRS parts from another car.
When repairing an SRS, use only new parts.
• Always disconnect both battery leads, earth lead • Do not use a circuit tester to check the system.
first before beginning work. • After completing work, check that the connectors
• On completion of work connect battery leads, are installed correctly.
earth lead last.
PRECAUTIONS 1
RESTRAINT SYSTEMS
Airbag Handling and Storage CAUTION: Improper handling or storage

can internally damage the airbag
• Do not try to disassemble the airbag assembly, it assembly, making it inoperative. If you
has no serviceable parts. Once an airbag has suspect the airbag assembly has been damaged,
been deployed, it cannot be repaired or reused. install a new unit and refer to the
• Be careful that the airbag assembly receives no Deployment/Disposal Procedures for disposing
strong shocks; it could deploy. of the damaged airbag.
• Special bolts are necessary for installing the
airbag assembly. Do not use other bolts. Overnight storage
For temporary storage of the airbag assembly during Airbag modules are classed as explosive articles
service, observe the following precautions: and as such must be stored in an approved secure
steel cabinet which has been registered by the local
authority.
• Always carry the airbag module with the pad

surface face up.
• Store the removed airbag assembly with the pad
surface face up.
• Do not allow anything to rest on the airbag
module.
• Place the airbag module in a designated storage
area.
• If no designated storage area is available, then
the boot of the vehicle should be used. Always
lock the boot when a module is stored in it and
inform the workshop supervisor.
WARNING: If the airbag is improperly

stored face down, accidental deployment
could propel the unit with enough force to
cause serious injury.
• Store the removed airbag assembly on a secure

flat surface away from any high heat source
(exceeding 85°C/185°F) and free of any oil,
grease, detergent or water.
2 PRECAUTIONS
RESTRAINT SYSTEMS
Wiring-related
• Never attempt to modify, splice or repair SRS

wiring. Never install electronic equipment such
as: a mobile telephone, two way radio or in car
entertainment system in such a way that it
interferes electrically with the airbag harness.
NOTE: SRS wiring can be identified by

special yellow outer protective covering.
• Always ensure SRS harnesses are routed

correctly. Be careful to avoid trapping or pinching
the SRS harness. Look out for possible points of
chafing.
• Always use specified earth fixings tightened to
the correct torque. Poor earthing can cause
intermittent problems that are difficult to
diagnose.
• Ensure all airbag harness connectors are mated
correctly and securely fastened. Do not leave the
connectors hanging loose.
PRECAUTIONS 3
RESTRAINT SYSTEMS
WARNING LABELS
A combination of symbols/icons are displayed (either 2. Rotary coupler

in a suitable, prominent position or are attached to
the component itself) to indicate:
(a) The need for caution when working in close
proximity to SRS components;
(b) The publication where suitable reference and
advice can be found (usually Workshop Manual or
Owner’s Handbook).
NOTE: It is imperative that before any

work is undertaken on the SRS system
that the appropriate publication is read
thoroughly.
The following list indicates current locations for

warning labels. Exact positions may vary dependent
on legislation and market trends.
1. Bonnet locking platform
Refer to the Owner’s Handbook for information on

the airbag system.
A - SRS - Refer to the Workshop Manual for detailed

instructions.
B - Ensure wheels are in the straight ahead position
before removal and refitting of the rotary coupler.
C - Rover part number/Bar code: The code number
must be quoted when ordering a replacement rotary
coupler.
DO NOT ROTATE ROTARY COUPLER

MECHANISM
4 PRECAUTIONS
RESTRAINT SYSTEMS
3. Door glass 6. Airbag module - passenger
Refer to the Owner’s Handbook for information on

the airbag system.
4. Airbag module - driver
A- ROVER Part Number/Bar code - The code

number must be quoted when ordering a
replacement module.
A- ROVER Part Number/Bar code - The code

number must be quoted when ordering a
replacement module.
5. Diagnostic control unit.
A- Refer to the Workshop Manual for information on

the airbag system.
B- ROVER Part number/Bar Code - The code

number must be recorded if the airbag control and
diagnostic unit is to be replaced.
PRECAUTIONS 5
RESTRAINT SYSTEMS
AIRBAG AND PRE-TENSIONER, MANUAL Deployment of pre-tensioner

DEPLOYMENT
These guidelines are written to aid authorised
NOTE: Pre-tensioner deployment is done personnel to carry out the safe disposal of the
in car only. pre-tensioner.
If a vehicle is to be scrapped and contains an WARNING:

undeployed airbag module, or pre-tensioner, the
components must be manually deployed. This
operation should only be carried out using the • Only use the Rover approved deployment
following recommended manual deployment equipment.
procedure. • Deploy pre-tensioner in a designated area.
• Ensure pre-tensioner is not damaged or
Before deployment is started the deployment tool ruptured before deploying.
self test procedure should be carried out. • Notify relevant authorities.
Deployment tool SMD 4082/1 self test procedure

1. Carry out deployment tool self test.
1. Insert blue and yellow connectors of tool lead 2. Slide seat fully forward to access pre-tensioner
into corresponding sockets on face of tool. harness connector.
2. Connect crocodile clips of second tool lead to 3. Disconnect pre-tensioner harness connector.
battery, red to positive and black to negative.
3. Red "READY" light should illuminate. WARNING: Ensure deployment tool SMD
4. Press and hold both operating buttons. 4082/1 is not connected to battery.
5. Green "DEFECTIVE" light should illuminate.
6. Release both operating buttons. 4. Connect flylead SMD 4082/5 to pre-tensioner
7. Red "READY" light should illuminate. connector.
8. Disconnect tool from battery. 5. Connect flylead SMD 4082/5 to tool SMD
9. Disconnect blue and yellow connectors from 4082/1.
tool face sockets.
10. Self test now complete. WARNING: Ensure pre-tensioner is
secured tightly to seat.
6. Connect tool SMD 4082/1 to battery.
WARNING: Ensure all personnel are

standing at least 15 metres away from
vehicle.
7. Press both operating buttons to deploy

pre-tensioner.
8. Using gloves, remove pre-tensioner from seat
and place pre-tensioner in plastic bag, and seal
bag.
9. Transport deployed pre-tensioner to
designated area for incineration.
NOTE: DO NOT transport pre-tensioner in

the vehicle passenger compartment.
6 PRECAUTIONS
RESTRAINT SYSTEMS
Deployment of driver airbag module 9. Press both operating buttons to deploy airbag
module.
These guidelines are written to aid authorised 10. DO NOT return to airbag module for 30
personnel to carry out the safe disposal of airbag minutes.
modules when removed from the vehicle. 11. Using gloves and face mask, remove airbag
module from tool, place airbag module in
WARNING: plastic bag, and seal bag.
12. Wipe down tool with damp cloth.
13. Transport deployed airbag module to
• Only use the Rover approved deployment designated area for incineration.
equipment.
• Deploy airbag modules in a well ventilated NOTE: DO NOT transport airbag module in
designated area. the vehicle passenger compartment.
• Ensure airbag module is not damaged or
ruptured before deploying. 14. Scrap all remaining parts of airbag system. DO
• Notify relevant authorities. NOT re-use or salvage any parts of the airbag
system.

2. Remove airbag module from steering wheel.
See Repairs.
3. Position tool SMD 4082/2 in vice, ensuring that
vice jaws grip tool above bottom flange to
prevent possibility of tool being forced upwards
from vice. Tighten vice.
WARNING: Ensure deployment tool SMD

4082/1 is not connected to battery.
4. Secure airbag module to tool SMD 4082/2.

Ensure module is correctly secured using both
fixings.
5. Ensure airbag module mounting brackets are
secure.
6. Connect flylead SMD 4082/4 to airbag module.
7. Connect flylead SMD 4082/4 to tool SMD
4082/1.
WARNING: Do not lean over airbag

module whilst connecting.

module.
PRECAUTIONS 7
RESTRAINT SYSTEMS
Deployment of passenger airbag module 10. Press both operating buttons to deploy airbag
module.
These guidelines are written to aid authorised 11. DO NOT return to airbag module for 30
personnel to carry out the safe disposal of airbag minutes.
modules when removed from the vehicle. 12. Using gloves and face mask, remove airbag
module from tool, place airbag module in
WARNING: plastic bag and seal bag.
13. Wipe down tool with damp cloth.
14. Transport deployed airbag module to
• Only use the Rover approved deployment designated area for incineration.
equipment.
• Deploy airbag modules in a well ventilated NOTE: DO NOT transport airbag module in
designated area. the vehicle passenger compartment.
• Ensure airbag module is not damaged or
ruptured before deploying. 15. Scrap all remaining parts of airbag system. DO
• Notify relevant authorities. NOT re-use or salvage any parts of the airbag
system.

2. Remove passenger airbag module. See
Repairs.
3. Position tool SMD 4082/6 in vice, ensuring that
vice jaws grip tool above bottom flange to
prevent possibility of tool being forced upwards
from vice. Tighten vice.
4. Position brackets SMD 4082/7 to tool, lightly
tighten bolts.
5. Position airbag module to tool SMD 4082/6.
Ensure module is correctly secured using all
fixings.
6. Ensure airbag module mounting brackets are
secure.
WARNING: Ensure tool SMD 4082/1 is not

connected to battery.
7. Connect flylead SMD 4082/5 to airbag module.

8. Connect flylead SMD 4082/5 to tool SMD
4082/1.
WARNING: Do not lean over airbag

module whilst connecting.

module.
8 PRECAUTIONS
RESTRAINT SYSTEMS
DIAGNOSTIC CONTROL UNIT Refit
Service repair no - 76.73.72 WARNING: Because the crash sensor is

incorporated inside the DCU, it is
WARNING: See Precautions. imperative that bolts securing the DCU are
tightened to their correct torque.
Remove 1. Fit DCU and tighten Torx bolts to 9 Nm.

2. Connect multiplug.
1. Make the SRS system safe.See Precautions.
2. Remove centre console panel. See BODY, CAUTION: Before connecting multiplug
Interior trim components. ensure that clip is in the open positon,
pointing away from the harness. Lock the
connector into position by pushing clip towards
harness.
3. Fit centre console panel. See BODY, Interior

trim components.
4. Carry out system check using TestBook.
3. Disconnect multiplug from diagnostic control

unit (DCU).
4. Remove 3 Torx bolts securing DCU to bracket.
5. Remove DCU.
REPAIRS 1
RESTRAINT SYSTEMS
DRIVER AIRBAG MODULE Refit
Service repair no - 76.73.71 1. Position module to steering wheel and connect

harness multiplug.
WARNING: See Precautions. 2. Align module to steering wheel, fit Torx screws
and tighten to 8 Nm
Remove
2. Remove 2 Tx30 Torx screws securing module

to steering wheel.
3. Release air bag module from steering wheel.
CAUTION: Do not allow the air bag module

to hang by the air bag harness.
4. Disconnect multiplug from air bag module.

5. Remove air bag module.
CAUTION: Store the air bag module in

accordance with the storage procedures
outlined in the precautions part of this
section.
NOTE: If the air bag module is to be

replaced, the bar code must be recorded.
2 REPAIRS
RESTRAINT SYSTEMS
Refit
PASSENGER AIRBAG MODULE
1. Position module to fascia bracket and tighten
Service repair no - 76.73.69 nuts to 8 Nm.
2. Tighten bolt securing bracket to fascia rail
WARNING: See Precautions. to 9 Nm.
3. Connect multiplugs.
4. Fit glovebox. See BODY, Interior trim
Remove components.
1. Make the SRS system safe. See Precautions.
2. Remove glovebox. See BODY, Interior trim
components.
3. Disconnect 2 multiplugs from airbag.

4. Remove bolt securing bracket to fascia cross
rail.
5. Remove 4 nuts securing airbag to bracket.
6. Remove airbag module.
CAUTION: Store the airbag module in

accordance with the storage procedures
outlined in the precautions part of this
section.
NOTE: If the airbag module is to be

replaced, the bar code must be recorded.
REPAIRS 3
RESTRAINT SYSTEMS
SRS HARNESS
Service repair no - 76.73.73
WARNING: See Precautions.
Remove
1. Make the SRS system safe.See Precautions. 7. Remove 4 Torx bolts securing DCU bracket to
2. Remove fascia. See BODY, Interior trim tunnel, release harness earth and position
components. DCU aside.
3. Disconnect SRS multiplug and SRS fuse 8. Remove 4 nuts and 3 bolts securing gear lever
satellite from fusebox. assembly to tunnel and position assembly
4. Disconnect multiplug from steering column. aside.
5. Disconnect multiplug from DCU and release 9. Release 11 cable clips securing SRS harness
harness from bracket clip. to main harness.
6. Disconnect 2 multiplugs from seatbelt 10. Remove SRS harness.
pre-tensioners.
4 REPAIRS
RESTRAINT SYSTEMS
Refit SEAT BELT
1. Position harness to body. Service repair no - 76.73.13

2. Connect fuse satellite and multiplug to fusebox.
3. Connect multiplugs to seatbelt pre-tensioners. Remove
4. Secure harness with clips.
1. Remove Torx bolt securing seat belt strap to
CAUTION: Ensure that pre-tensioner leads seat frame.
pass through grommets in centre console 2. Remove hoodwell trim. See BODY, Interior
area. trim components.
5. Position gear lever assembly to tunnel and

tighten fixings to 9 Nm.
WARNING: Because the crash sensor is

incorporated inside the DCU, it is
imperative that all bolts securing the DCU
are tightened to their correct torque.
6. Position DCU bracket to tunnel, fit harness

earth lead and tighten fixings to 9 Nm.
7. Connect multiplug to steering column.
CAUTION: Before connecting DCU

multiplug ensure that clip is in the open
position, pointing away from the harness. 3. Remove Torx screw securing seat belt reel to
Lock the connector into position by pushing clip body.
towards the harness. 4. Remove seat belt.
8. Connect multiplug to DCU and fit harness to Refit

clip.
9. Fit fascia. See BODY, Interior trim 1. Position seat belt to body and tighten bolt to 30
components. Nm.
10. Carry out system check using TestBook. 2. Fit hoodwell trim. See BODY, Interior trim
components.
3. Position seat belt strap to seat, fit bolt and
tighten to 35 Nm.
REPAIRS 5
RESTRAINT SYSTEMS
SEAT BELT PRE-TENSIONER Refit
Service repair no - 76.73.75 1. Position pre-tensioner to seat and tighten bolt

to 45 Nm.
WARNING: See Precautions.
Remove
CAUTION: Ensure pre-tensioner multiplug

is disconnected before seat is removed.
2. Remove seat. See BODY, Interior trim

components.
2. Ensure that pre-tensioner lead is correctly

clipped to seat base.
3. Fit seat. See BODY, Interior trim
components.
3. Remove bolt securing pre-tensioner to seat. 4. Carry out system check using TestBook.
4. Remove pre-tensioner.
6 REPAIRS
RESTRAINT SYSTEMS
ROTARY COUPLER CAUTION: Do not dismantle the rotary

coupler. It has NO serviceable parts and
Service repair no - 86.65.85 must be replaced as a complete assembly.
WARNING: See Precautions. Refit
1. Position rotary coupler to switch pack.

Remove 2. Connect multiplugs.
3. Fit and tighten screws.
1. Make the SRS system safe.See Precautions. 4. Remove adhesive tape.
2. Ensure wheels are in the straight ahead 5. Fit steering column nacelle. See STEERING,
position. Repairs.
3. Remove steering wheel. See STEERING, 6. Fit steering wheel. See STEERING, Repairs.
Repairs. 7. Carry out system check using TestBook.
4. Remove steering column nacelle. See
STEERING, Repairs.
5. If the rotary coupler is being re-used, place
adhesive tape around moulding to prevent
rotation.
6. Remove 4 screws securing rotary coupler to

steering column switch pack.
7. Release rotary coupler from column and
disconnect 2 multiplugs.
8. Remove rotary coupler.
REPAIRS 7
BODY
ELECTRIC WINDOW LIFT COMPONENTS
1. Door glass 11. Sash

2. Regulator 12. Nut - upper rail bracket, 2 off
3. Motor 13. Stud bracket - glass retention
4. Cheater assembly 14. Nut - glass retention
5. Sash 15. Glass retention assembly
6. Screw - sash to cheater, 2 off 16. Sleeve - sash adjuster, 2 off
7. Screw - cheater, 2 off 17. Screw - sash adjuster, 2 off
8. Fastner - cheater 18. Nut - sash adjuster, 2 off
9. Glass stop, 19. Bolt - glass retention
10. Bolt - glass to regulator, 2 off 20. Bolt - regulator, 2 off
DOORS 1
BODY
ELECTRIC WINDOW OPERATION
1. Window switch
2. Window relay
3. Motor
4. Regulator
5. Glass
The two window lift system is controlled by switches

fitted in the centre console. When the ignition is
switched on, the electric window relay located on the
driver’s compartment fusebox, switches power
supply to the window circuit. The electric motor via
an integral gearbox, operates the regulator
assembly to lift and lower the window glass.
Battery supply from the electric window relay to the

window switches is via two fuses, one for each door,
located in the driver’s compartment fusebox.
2 DOORS
BODY
DOOR - CENTRAL LOCKING COMPONENTS
1. External door handle assembly 9. Screw - inside door handle

2. Retaining clip - cylinder block 10. Holder - lock rod
3. Bolt - outer door handle 11. Escutcheon - remote door handle
4. Latch assembly 12. Screw - escutcheon
5. Cable - remote door handle 13. Striker - door lock
6. Sill button and rod 14. Bolt - striker
7. Screw - latch assembly 15. Lock motor
8. Remote door handle assembly
DOORS 3
BODY
DOOR CENTRAL LOCKING - OPERATION
1. Anti-theft alarm ECU 4. Internal door handle

2. Latch assembly 5. External door handle and lock
3. Lock motor 6. Sill button
Central door locking is operated by using any one of When the driver’s door key is turned or the sill button
the following: is depressed, the driver’s door is mechanically
locked by the door latch which triggers the latch
- Remote handset, switch. The latch switch sends an earth signal to the
- Key in the driver’s door lock, alarm ECU, which in turn controls the electrical
- Driver’s door sill button. current sent to the passenger door motor to lock the
door.
Both door locks are operated by separate integral
lock motors which function simultaneously. They are Operation of the passenger door sill button will lock
controlled by the alarm ECU mounted behind the or unlock the passenger door but will not operate the
fascia centre console, below the heater control unit. central door locking system.
A signal from the remote handset is received by the

alarm ECU. Depending on this signal the ECU will
either lock or unlock the doors by controlling the
direction of electrical current sent to the lock motors.
4 DOORS
BODY
DOOR - ALIGN ON HINGES DOOR STRIKER - ADJUST
Service repair no - 76.28.07 Service repair no - 76.28.05
1. Turn wheel in lock for access to wheel arch

liner screws.
2. Remove 3 screws and 3 scrivets securing
wheel arch liner.
3. Remove wheel arch liner to gain access to
hinge bolts.
4. Open door.
5. Remove screws securing door striker to ’B’
post collect striker.
6. Loosen bolts securing hinges to ’A’ post.
7. Align door to meet the profile of adjacent
panels, and ensure all surrounding door gaps
are parallel.
8. Tighten door hinge bolts.
9. Re-check door alignment.
10. Position door striker and fit screws. 1. Using a Torx bit loosen 2 striker screws and
11. Adjust door striker so that the door closes close door.
without the need for slamming it. 2. Check door for flush fit to adjacent panels and
12. Tighten door striker screws to 18 Nm . edges for equal gap.
13. Fit and wheel arch liner and secure with 3. Open door and tighten striker screws to 18 Nm.
screws and scrivets.
DOOR GLASS - ADJUST
For information on adjustment of the door glass, see

hood seals and door glass - adjust. See Hood.
DOORS 5
BODY
DOOR MIRROR GLASS
Remove Remove
1. Remove trim casing. See this section. 1. Remove trim casing. See this section.
2. Disconnect heated door mirror glass multiplug.

3. Remove door mirror adjustment lever.
4. Remove 2 screws securing door mirror to
cheater panel.
5. Release mirror harness from cheater and
remove mirror.
Refit
2. Release 5 clips securing outer waist seal to
1. Feed mirror harness through cheater, align door and remove seal.
mirror and tighten screws. 3. Peel back plastic sheet to allow access to inner
2. Fit door mirror adjustment lever. door.
3. Connect door mirror harness multiplug to 4. Switch ignition ON and lower window to allow
vehicle harness. access to bolts.
4. Fit trim casing. See this section. 5. Switch ignition OFF.
6 DOORS
BODY
DOOR GLASS REGULATOR
Remove
1. Remove glass. See this section.

2. Remove plastic sheet. See this section.
3. Disconnect multiplug from motor.
6. Remove 3 bolts securing glass to regulator.

7. Remove glass.
Refit
1. Position glass to regulator and align rear guide

to glass.
2. Fit bolts securing glass to regulator but do not
tighten.
3. Adjust door glass. See this section.
4. Position plastic sheet and secure in place. 4. Remove 4 bolts securing regulator to door.
5. Fit outer waist seal and secure with clips. 5. Loosen 2 bolts securing regulator to door.
6. Fit trim casing. See this section. 6. Remove regulator.
Refit
1. Position regulator to door and feed multiplug

through aperture.
2. Align bolts to slotted holes and tighten to 7 Nm.
3. Fit and tighten bolts to 7 Nm.
4. Fit glass. See this section.
5. Fit plastic sheet. See this section.
DOORS 7
BODY
OUTER WAIST SEAL DOOR AND HEADER SEAL
Remove Remove
1. Open both doors.

2. Lower both sun visors.
3. Release catches and lower hood.
4. Remove 2 Tx30 Torx screws securing each

hood striker and remove both strikers.
5. Remove 2 studs securing seal to ’A’ posts.
6. Remove seal.
Refit
1. Starting from the rear of the door, release 5
clips securing seal to door.
1. Position and centralise seal to header rail.
2. Remove seal.
2. Secure seal to ’A’ posts with studs.
3. Engage seal to flanges of header, ’A’ posts and
Refit
sills.
4. Fit hood strikers and tighten screws to 6 Nm.
1. Position seal to door and align clips.
5. Reposition sun visors.
2. Fit seal and engage clips.
6. Raise hood and secure catches.
7. Close doors.
8 DOORS
BODY
TRIM CASING PLASTIC SHEET
Service repair no - 76.34.01/99 Service repair no - 76.34.26
Remove NOTE: A NEW plastic sheet must always

be fitted, do not attempt to repair an
existing plastic sheet.
NOTE: To obtain an effective seal when

fitting a new plastic sheet, ensure that the
plastic sheet and door contact surface are
at room temperature: between 18 °C to 30 °C.
Remove
1. Remove the remote door handle. See this

section.
1. Remove 2 screws securing door pull.

2. Remove door pull from trim casing.
3. Remove screw securing remote door handle
escutcheon.
4. Remove remote door handle escutcheon.
5. Remove 3 screws securing trim casing.
6. Release 6 lower trim casing retaining clips,
remove trim casing.
Refit
1. Fit trim casing to door and secure with clips.

2. Fit screws securing trim casing to door.
3. Fit remote door handle escutcheon and secure
with screw.
4. Fit door pull to trim casing and secure with
screws.
2. Remove 3 screws securing door speaker.

3. Release speaker, disconnect 2 Lucars and
remove speaker.
DOORS 9
BODY
REMOTE DOOR HANDLE
Remove
1. Remove trim casing. See this section.
4. Remove 2 trim rear fixing clips from door.

5. Remove 2 screws securing door pull fixing
bracket to door, remove bracket.
6. Release 2 door harness retaining clips from
door.
7. Disconnect heated door mirror multiplug.
8. Remove trim casing rear upper fixing clip from
door.
9. Release plastic sheet from door. Feed harness
connectors through sheet and remove plastic
sheet.
Refit
1. Ensure door is clean and dry where it comes in

to contact with the adhesive strip on the plastic
sheet.
2. Fit plastic sheet, by fitting the adhesive strip to
the bottom centre of the door first.
3. Starting from the bottom centre of the adhesive 2. Release latch operating cable from remote
strip apply even pressure along the strip in door handle abutment bracket.
both directions simultaneously, until the top 3. Remove 2 screws securing remote door
centre of seal is reached. handle.
4. Feed harness connectors through sheet and 4. Release remote door handle from door by
secure to door. sliding in a forward direction.
5. Fit fixing clips to door. 5. Release clip securing latch operating cable to
6. Connect heated door mirror multiplug. remote door handle, remove remote door
7. Secure harness retaining clips to door. handle.
8. Fit door pull fixing bracket to door and tighten
screws. Refit
9. Fit trim casing rear fixing brackets to door.
10. Position door speaker, connect Lucars and 1. Fit latch operating cable to remote door handle
tighten screws. and secure with clip.
11. Fit the remote door handle. See this section. 2. Position remote door handle to door and
secure with screws.
3. Secure latch operating cable to remote door
handle abutment bracket.
4. Fit trim casing. See this section.
10 DOORS
BODY
PRIVATE LOCK OUTSIDE HANDLE
Remove Remove
1. Remove trim casing. See this section. 1. Remove trim casing. See this section.
2. Carefully peel back plastic sheet to allow 2. Switch the ignition ON and fully lower door
access to inner door. glass.
3. Switch ignition OFF.
4. Carefully peel back corner of plastic sheet to
allow access to door latch.
3. Unclip link rod from lock.

4. Release spring clip from lock.
5. Remove private lock.
5. Release clip securing door handle link rod to
Refit latch assembly and position aside.
6. Driver’s side: release lock link rod from lock.
1. Fit lock to handle and secure with spring clip.
2. Engage link rod to lock.
3. Position plastic sheet and press into place.
DOORS 11
BODY
Refit
1. Fit rod to handle and position handle to door.

2. Engage handle to door and tighten
bolts to 2.5 Nm.
3. Adjust rod length to align rod to latch.
4. Position rod and secure with clip.
5. Driver’s side: engage lock connecting rod.
6. Fully raise door window.
7. Position lock to handle and secure with clip.
8. Secure plastic sheet.
7. Remove 2 bolts securing handle to door.

8. Release 2 clips retaining handle to door and
position handle.
9. Release clip securing lock to handle and

remove lock.
10. Remove handle.
11. Remove rod from handle.
12 DOORS
BODY
BONNET - ADJUST BONNET LOCK PLATE - ADJUST
Adjust Adjust
1. Check alignment of bonnet. 1. Open bonnet.

2. Open bonnet.
2. Loosen 2 bolts securing lock plate to body.

3. Position lock plate fully forward.
4. Gently lower bonnet. Align striker pin with lock
and ensure safety catch engages in lock plate.
5. Tighten bolts to 25 Nm.
6. Check correct operation of bonnet latch and
alignment of bonnet.
7. If necessary adjust bonnet. See this section.
3. Loosen 4 bolts securing bonnet to hinges and

adjust bonnet.
4. Lightly tighten bolts and close bonnet.
5. Check gaps are equal and bonnet is aligned
with adjacent panels.
6. Open bonnet, adjust hinges if necessary and
tighten bolts to 9 Nm.
7. If necessary, adjust bonnet locking plate. See
this section.
EXTERIOR FITTINGS 1
BODY
BOOT LID - ADJUST BOOT LID STRIKER - ADJUST
Adjust Adjust
1. Check for equal gaps around boot and 1. Open boot lid.
alignment with adjacent panels.
2. Open boot lid.
2. Loosen 2 bolts securing striker to body and

approximately position striker.
3. Lightly tighten bolts and close boot lid. Check
for equal gaps and alignment with adjacent
panels.
4. Open boot lid, re-position latch as necessary
and tighten bolts to 10 Nm.
3. Loosen 4 bolts securing boot lid to hinges and

adjust boot lid.
4. Lightly tighten bolts and close boot.
5. Check alignment of boot lid.
6. Open boot lid.
7. Adjust boot lid if necessary and tighten bolts to
9 Nm.
8. If necessary, adjust boot striker. See this
section.
2 EXTERIOR FITTINGS
BODY
FRONT WHEEL ARCH LINER UNDERBONNET CLOSING PANEL
Remove Remove
1. Raise front of vehicle. 1. Open bonnet.
WARNING: Support on safety stands.
2. Remove road wheel(s).
2. Remove 2 fixings securing closing panel to

spare wheel well.
3. Release wheel arch flange seal from rear lower
3. Remove 2 fixings securing closing panel to
edge of wing panel.
scuttle.
4. Remove 3 screws securing wheel arch liner.
4. Remove fixing securing closing panel to air
5. Remove 3 scrivet screws securing wheel arch
intake plenum.
liner, remove scrivets.
5. Remove closing panel.
6. Remove wheel arch liner.
Refit
Refit
1. Fit closing panel to body studs and secure
1. Fit and align wheel arch liner.
fixings.
2. Fit scrivet fasteners securing wheel arch liner.
2. Close bonnet.
3. Fit and tighten screws securing wheel arch
liner.
4. Secure wheel arch flange seal.
5. Fit road wheel(s) and tighten nuts to correct
torque. See INFORMATION, Torque wrench
settings.
6. Remove stand(s) and lower vehicle.
EXTERIOR FITTINGS 3
BODY
ENGINE COMPARTMENT ACCESS PANEL CROSSMEMBER
Remove Remove
1. Raise vehicle on a 2 post ramp.
2. Remove 22 bolts securing crossmember to

floorpan.
3. Remove crossmember.
1. Release 4 retaining clips along front edge of
closing panel by pulling each clip away from Refit
the seal and lifting upwards.
2. Remove panel. 1. Position crossmember to floorpan and tighten
Do not carry out further dismantling if bolts to 22 Nm.
component is removed for access only. 2. Lower vehicle.
3. Remove 6 screws securing LH plate to panel,
remove plate.
4. Remove 3 screws securing RH plate to panel,
remove plate.
Rebuild
5. Fit RH plate to panel and secure with screws.

6. Fit LH plate to panel and secure with screws.
Refit
1. Fit closing panel and secure.
4 EXTERIOR FITTINGS
BODY
BONNET RELEASE CABLE
Remove
1. Remove headlamp assembly. See

ELECTRICAL, Repairs.
3. Release grommet from body

4. Feed bonnet release cable through hole.
2. Release cable from bonnet lock plate.

5. Loosen bolt securing earth header to inner
wing and release cable from 2 inner wing clips.
6. Remove engine compartment access panel.
See this section.
7. Remove hoodwell trim. See Interior trim
components.
EXTERIOR FITTINGS 5
BODY
13. Remove stud securing carpet to inner wheel

arch.
14. Release carpet from door seal and 5 velcro
strips.
15. Remove 2 studs securing carpet to ’B’ post,
and release carpet from door seal and velcro to
reveal cables.
8. Position carpet aside and remove 2 bolts

securing bonnet release lever to luggage
compartment bulkhead.
9. Release cable abutment and cable from lever
assembly.
10. Release cable from rear, inner wing clip.
11. Position felt pad aside and release grommet
from hoodwell panel.
12. Feed cable through body holes and remove
grommet from cable. 16. Release cable from 3 sill clips and 3 ’B’ post
clips.
17. Release cable from floorpan crossmember.
18. Release grommet from scuttle and remove
cable.
6 EXTERIOR FITTINGS
BODY
Refit PRIVATE LOCK - BOOT LID
1. Feed cable through scuttle and under carpet Service repair no - 76.19.10
insulation.
2. Position grommet to cable timing mark and Remove
engage grommet to scuttle.
3. Position cable to front inner wing and through 1. Open boot lid.
hole in body.
4. Engage cable and abutment to bonnet lock
plate.
5. Engage grommet to body.
6. Fit headlamp assembly. See ELECTRICAL,
Repairs.
7. Engage cable to inner wing clip and tighten
earth header bolt to 9 Nm.
8. Feed cable through floorpan crossmember and
engage to clips.
9. Position carpet and secure with studs and
velcro.
10. Position carpet beneath door flip seal.
11. Fit grommet to cable and position to timimg
mark.
12. Position cable through hole in hoodwell panel
and luggage compartment bulkhead.
13. Engage cable and abutment to bonnet release
lever.
14. Position lever to bulkhead and tighten bolts to
9 Nm.
15. Position carpet beneath luggage compartment
flip seal.
16. Engage grommet and cable clip.
17. Fit hoodwell trim. See Interior trim
components.
18. Fit engine compartment access panel. See
this section. 2. Release multiplug from boot lid latch, bracket.
19. Fit front bumper valance. See this section. 3. Disconnect multiplug.
4. Disconnect release cable from boot lid latch.
5. Remove clip securing lock to boot lid.
6. Remove lock assembly from boot lid.
Refit
1. Position lock to boot lid and secure with clip.

2. Connect release cable to boot lid latch.
3. Connect multiplug.
4. Secure multiplug to boot lid latch, bracket.
EXTERIOR FITTINGS 7
BODY
BOOT LID LATCH FRONT BUMPER ARMATURE
Remove Remove
1. Open boot lid. 1. Remove front bumper valance. See this

section.
2. Remove 2 bolts and 2 nuts securing each end

of armature to front panel.
3. Remove armature.
2. Disconnect 2 Lucars and multiplug from latch
assembly. Refit
3. Release cable from latch.
4. Release clip and remove cover from latch. 1. Fit armature to fixing studs.
5. Mark position of latch to boot for reference. 2. Fit nuts and bolts and tighten to 25 Nm.
6. Remove 2 bolts securing latch to boot lid. 3. Fit front bumper valance. See this section.
7. Remove latch assembly.
Refit
1. Position latch to boot lid using reference marks

and tighten bolts to 10 Nm.
2. Connect cable and secure to latch.
3. Connect Lucars and multiplug, and fit latch
cover.
4. Check latch operation and if necessary, adjust
boot lid striker. See this section.
8 EXTERIOR FITTINGS
BODY
REAR BUMPER ARMATURE FRONT BUMPER VALANCE
Remove Remove
1. Remove rear bumper valance. See this 1. Raise front of vehicle.

section.
2. Remove both direction indicators. See

2. Position luggage compartment carpet aside

and remove 4 bolts securing bumper armature
3. Remove 2 screws securing each end of
to body.
bumper valance to wheel arch liner.
3. Remove bumper armature.
4. Remove screw securing each end of bumper
valance to wings.
Refit
1. Align armature to body and tighten bolts to 22

Nm.
2. Fit rear bumper valance. See this section.
5. Remove 5 screws securing bumper valance to

bonnet lock panel.
6. Working through direction indicator housings,
remove 2 bolts securing bumper valance to
bumper armature.
7. Remove front bumper valance.
EXTERIOR FITTINGS 9
BODY
Refit REAR BUMPER VALANCE
1. Fit bumper valance. Service repair no - 76.22.74

2. Fit bolts securing bumper valance to bumper
armature and tighten to 25 Nm. Remove
3. Fit and tighten screws securing bumper
valance to bonnet locking platform.
4. Fit and tighten screws securing each end of
bumper valance to wheel arch liners.
5. Fit and tighten screws securing each end of
bumper valance to wings.
6. Fit both direction indicators. See
7. Remove stand(s) and lower vehicle.
1. Remove 4 screws securing bumper to wheel

arches.
10 EXTERIOR FITTINGS
BODY
2. Remove 2 bolts securing bumper valance to

bumper armature.
3. Open boot lid and position luggage

compartment carpet aside.
4. Disconnect 2 number plate lamp multiplugs.
5. Release 2 grommets from body.
6. Remove 3 thread covers and 3 nuts securing
bumper to body.
7. Remove bumper taking care to release wires
from holes.
Do not carry out further dismantling if
component is removed for access only.
EXTERIOR FITTINGS 11
BODY
SIDE AIR VENT
Remove
8. Release clip securing number plate lamp

assembly to bumper and remove lamp.
9. Remove other number plate lamp.
1. Remove 2 screws securing outer grille.
2. Remove outer grille.
Refit
3. Remove 3 screws securing inner retaining
plate.
1. Fit number plate lamps to bumper and engage
4. Remove inner retaining plate.
clips.
5. Remove air intake pipe.
2. Position wires through holes and align bumper
to body fixings.
Refit
3. Fit nuts and tighten to 25 Nm.
4. Fit thread covers.
1. Locate air intake pipe to body.
5. Connect multiplugs and position carpet.
2. Fit inner retaining plate and tighten screws.
6. Fit bolts and tighten to 25 Nm.
3. Fit outer grille and tighten screws.
7. Secure bumper to wheel arches with screws.
12 EXTERIOR FITTINGS
BODY
HOOD ASSEMBLY COMPONENTS - SOFT TOP
1. Hood frame 14. Front header fabric cover

2. Hood 15. Front header insert
3. Backlight 16. Catch - front header, 2 off
4. Backlight zip 17. Torx screw - catch, 6 off
5. Hood cover, tonneau 18. Striker - front header, 2 off
6. Retaining plate, 6 off 19. Torx screw - striker, 4 off
7. Tape elastic, 2 off 20. Seal - cantrail, 2 off
8. Tension cable, 2 off 21. Seal - B post, 2 off
9. Rear bow extrusion 22. Mounting plate - B post, 2 off
10. Rear bow, canopy insert 23. Screw - plate to body, 4 off
11. Pop rivet - tonneau panel, 2 off 24. Catch - rear hoodwell, 5 off
12. Stud - tonneau panel, 2 off 25. Rivet - hoodwell catch, 10 off
13. Link rod, 2 off
HOOD 1
BODY
HOOD ASSEMBLY COMPONENTS - HARD TOP
1. Hard top assembly 9. Harness extension

2. Backlight glass 10. Catch assembly - front header, 2 off
3. Weatherstrip - backlight 11. Screw - front catch assembly, 6 off
4. Headlining 12. Catch assembly - B post, 2 off
5. Trim stud - headlining, 2 off 13. Mounting plate - B post, 2 off
6. Seal 14. Header finisher - front
7. Finisher - lower edge 15. Clip - header seal, 6 off
8. Block spacer, 2 off
2 HOOD
BODY
HOOD SEALS AND DOOR GLASS - ADJUST Cheater
1. Check door alignment See Doors.
Adjust
Cantrail seal
1. Check that cantrail seal butts up to ’A’ post

seal correctly, the cantrail seal must not be
distorted when the hood is closed.
2. To adjust cantrail seal release hood and
carefully slide seal either backwards or
forwards in its channel.
3. Ensure seals are located correctly in their
channels. 1. Check position of cheater, the cheater must be
parallel with ’A’ post when viewed from the side
’A’ post seal and front of vehicle.
2. If cheater is protuding out at the top when
viewed from the front it will hold the door glass
away from the seal.
3. To access cheater adjusters remove door
speaker See ELECTRICAL, Repairs.
1. Check that ’A’ post seal is positioned square at

the corner of the ’A’ post and header.
2. To adjust ’A’ post seal remove 2 Torx screws
securing header striker and remove striker.
3. Manoeuvre ’A’ post seal to its correct position.
4. Close hood and secure with opposite side
hood catch, apply downward pressure on hood
and check that ’A’ post seal is aligning
correctly.
5. Release hood and fit header striker and secure
with Torx screws, tighten to 6 Nm .
4. Lower window and loosen screws B and C .
5. Loosen lock-nut on adjuster A , position
adjuster screw so that it is level with the back
of the nut it screws in to.
6. Push cheater down and pull inboard as far as
possible.
7. Hold cheater in this position and tighten screws
B and C, and the adjuster lock nut A.
8. Ensure window can be raised and lowered
smoothly.
HOOD 3
BODY
9. Close door and check cheater is positioned

correctly, this can be judged by the bulge made
by the glass on the ’A’ post seal which should
be uniform along the seal.
10. Fit speaker See ELECTRICAL, Repairs.
11. Fit door trim casing See Doors.
Door Glass
A: This gives glass deflection adjustment (pivoting at F: These give glass height adjustment (this is also
waist rail). the glass stop).
B: This gives glass deflection adjustment (pivoting at G: This is used at beginning of adjustment to
waist rail). position the door glass centrally in waist rail slot.
C: This gives glass height adjustment (this is also Tighten bolt to 7 Nm.
the glass stop). H: This is positioned at rear glass rail at final stage
D: This gives glass lateral and vertical adjustment. of adjustment and tightened to 7 Nm.
E: This gives glass lateral and vertical adjustment.
4 HOOD
BODY
NOTE: All glass adjustments must be 4. Loosen adjuster bolt H .

done before the upstroke of the glass. 5. Raise glass until adjusters D and E can be
accessed, then close the door.
1. Remove door speaker See ELECTRICAL, 6. Adjust the position of the glass until it is parallel
Repairs. with the ’A’ post, tighten adjusters D and E .
2. Peel back water shedder to access adjusters.
Height
NOTE: Glass height is correct when

pressure is being applied to the soft part
of the cantrail seal.
1. Lower glass slightly and loosen adjusters C

and F these also act as glass stops.
2. Raise glass to height required, pull adjusters
down in slots and tighten adjusters.
3. Lower glass and then raise fully to ensure 7. Open door and lower glass then raise fully,
required height has been obtained. check that front edge of glass and cheater are
in line.
Parallelism 8. Close door by pushing on glass, check glass
height.
9. If glass height is correct, pull adjusters down in
slots and tighten adjusters C and F .
NOTE: If glass height is incorrect refer to

height adjustment above.
10. Lower glass to access rear sash bracket,

tighten adjuster H .
11. Raise glass and ensure it pre-loads all
surrounding seals.
12. If pre-load is not sufficient loosen lock-nut on
adjuster B .
13. Position adjuster so that it is level with the back
of nut it is screwed in to, this will tilt the top
edge of the glass inwards.
14. Tighten lock-nut and check pre-load of glass
on seal.
15. If pre-load is still not sufficient loosen bolt G
NOTE: The glass is parallel when it is in and slide the bolt down one notch, tighten bolt.
the fully raised position and there is a 16. Repeat previous instruction until pre-load is
constant clearance of 7 mm between the correct.
glass and the rear face of the ’A’ post. 17. Secure water shedder.
18. Fit speaker See ELECTRICAL, Repairs.
1. Loosen two height adjusters C and F . 19. Fit door trim casing See Doors.
2. Lower glass sufficiently to gain access to
adjusters D and E , loosen adjusters.
3. Lower glass further to gain access to rear sash
rail bracket.
HOOD 5
BODY
CANTRAIL TENSIONING CABLES - ADJUST HARDTOP - ADJUST
Service repair no - 76.61.25 Service repair no -
1. Partially lower hood. NOTE: Check that soft top hood fit is
correct before making any adjustments to
the hardtop fit. See this section.
1. Fit hardtop. See this section.
Adjust
NOTE: If necessary, only make

adjustments to the cantrail seal and glass
height. It should not be necessary to
disturb any other settings.
Cantrail seal
1. Check that cantrail seal butts up to ’A’ post

2. Loosen cable locking screws. seal correctly, the cantrail seal must not be
3. Raise hood fully, but do not secure catches. distorted when the hardtop is secured.
4. Using pliers, pull cables taught and tighten 2. To adjust cantrail seal release hardtop and
locking screws. carefully slide seal either backwards or
5. Secure hood catches and check cable tension. forwards in its channel.
6. If necessary, release hood catches, slacken 3. Ensure seals are located correctly in their
cable locking screws and adjust cable tension. channels.
Tighten locking screws.
7. Secure catches. Glass height
NOTE: If glass height is incorrect adjust

the height to the minimum requirement, to
prevent too much disturbance to the soft
top hood settings.
1. Adjust glass height See this section.
6 HOOD
BODY
HARD TOP Refit
Service repair no - 76.61.01 NOTE: Ensure side catches are in the

raised position before fitting the hard top
Remove to the vehicle.
1. With assistance, position hard top to vehicle.

2. Secure hard top to header rail with catches.
3. If nessesary, release clips and adjust catches.
4. Secure hard top to hood mounting brackets.
5. Adjust catches if required.
6. Connect screen heater multiplug.
1. Disconnect multiplug from heated rear window.

2. Release 2 catches securing hard top to header
rail.
3. Release 2 catches securing hard top to hood
mounting brackets.
4. With assistance, remove hard top from vehicle.
HOOD 7
BODY
HOOD ASSEMBLY
Service repair no - 76.61.10/99
Remove
1. Lower both windows.

2. Release both hood catches, but do not lower
hood.
6. Remove 3 screws securing bulkhead finisher.

Collect press studs.
7. Release 6 clips and position bulkhead finisher
aside.
8. Remove 4 bolts securing hood to body.
9. Collect 2 hard top strikers.
10. With assistance, remove hood assembly.
CAUTION: Support assembly beneath

backlight and hinges during removal.
11. Position hood on a soft covered work surface.
3. Release rear edge of hoodwell carpet and

release 5 clips securing hood to body.
4. Fold rear of hood, up to release from body.
CAUTION: Clips must be fully released to

ensure that backlight is not damaged
when hood is lowered.
5. Tilt both seat squabs forward.
8 HOOD
BODY
Refit HOOD OUTER COVER
1. With assistance, position hood to body. Service repair no - 76.61.11

2. Position hard top strikers.
3. With assistance, align hinge brackets to body Remove
and fit bolts but do not tighten at this stage.
4. Raise hood but do not secure catches. The following operation involves the bonding of
5. Tighten hinge bracket bolts to 45 Nm. fabric backed vinyl to various steel components of
6. Position bulkhead finisher and engage clips. the hood frame. If adhesive is to be applied to the
7. Position press studs and secure bulkhead fabric backing, Dunlop 758 adhesive or equivalent
finisher with screws. should be used. For direct application on vinyl
8. Return seat squabs to original positions. surfaces, use Dunlop S1588 adhesive or equivalent.
9. Engage clips to secure rear of hood to body.
10. Engage hoodwell carpet beneath flip seal A thin coating of adhesive should be applied to both
11. Secure catches to secure front of hood. surfaces and then allowed to cure, until just touch
12. Raise windows. dry, for between 5 and 10 minutes, before the bond
is made.
1. Remove both hood catches. See this section.

2. Remove both ’B’ post seals. See this section.
3. With hood in the lowered position, remove

edge protector from rear of header rail.
4. Release forward 150 mm of cantrail seals from
retainers. release covering from rear of header
rail and fold cover forward to reveal retaining
strip.
5. Locally release foam from retaining strip to
reveal 11 rivets, drill out rivets.
6. Collect header cover assembly.
HOOD 9
BODY
7. Release outer cover from adhesive on 9. Release outer cover from adhesive on ’B’ post
underside of header rail. brackets.
8. Drill out 5 pop rivets securing each ’B’ post 10. Bend up tabs and release ’rivet’ plates
seal retainer. Collect retainers. securing outer cover to base of ’B’ post
brackets.
11. Raise hood frame.
10 HOOD
BODY
14. Drill out 5 pop rivets securing each retaining

strip and collect retaining strips.
15. Drill out any rivet heads still captive in hood
frame.

release 5 clips.
16. Loosen cable locking screws and release

cables from outer cover.
NOTE: Leave cables attached at header

rail.
17. Release outer cover flaps from adhesive on 1st

and 2nd hood bows.
HOOD 11
BODY
Refit
1. Remove any uneven deposits of adhesive from

’B’ post brackets, clamp rail and header rail
using a suitable solvent.
2. Position new outer cover to a soft covered
work surface.
3. Fold outer cover in half and chalk centre line to
aid alignment.
4. Measure and mark centre line on underside of
hood header rail.
5. Apply adhesive to clamp rail and outer cover.
18. Release felt covering from 3rd hood bow.
6. Bond clamp rail to outer cover with larger

flange towards edge of material.
7. If necessary, apply adhesive to clamp rail and
felt covering. Bond covering centrally to clamp
rail, ensuring that slotted ends remain free.
8. Position outer cover over raised hood frame
and engage clamp rail studs to bow.
9. Secure clamp rail with nuts.
10. Apply adhesive to 3rd hood bow and mating
surface of felt covering.
CAUTION: Ensure underside of outer

cover does not become contaminated with
adhesive.
11. Bond felt covering to 3rd bow, ensuring that

slots are correctly positioned around frame
straps.
19. Remove 7 nuts securing outer cover clamp rail

to 3rd hood bow.
20. Release clamp rail studs from bow and remove
outer cover assembly.
21. Remove clamp rail from outer cover.
12 HOOD
BODY
21. Temporarily fit hood catches.

22. Position outer cover to header, then make
adhesive joint in three small areas.
CAUTION: Do not make a permanent joint

at this stage as adjustment may be
necessary.

24. Check outer cover tension.
25. Lower hood partially.
26. Adjust position of outer cover and recheck
tension if necessary.
27. Remove hood catches.
28. Bond outer cover securely to header rail,
ensuring cover does not crease.
29. Trim off excess material using a sharp knife.
30. Lower hood fully.
31. Position header cover assembly.
32. Transfer holes in header cover retainer through
outer cover into header rail.
33. Secure header cover retainer with pop rivets.
34. Apply adhesive to header rail and mating
surface of header cover.
CAUTION: Ensure underside of outer

12. Align hood rear quarters to lower rail, ensuring adhesive.
that:
Lower edge of rail and cover reinforcement 35. Bond header cover.
strip are aligned. 36. Fit edge protector to rear of header rail.
Centre of rivet hole in lower rail is 5 mm from 37. Secure forward ends of cantrail seals in
end of reinforcement strip as shown. retainers.
13. Transfer holes from lower rail into outer cover, 38. Fit hood catches. See this section.
using a bradawl or similar tool. 39. Raise hood partially.
14. With carefull use of a drill, open out holes to 40. Engage outer cover rivet plates to ’B’ post
3.5 mm. brackets and bend over tabs to secure.
15. Position retaining strips and secure hood rear 41. Apply adhesive to ’B’ post brackets and mating
quarters to lower rail with pop rivets. surfaces of outer cover.
16. Raise backlight into position and secure with 42. Raise hood, but do not secure catches.
zip.
18. Engage hoodwell carpet beneath flip seal
19. Partially lower hood frame.
20. Apply adhesive to underside of header rail and
mating surface of outer cover.
HOOD 13
BODY
43. Thread cantrail cables through pockets in outer HOOD FRAME

cover and engage in frame locations.
44. Bond outer cover to ’B’ post brackets, ensuring Service repair no - 76.61.12
that even tension is applied as bond is made.
45. Position ’B’ post seal retainers. Remove
46. Transfer holes in retainers through outer cover
into brackets. 1. Remove outer cover. See this section.
47. Secure retainers with pop rivets. 2. Remove backlight. See this section.
48. Fit ’B’ post seals. See this section. 3. Tilt both seat squabs forward.
49. Apply adhesive to outer cover flaps and mating
surfaces of 1st and 2nd hood bows.
CAUTION: Ensure that underside of outer

adhesive.
50. Check cosmetic appearance of hood.

51. Adjust cantrail cables. See this section.
52. Remove protection.
53. Secure hood catches.
54. Close windows.
4. Remove 3 screws securing bulkhead finisher,

collect press studs.
5. Release 6 clips and position bulkhead finisher
aside.
6. Remove 4 bolts securing hood frame to body.
7. Collect hard top strikers.
8. With assistance, remove hood frame.
9. Remove cantrail seals, See this section.
10. Bend up tabs securing cantrail tensioning
cables to header rail.
11. Remove tensioning cables.
14 HOOD
BODY
Refit BACKLIGHT
1. Position cantrail tensioning cables to header Service repair no - 76.61.15

rail.
2. Secure cables top header rail by bending tabs. Remove
3. Fit cantrial seals, leaving forward ends
disengaged from retainer. See this section. 1. Lower both windows.
4. With assistance, position frame. 2. Release hood catches, but do not lower hood.
5. Position hard top strikers.
6. With assistance, align hinge brackets to body
and secure with bolts. Tighten bolts to 45 Nm.
7. Raise hood frame.
8. Position bulkhead finisher and engage clips.
9. Position press studs and secure bulkhead
finisher with screws.
10. Return seat squabs to original positions.
11. Fit outer cover. See this section.
12. Fit backlight. See this section.

release 5 clips.
CAUTION: Clips must be fully released to

ensure that backlight is not damaged.
5. Unzip backlight.
6. Lay backlight flat in hoodwell.
7. Place protective covering over backlight and
boot.
HOOD 15
BODY
8. Remove 2 rivets securing ends of hood rear

quarter retaining strips.
9. Carefully bend back ends of strips to reveal
rivets.
10. Drill out 13 pop rivets securing backlight
retaining strip.
11. Collect retaining strip and remove backlight.
12. Release felt covering from 3rd hood bow.

13. Remove 7 nuts securing outer cover clamp rail.
14. Partially lower hood frame.
15. Release clamp rail studs from hood frame.
16. Lay protective sheet over backlight, luggage
compartment lid and seats.
17. Release foam from ends of zip retainer to
reveal pop rivets.
18. With assistance to hold outer cover aside, drill
out 9 pop rivets securing zip retainer to hood
frame.
19. Remove backlight zip.
16 HOOD
BODY
Refit HOOD CATCH
1. Drill out any rivet heads still captive in hood Service repair no - 76.61.17
frame.
Remove
CAUTION: Clear away swarf from
protective covering to ensure that new 1. Lower hood.
backlight does not become scratched.
2. With assistance, position backlight to frame,

centralise and transfer holes into backlight.
3. Position backlight to a soft covered work
surface.
4. With careful use of a drill, enlarge holes to
3.5mm
5. Position backlight to frame, align retainer and
secure with pop rivets.
NOTE: Start at the centre location and

work outwards.
6. Secure ends of rear quarter retaining strips

with rivets.
7. Position zip assembly to frame and secure with
rivets.
8. Fit foam pads to both ends of hood bow.
2. Remove 3 Allen screws securing catch to hood
NOTE: Foam pads are designed to prevent header rail.
outer cover being damaged by ends of 3. Remove hood catch.
hood bow and zip retainer.
Refit
9. Position outer cover clamp rail to frame and
engage studs. 1. Position catch and fit screws, finger tight.
10. Raise hood, but do not secure catches. 2. Raise hood, but do not secure catches.
11. Secure outer cover, clamp rail with nuts. 3. Align catch to striker and tighten screws to 20
12. Apply adhesive to 3rd hood bow and mating Nm.
surface of felt covering. 4. Check operation of hood catches. If necessary,
release locking wire and turn hexagonal
CAUTION: Ensure underside of outer adjuster to give correct action.
cover does not become contaminated with 5. Secure locking wire.
adhesive. 6. Secure hood catches.
13. Bond felt covering to 3rd bow, ensuring that

slots are correctly positioned around frame
straps.
14. Remove protective covering.
15. Raise backlight into position and secure with
zip.
17. Engage hoodwell carpet beneath flip seal
19. Raise windows.
HOOD 17
BODY
CANTRAIL TENSIONING CABLE 6. Peel outer cover away from header in

immediate area of cable location.
Service repair no - 76.61.26 7. Bend location tag up by minimum amount
necessary and release cantrail tensioning
The following operation involves the bonding of cable from header rail.
fabric backed vinyl to various steel components of 8. Remove cantrail tensioning cable.
the hood frame. If adhesive is to applied to the fabric
backing, Dunlop 758 adhesive or equivalent should Refit
be used. For direct application on vinyl surfaces, use
Dunlop S1588 adhesive or equivalent. 1. Locate cable loop over location tag in header
rail and bend tag over to retain cable.
A thin coating of adhesive should be applied to both 2. Apply adhesive to outer cover and header rail.
surfaces and then allowed to cure, until just touch 3. Bond outer cover to header rail, ensuring that
dry, for between 5 and 10 minutes, before the bond beading at side of header is correctly
is made. positioned.
4. Fit forward end of cantrail seal to retainer.
1. Partially lower hood. 5. Partially raise hood.
6. Insert new cable into pocket of outer cover.
7. Thread cable through location in 2nd hood
bow.
8. Raise hood fully, but do not secure catches.
9. Using pliers, pull cable taught and tighten
locking screw.
10. Secure hood catches and check cable tension.
11. If necessary, release hood catches, slacken
cable locking screw and adjust cable tension.
Tighten locking screw.
12. Secure catches.
2. Loosen cable locking screw.

3. Release cable from location.
4. Lower hood fully.
5. Release forward 100 mm of cantrail seal from
retainer.
18 HOOD
BODY
BACKLIGHT ZIP HARD TOP HEADLINING
Remove Remove
1. Remove backlight assembly. See this section. 1. Remove front catches. See this section.
2. Entrust replacement of zip to trim specialist.
Refit
1. Refit backlight assembly. See this section.
2. Remove 2 trim studs securing rear of

headlining to hard top.
3. Remove headlining.
Refit
1. Position headlining and secure with trim studs.

2. Fit front catches. See this section.
HOOD 19
BODY
HARD TOP CATCH - REAR HARD TOP CATCH - FRONT
Remove Remove
1. Remove hard top. See this section. 1. Remove hard top. See this section.
2. Invert hard top on a soft covered work surface. 2. Invert hard top on a soft covered work surface.
3. Position protection over headlining and
backlight.
3. Remove 3 Allen screws securing catch to hard

top.
4. Remove catch.
Refit
4. Drill out 2 pop rivets securing catch to hard top.
1. Position catch and tighten screws to 10 Nm.
5. Remove catch.
2. Fit hard top. See this section.
3. Check operation of catch. If necessary, release
Refit
locking wire and turn hexagonal adjuster to
give correct action.
1. Position catch and secure with rivets.
4. Secure locking wire.
5. Secure catch.
3. Check operation of catch. If necessary, turn
adjuster to give correct action.
4. Secure catch.
20 HOOD
BODY
HARD TOP SEAL Refit
Service repair no - 76.61.34 1. Remove all traces of dirt and grease from
surfaces to be bonded using a suitable mild
Remove solvent.
2. Apply Loctite 401 to hard top using old
1. Remove hard top. See this section. deposits as a guide.
2. Invert hard top on a soft covered work surface. 3. Position seal, centralise and carefully bond to
3. Release seal from adhesive at header and hard top.
below backlight. 4. Engage studs securing seal to hard top.
4. Release 26 studs securing seal to hard top.

5. Remove seal.
HOOD 21
BODY
CANTRAIL SEAL ’B’ POST SEAL
1. Lower both windows. 1. Lower both windows.

2. Depress locking buttons and release both hood 2. Depress locking buttons and release both hood
catches. catches.
3. Partially lower hood. 3. Partially lower hood.
4. Position protective covering beneath frame.
5. Drill out pop rivets securing seal to frame

channels.
6. Release seal from 2 retainers.
7. Remove seal.
Refit
1. Apply liquid soap to seal retainers. 4. Remove seal from retainer.

2. Position seal and engage to retainers.
3. Raise hood and check seal fit. Refit
4. If necessary, partially lower hood, reposition
seal in retainers and recheck. 1. Apply liquid soap to seal retainer.
5. Carefully transfer rivet holes into seal using a 3 2. Fit seal to retainer.
mm drill bit. 3. Raise hood and check seal fit.
4. If necessary, partially lower hood, reposition
CAUTION: Care must be taken not to drill seal in retainer and recheck.
through the outer surface of the seal. 5. Raise hood and secure catches.
6. Raise windows.
6. Secure seal with pop rivets.
8. Raise windows.
22 HOOD
BODY
HARD TOP - BACKLIGHT CAUTION: Use assistance to support

glass as it is removed.
5. Remove and discard rubber seal.
Remove
Refit
1. Remove hard top. See this section.
2. Invert hard top on a soft covered work surface. 1. Clean hard top aperture and edge of glass.
2. Apply rubber lubricant to seal channels.
3. Fit sealing rubber to glass.
WARNING: Gloves and suitable eye

protection must be worn when fitting
glass.
3. Disconnect 2 Lucar terminals and remove

heated screen harness.
WARNING: Gloves and suitable eye

protection must be worn when removing
glass.
4. Working from inside hard top and commencing 4. Insert a suitable length of cord in hard top
from lower LH corner, release sealing rubber. aperture channel of sealing rubber.
Remove glass and seal.
HOOD 23
BODY
5. Using assistance, push glass against hard top

aperture whilst using cord to pull lip of seal
over aperture flange.
6. Clean all traces of rubber lubricant from glass
and hard top using white sprit.
7. Fit heated screen harness and connect Lucar
terminals.
9. Press firmly around outside edges of glass to
ensure that seal is fully seated.
24 HOOD
BODY
SUN VISOR INTERIOR MIRROR
Remove Remove
1. Lower sun visor.
1. Release mirror from screen mounted clip.

2. Remove 2 screws securing visor to header rail. 2. Release cable and multiplug from header
3. Remove visor. finisher.
3. Disconnect multiplug and remove mirror.
Refit
Refit
1. Position visor and secure with screws.
1. Connect multiplug and position cable to recess
in mirror mounting.
2. Fit mirror to windscreen.
3. Position excess cable and multiplug behind
header finisher.
INTERIOR TRIM COMPONENTS 1

BODY
LUGGAGE COMPARTMENT TRIM ’A’ POST TRIM
Remove Remove
1. Lower sun visor.

2. Release catches and lower hood.
3. Remove 2 Tx30 Torx screws securing hood

striker.
4. Remove striker.
5. Release 4 sprag clips securing trim to ’A’ post.
6. Remove ’A’ post trim.
Refit
1. Position trim and engage sprag clips.

2. Fit hood striker and tighten screws to 6 Nm.
1. Remove 4 clips securing trim to engine 3. Reposition sun visor.
compartment bulkhead. 4. Raise hood and secure catches.
2. Release trim from flip seal, bonnet release
lever and boot lid striker.
3. Remove trim.
Refit
1. Fit trim and secure with clips.

2. Position trim behind flip seal.
3. Position trim to bonnet release lever and boot
lid striker.
2 INTERIOR TRIM COMPONENTS

BODY
REAR BULKHEAD FINISHER
Remove
4. Release belt guides and unthread seat belts

from finisher.
5. Remove bulkhead finisher.
1. Using tool 18G 1744, remove Torx bolt
Refit
securing seat belt straps to seat frames.
1. Position finisher and thread seat belts into
position.
2. Engage belt guides to finisher.
3. Align finisher to bulkhead and engage studs.
4. Position press studs and secure with screws.
5. Fit seat belt straps to seats and tighten bolts to
30 Nm.
6. Return seats to original positions.
2. Remove 3 screws securing finisher and collect

press studs.
3. Release studs securing finisher to bulkhead
and rear of centre console.

BODY
HEADER TRIM FRONT CONSOLE
Remove WARNING: See RESTRAINT SYSTEMS,

Precautions.
1. Remove both sun visors. See this section.
2. Release catches and lower hood. Remove
1. Make SRS system safe. See RESTRAINT

SYSTEMS, Precautions.
2. Remove centre console panel. See this
section.

3. Remove both seats. See this section.

4. Remove rear console. See this section.
5. Remove both console closing panels. See this
section.
3. Remove 2 Tx30 Torx screws securing each

hood striker and remove strikers.
4. Release 6 sprag clips securing trim to header
rail.
5. Remove trim.
6. Remove 6 screws securing console to tunnel.
Refit
1. Position trim and engage sprag clips.

2. Fit hood strikers and tighten screws to 6 Nm.
3. Fit sun visors. See this section.

BODY
Refit
1. Position front console, connect cigar lighter

multiplug and position volumetric sensor cable.
2. Position console and secure with screws.
3. Fit handbrake gaiter and secure with band.
4. Engage gaiter to console.
5. Adjust handbrake. See BRAKES,
Adjustments.
6. Fit console closing panels. See this section.
7. Fit rear console. See this section.
CAUTION: Ensure that pre-tensioner

flylead is correctly clipped to seat base
before fitting seat, as shown in seat refit.
See this section.
8. Fit seats. See this section.

9. Fit centre console panel. See this section.
10. Connect both battery terminals, earth lead last.
7. Loosen handbrake adjustment and position

hand brake lever in ON position.
8. Release handbrake gaiter from console and
remove gaiter from handbrake.
9. Release console and disconnect multiplug from
cigar lighter.
10. Release volumetric sensor cable and remove
console.

BODY
REAR CONSOLE Refit
Service repair no - 76.25.04 1. Fit sensor to console and secure with screws.
2. Fit rear console to bulkhead and secure with 2
Remove upper screws. Ensure correct position of cable.
3. Fit console lid assembly and secure with
1. Remove rear bulkhead finisher. See this screws.
section. 4. Fit front console storage bin.
5. Connect multiplug to sensor.
6. Fit rear bulkhead finisher. See this section.
2. Disconnect multiplug from volumetric sensor.

3. Remove 2 screws securing rear console to rear
bulkhead.
4. Open rear console lid and remove 2 screws
securing rear console to front console.
5. Open front console lid and remove storage bin
from front console.
6. Remove 2 screws securing console lid bracket
to front console and remove console lid
assembly.
7. Remove rear console.
8. Remove 2 screws securing volumetric sensor
to rear console and remove sensor.

BODY
GEAR LEVER GAITER CENTRE CONSOLE PANEL
Remove Remove
1. Remove centre console panel. See this 1. Disconnect battery earth lead.
section. 2. Remove radio. See ELECTRICAL, Repairs.
3. Remove gear knob.

4. Release 6 clips securing console to fascia.
2. Remove 2 screws securing gaiter retaining

bracket to gaiter.
3. Remove bracket and gaiter.
Refit
1. Position gaiter.
2. Fit bracket and secure with screws.
3. Fit centre console panel. See this section.

BODY
5. Release 3 Lucars from clock.

6. Release multiplug and bulb holder from oil 8. Release 6 multiplugs from switches.
temperature gauge. 9. Release gaiter from gear lever and remove
7. Release hazard switch multiplug. centre console.
Refit
1. Position console and engage gaiter to gear

lever.
2. Connect multiplugs, Lucars and bulb holder.
3. Secure console clips to fascia.
4. Fit gear knob.
5. Fit radio. See ELECTRICAL, Repairs.
6. Connect battery earth lead.

BODY
CONSOLE CLOSING PANEL FASCIA PANEL
Remove WARNING: See RESTRAINT SYSTEMS,

Precautions.
Remove
1. Make SRS system safe.See RESTRAINT

2. Remove front console. See this section.
3. Remove steering column switch pack. See
4. Remove instrument pack. See
INSTRUMENTS, Repairs.
5. Remove glovebox. See this section.
6. Remove 4 screws securing heater controls to

fascia and position aside.
1. Remove 2 screws securing panel to console.

2. Release panel and disconnect 2 Lucars from
lamp.
3. Remove lamp from panel.
Refit
1. Fit lamp to panel and connect Lucars.

2. Position panel and secure with screws.
7. Loosen 2 screws securing fuse box cover to

fascia and remove cover.
8. Release both screen heater ducts from fascia
and position aside.

BODY
GLOVEBOX
Remove
1. Open glovebox lid.
2. Remove 4 screws securing glovebox to fascia.

9. Loosen 4 nuts securing fascia to lower ’A’ post.
3. Release glovebox and disconnect 4 Lucars.
10. Release 4 retaining bolt caps from fascia and
4. Remove glovebox.
collect caps.
11. Remove 4 bolts securing fascia to scuttle.
Refit
12. Remove fascia panel.
1. Position glovebox and connect Lucars.
Refit
2. Engage glovebox to fascia and secure with
screws.
1. Position fascia to scuttle.
3. Close glovebox lid.
2. Align fascia and secure with nuts and bolts.
3. Fit retaining bolt caps.
4. Engage heater ducts to fascia.
5. Position fuse box cover to fascia and secure
with screws.
6. Align heater controls to fascia and secure with
screws.
7. Fit glovebox. See this section.
8. Fit instrument pack. See INSTRUMENTS,
Repairs.
9. Fit steering column switch pack. See
10. Fit front console. See this section.

BODY
GLOVEBOX LATCH HOODWELL TRIM
Remove Remove
1. Open glovebox lid. 1. Lower both windows.

2. Release hood catches, do not lower hood.
2. Remove screw securing latch to glovebox lid.

3. Remove latch.
Refit
1. Position latch to glovebox lid and secure with

screw.
2. Close glovebox lid.
3. Release rear edge of hoodwell trim to reveal 5
clips.
4. Release clips securing rear of hood to body.
5. Raise rear edge of hood.
6. Remove hoodwell trim.

BODY
Refit HEAD RESTRAINT
1. Fit trim and engage beneath lip of bulkhead Service repair no - 78.10.36/99
finisher.
2. Reposition rear edge of hood. Remove
4. Engage hoodwell trim beneath flip seal.
6. Raise windows.
1. Rotate inboard head restraint, guide cap 90°.

2. Remove head restraint.
Refit
1. Fit head restraint.

2. Rotate inboard head restraint, guide cap back
90° to lock head restraint.

BODY
SEAT
Service repair no - 78.10.44/99
WARNING: See RESTRAINT SYSTEMS,

Precautions.
Remove
1. Make the SRS system safe.See RESTRAINT

2. Lift seat adjuster, move seat rearwards.
7. Disconnect seat belt pre-tensioner multiplug.

8. Position seat and remove Torx screw securing
seat belt strap to seat frame.
9. Remove seat.
3. Remove Torx screw from front of each seat

runner.
4. Lift seat adjuster, move seat forwards.
5. Rotate recline handle to tilt squab fully forward.
6. Remove Torx screw from rear of each seat
runner.

BODY
Refit SEAT SQUAB ASSEMBLY
1. Ensure harness lead does not become trapped Service repair no - 78.10.50/99
under seat runner when fitting seat.
Precautions.
Remove


2. Remove seat. See this section.
2. Ensure that pre-tensioner lead is correctly

clipped to seat base.
3. Position seat and align runners to floor bolt
holes.
4. Connect pre-tensioner multiplug.
5. Fit but do not tighten Torx screw securing rear
of each seat runner.
6. Lift seat adjuster, move seat rearwards.
7. Fit Torx screw securing front of each seat
runner and tighten to 45 Nm.
8. Lift seat adjuster, move seat forwards.
9. Tighten Torx screw securing rear of each seat
runner to 45 Nm.
10. Connect both battery leads, earth lead last.
11. Position seat belt strap to seat frame and
tighten Torx screw to 30 Nm.
3. Release 2 clips securing pre-tensioner flylead

to underside of seat.
4. Remove Torx bolt securing pre-tensioner to
squab frame.

BODY
6. Remove outer half of squab recline handle.

7. Remove inner half of squab recline handle.
8. Using a suitable punch, drive out 2 retaining
pins from the side valance.
9. Remove side valance. 10. Remove 4 Torx bolts securing squab frame to
cushion frame.
11. Remove squab assembly.
Refit
1. Fit squab frame to cushion frame, fit Torx bolts

and tighten to 45 Nm.
2. Fit side valance and secure with pins.
3. Fit inner half of squab recline handle.
4. Fit outer half of squab recline handle.
5. Fit pre-tensioner to squab frame, fit Torx bolt
6. Secure pre-tensioner flylead clips to underside
of seat.
CAUTION: To prevent damage to the

pre-tensioner flylead ensure flylead is
positioned correctly to seat, as shown in
seat refit. See this section.
7. Fit seat. See this section.

BODY
CUSHION COVER Do not carry out further dismantling if

component is removed for access only.

Precautions.
Remove

2. Remove seat squab assembly. See this
section.
6. Remove 9 Hog rings securing cushion cover to

pad.
7. Remove cushion cover from pad.
Rebuild
3. Remove 2 spring clips securing front lower 8. Fit cushion cover to pad.
edge of cover to frame. 9. Secure cushion cover to pad with Hog rings.
4. Release cushion cover retainers from frame.
5. Remove cover and pad assembly from frame. Refit
1. Position cover and pad assembly to frame.

2. Secure cushion retainers to frame.
3. Fold front lower edges of cover under frame
and secure with spring clips.
4. Fit seat squab assembly. See this section.

BODY
PULLMAFLEX - SEAT CUSHION CUSHION FRAME
WARNING: See RESTRAINT SYSTEMS, WARNING: See RESTRAINT SYSTEMS,

Precautions. Precautions.
Remove Remove
1. Make the SRS system safe.See RESTRAINT 1. Make the SRS system safeSee RESTRAINT
SYSTEMS, Precautions. SYSTEMS, Precautions.
2. Remove cushion cover. See this section. 2. Remove seat cushion pullmaflex. See this
section.
Refit
1. Fit seat cushion pullmaflex. See this section.
CUSHION PAD

Precautions.
Remove

2. Remove cushion cover. See this section.
Refit
1. Fit cushion cover. See this section.
3. Release 4 pullmaflex straps from frame.

4. Release 2 pullmaflex frame retainers.
5. Remove pullmaflex from frame.
Refit
1. Fit pullmaflex to frame.

2. Secure pullmaflex to frame retainers.
3. Secure pullmaflex straps to frame.
4. Fit cushion cover. See this section.

BODY
SQUAB COVER

Precautions.
Remove


6. Remove outer half of squab recline handle.

7. Remove inner half of squab recline handle.
8. Using a suitable punch, drive out 2 retaining
pins from the side valance.
9. Remove side valance.
3. Release 2 clips securing pre-tensioner flylead

to underside of seat.
4. Remove Torx bolt securing pre-tensioner to
squab frame.

BODY
13. Release squab cover lower retainer.

14. Raise squab centre panel.
10. Rotate inboard head restraint guide cap 90°.

11. Remove head restraint.
12. Remove head restraint, guide caps.

BODY
15. Remove 11 Hog rings securing squab cover to 17. Remove 12 Hog rings securing squab cover to
frame. centre pad.
16. Remove squab cover from pad. 18. Remove seat squab, centre pad.
Do not carry out further dismantling if
component is removed for access only. Rebuild
19. Position seat squab, centre pad.

20. Secure squab cover to centre pad with hog
rings.

BODY
Refit PULLMAFLEX - SEAT SQUAB
1. Fit squab cover to pad. Service repair no - 78.90.21

2. Fit Hog rings securing squab cover to frame.
3. Position squab centre panel. WARNING: See RESTRAINT SYSTEMS,
4. Secure squab cover, lower retainer. Precautions.
5. Fit head restraint, guide caps.
6. Fit head restraint. Remove
7. Rotate inboard head restraint, guide cap back
90° to lock head restraint. 1. Make the SRS system safe.See RESTRAINT
8. Fit side valance and secure with pins. SYSTEMS, Precautions.
9. Fit inner half of squab recline handle. 2. Remove squab cover. See this section.
10. Fit outer half of squab recline handle.
11. Fit pre-tensioner to squab frame, fit Torx bolt
CAUTION: To prevent damage to the

pre-tensioner flylead ensure flylead is
correctly positioned to seat, as shown in
seat refit. See this section.
12. Secure pre-tensioner flylead clips to underside

of seat.
3. Remove squab pad from frame.

4. Release springs from pullmaflex.
5. Remove pullmaflex.
6. Noting there fitted positions collect pullmaflex
springs.
Refit
1. Fit springs to squab frame.

2. Position pullmaflex to squab frame and secure
with springs.
3. Fit squab pad to frame.
4. Fit squab cover. See this section.

BODY
SQUAB FRAME Refit
Service repair no - 78.90.22 1. Fit squab frame to cushion frame.

2. Fit Torx bolts securing squab frame to cushion
WARNING: See RESTRAINT SYSTEMS, frame and tighten to 45 Nm.
Precautions. 3. Fit seat squab pullmaflex. See this section.
Remove

SQUAB PAD
2. Remove seat squab pullmaflex. See this
section.
Precautions.
Remove

2. Remove squab cover. See this section.
3. Remove squab pad from frame.
Refit
1. Fit squab pad to frame.

2. Fit squab cover. See this section.
3. Remove 4 Tx50 Torx bolts securing squab

frame to cushion frame.
4. Remove squab frame.

BODY
SQUAB PAD - CENTRE

Precautions.
Remove


5. Remove 12 Hog rings securing squab cover to

centre pad.
6. Remove seat squab, centre pad.
Refit
1. Position seat squab, centre pad.

2. Secure squab cover to centre pad with hog
rings.
3. Position squab centre panel.
4. Secure squab cover, lower retainer.
3. Release squab cover, lower retainer.

4. Raise squab centre panel.

BODY
WINDSCREEN
NOTE: The following equipment is

required:
Cutting wire and handles

Windscreen repair kit
Sealer applicator gun
Suction cups
WARNING: Wear protective gloves when

handling glass, solvents and primers.
WARNING: Wear suitable eye protection

when removing and refitting glass.
Remove
1. Remove air intake panel. See HEATING &

VENTILATION, Repairs.
2. Remove header trim. See Interior trim
components.
3. Remove ’A’ post trim, See Interior trim
components.
9. Insert cutting wire through previously made
knife cut and fit handles as shown, with
approximately 200 mm of wire between
handles.
10. With assistance, wedge tube of handle A
between glass and body, ahead of cutting
position, and carefully cut sealer using a
continuous pull on handle B from the outside.
Ensure that glass is retained as last sealant is
cut.
NOTE: If multi-strand cutting wire is used,

a sawing action can be used to cut
through heavy sealant deposits around
corners.
4. Remove interior mirror. See Interior trim
components. CAUTION: Use of a sawing action may
5. Fit protection to bonnet and areas around overheat and break single strand wire.
screen.
6. Cover heater ducts with masking tape.
7. Cover interior of vehicle with protective sheet.
8. Make knife cut in sealant at bottom of ’A’ post.
SCREENS 1
BODY
11. Attach suction cups and use assistance to NOTE: Nozzle will need modification to
remove glass from body. achieve required bead section.
CAUTION: Lay glass on felt covered

supports. Do not stand on edge. Any
chipping of glass edge may develop into
cracks.
Refit
1. Carefully remove excess sealer from body

leaving a smooth surface.
2. Use a vacuum cleaner to clear away any
waste.
3. Original glass: Carefully cut back old sealer to
obtain a smooth surface without damaging
obscuration band on glass.
15. Apply a continuous bead of sealer around edge

of frame as shown. Make bead slightly thicker
at each corner.
16. Check for breaks and air bubbles in sealer.
17. With assistance, lift screen into place and align
to brackets and tape. Lightly press glass to
4. Fit 2 brackets and tighten screws. seat sealer.
5. With assistance, locate screen upright on 18. Remove protective covers and tape.
brackets and then lay in position in body frame. 19. Test sealer for leaks, apply additional sealer if
6. Carefully centre screen in body frame and necessary. If water is used, allow sealer to dry
apply masking tape reference marks from before testing. Spray water around glass and
screen to body, on each side of lower screen. check for leaks. Mark any area that leaks. Dry
7. Cut tape at edge of screen, and with glass and sealer then apply additional sealer.
assistance remove screen and place aside. 20. Fit ’A’ post trim. See Interior trim
8. Clean frame and edge of screen with solvent. components.
21. Fit header trim. See Interior trim
CAUTION: Do not touch cleaned or primed components.
surfaces with fingers. 22. Fit interior mirror. See Interior trim
components.
9. Apply etch primer to any bare metal on frame. 23. Fit air intake panel. See HEATING &
10. Apply bonding agent to screen and allow to VENTILATION, Repairs.
cure.
11. Apply primer over etch primer on frame. CAUTION: A curing time of 6 hours is
12. Apply activator over old sealer on frame. desirable, during this time leave a window
13. Allow activator to cure. open and do not slam the doors. If the car
14. Fit pre-cut nozzle to sealer cartridge, remove must be used, drive slowly.
lid and shake out crystals, and install in
applicator gun.
2 SCREENS
PANEL REPAIRS
CONTENTS Page
SEALING AND CORROSION PROTECTION

CORROSION PREVENTION ................................................................................... 1
CAVITY WAX ............................................................................................................ 7
SEALANTS AND ADHESIVES ................................................................................. 8
SEALING CHARTS ................................................................................................. 11
PANELS
PAINT ....................................................................................................................... 1
SERVICE CONDITION OF PANELS ........................................................................ 3
PROCEDURES
GENERAL WELDING PRECAUTIONS .................................................................... 1
PANEL REPLACEMENT PROCEDURE .................................................................. 3
REPAIRS
HEADLAMP MOUNTING .......................................................................................... 1
FRONT PANEL ASSEMBLY .................................................................................... 2
FRONT CROSSMEMBER ........................................................................................ 3
VALANCE REINFORCEMENT ................................................................................. 4
FRONT VALANCE .................................................................................................... 5
FRONT VALANCE SECTION ................................................................................... 6
FRONT SIDEMEMBER SECTION ........................................................................... 7
FRONT SIDEMEMBER ASSEMBLY ........................................................................ 8
’A’ POST ASSEMBLY ............................................................................................... 9
OUTER SILL ........................................................................................................... 10
TONNEAU ASSEMBLY .......................................................................................... 11
REAR BODY ASSEMBLY ...................................................................................... 12
LUGGAGE FLOOR AND LONGITUDINALS .......................................................... 13
PANEL REPAIRS
CORROSION PREVENTION Underbody Sealer
Factory Treatments Underfloor areas and sill outer panels are treated
with a Plastisol PVC underbody sealer. This material
The MGF is treated with the following anti-corrosion is not suitable for re-treatment.
materials in production:
• A PVC-based underbody sealer material which is When repairing areas of underbody sealer, strip the
sprayed onto the underfloor, wheel arches and factory-applied underbody sealer back to a suitable
undersill areas. break point, ensuring that a clean metal surface is
• An application of cavity wax which is sprayed into exposed and that the edge of the existing sealer
sill panels and lower inner door panels. adheres soundly to the panel.
• A final coating of underbody wax to cover the
complete underfloor including components but Ensure that blanking plugs and grommets in the
excluding brake discs. floor pan (except those used for wax injection) are
• A coat of protective lacquer or wax applied to the fitted before underbody sealer application. Refit any
engine bay area. heat-fusible plugs which have been disturbed in
repair with the aid of a hot air blower, or replace with
The information given on the following pages is rubber grommets.
intended as a guide and shows the areas to be
treated with cavity wax, as well as the access holes NOTE: Apply new underbody sealer
used during manufacture. Use only recommended between primer and surfacer paint
materials and application procedures in repair. See operations. Apply seam sealer as
INFORMATION, Sealing and corrosion necessary before application of underbody
protection. sealer.
Underbody Wax CAUTION: Ensure that suspension units,

wheels, tyres, power unit, driveshafts,
The underbody wax must be reinstated following all exhaust and brakes (including all
repairs affecting floor panels. mounting points) are shielded prior to
application of fresh underbody sealer.
CAUTION: Remove old underbody wax
completely from a zone extending at least Engine Bay Wax
200mm beyond the area where new
underbody sealer is to be applied. Reinstate all protective engine bay wax disturbed
during repairs using the approved material.

PANEL REPAIRS
Stone Chip Resistant Paint/Primer NOTE: The presence of small blisters in

PVC underbody sealer is acceptable,
Ensure that all areas protected with anti-chip primer providing they do not expose bare metal.
during manufacture are re-treated in repair with a
suitable approved material. Pay especial attention to signs of damage caused to
panels or corrosion protection material by incorrect
Inspections during Maintenance Servicing jack positioning.
It is a requirement of the Rover Corrosion Warranty It is essential to follow the correct jacking and
that the vehicle body is checked for corrosion by an lifting procedures.See INFORMATION, Lifting
authorised Rover Dealer at least once a year, to and towing.
ensure that the factory-applied protection remains
effective. With the vehicle lowered, visually check for evidence
of damage and corrosion on all visible painted
Service Job Sheets include the following operations areas, in particular the following:
to check bodywork for corrosion: • Front edge of bonnet.
• With the vehicle on a lift, carry out visual check of • Visible flanges in engine compartment and boot.
underbody sealer for damage. • Lower body and door panels.
• With the vehicle lowered, inspect exterior
paintwork for damage and body panels for Rectify any bodywork damage or evidence of
corrosion. corrosion is found during inspection as soon as is
practicable, both to minimise the extent of the
NOTE: The vehicle must be washed and damage and to ensure the long term effectiveness of
free from deposits prior to inspection. It is the factory-applied corrosion prevention treatment.
part of the owner’s responsibility to Where the cost of rectification work is the owner’s
ensure that the vehicle is kept free of responsibility, the Dealer must advise the owner and
accumulations of mud which could accelerate endorse the relevant documentation accordingly.
the onset of corrosion. It will be necessary for
the vehicle to be washed by the Dealer prior to Where corrosion has become evident and is
inspection of bodywork if the customer has emanating from beneath a removable component
offered the vehicle in a dirty condition. Particular (e.g. trim panel, window glass, seat etc.), remove the
attention should be paid to areas where access component as required to permit effective
is difficult. rectification.
NOTE: The checks described above are

intended to be visual only. It is not
intended that the operator should remove
trim panels, finishers, rubbing strips or
sound-deadening materials when checking the
vehicle for corrosion and paint damage.
With the vehicle on a lift, and using an inspection or

spot lamp, visually check for the following:
• Corrosion damage and damaged paintwork,
condition of underbody sealer on front and rear
lower panels, sills and wheel arches.
• Damage to underbody sealer on main floor and
chassis members. Corrosion in areas adjacent to
suspension mountings and fuel tank fixings.

PANEL REPAIRS
Underbody Protection Repairs Use the following procedure when repairing

underbody coatings:
Whenever body repairs are carried out, ensure that
full sealing and corrosion protection treatments are
reinstated. This applies both to the damaged areas 1. Remove existing underbody coatings.
and also to areas where protection has been 2. After panel repair, clean the affected area with
indirectly impaired as a result either of accident a solvent wipe, and treat bare metal with an
damage or repair operations. etch phosphate material.
3. Re-prime the affected area. DO NOT under
Remove corrosion protection from the damaged any circumstances apply underbody sealer
area before straightening out or panel beating, it is directly to bare metal surfaces.
important to Remove corrosion protection material. 4. Replace all heat-fusible plugs which have been
This applies particularly to panels coated with wax, disturbed. Where such plugs are not available
PVC underbody sealer, sound deadening pads etc. use rubber grommets of equivalent size,
ensuring that they are embedded in sealer.
WARNING: DO NOT use oxy-acetylene gas 5. Mask off all mounting faces from which
equipment to remove corrosion mechanical components, hoses and pipe clips,
prevention materials whenever possible. have been removed. Underbody sealer must
Large volumes of fumes and gases are liberated be applied before such components are
by these materials when they burn. refitted.
6. Brush sealer into all exposed seams.
Equipment for the removal of tough anti-corrosion 7. Spray the affected area with an approved
sealers offers varying degrees of speed and service underbody sealer.
effectiveness. The compressed air-operated scraper 8. Remove masking from component mounting
(NOT an air chisel) offers a relatively quiet faces, and touch-in where necessary. Allow
mechanical method using an extremely rapid adequate drying time before applying
reciprocating action. Move the operating end of the underbody wax.
tool along the work surface to remove the material.
Underbody Wax
The most common method of removal is by means
of a hot air blower with integral scraper. After refitting mechanical components, including
hoses and pipes and other fixtures, mask off the
NOTE: High temperatures can be brake discs and apply a coat of approved underbody
generated with this equipment which may wax.
cause fumes. Take care during its use.
NOTE: Where repairs include the
Another tool, and one of the most efficient methods, application of finish paint coats in the
is the rapid-cutting ’hot knife’. This tool uses a wide areas requiring underbody wax, carry out
blade and is quick and versatile, able to be used paint operations before applying wax.
easily in profiled sections where access is otherwise
difficult.

PANEL REPAIRS
Underbonnet Wax Before wax injection, ensure that the cavity to be

treated is free from any contamination or foreign
Where repairs have involved replacement of engine matter. Where necessary, clear out any debris using
bay panels, treat the entire engine compartment a compressed air supply.
including all components, clips and other fixtures
with an approved underbonnet lacquer or wax. Carry out wax injection AFTER final paint
operations.
Proprietary Anti-Corrosion Treatments
During application, ensure that the wax covers all
The application of proprietary anti-corrosion flange and seam areas and that it is adequately
treatments in addition to the factory-applied applied to all repaired areas of both new and
treatment could invalidate the Corrosion Warranty existing panels.
and should be discouraged. This does not apply to
approved, compatible, preservative waxes which NOTE: Ensure that cavity wax is applied
may be applied on top of existing coatings. AFTER the final paint process and
BEFORE refitting any trim components.
Fitting Approved Accessories
It should be noted that new panel assemblies and
When fitting accessories it is important that the complete body shells serviced as replacements are
vehicle’s corrosion protection is not affected, either supplied without wax injection treatment. Ensure that
by breaking the protective coating or by introducing such treatment is carried out after repairs.
a moisture trap.
Effective cavity wax protection is vital. Always
Do not screw self-tapping screws directly into body observe the following points:
panels. Fit suitable plastic inserts to the panel • Complete all paint refinish operations before wax
beforehand. Always ensure that the edges of holes application.
drilled into panels, chassis members and other body • Clean body panel areas and blow-clean cavities
parts are protected with a suitable zinc rich or acid if necessary, before treatment.
etch primer, and follow with a protective wax coating • Maintain a temperature of 18°C during
brushed onto the surrounding area. application and drying.
• Check the spray pattern of injection equipment.
Do not attach unpainted metal surfaces of any • Mask off all areas not to be wax coated and
accessory directly to the vehicle’s bodywork unless which could be contaminated by wax overspray.
suitably protected. Where metal faces are bolted • Remove body fixings, such as seat belt
together always interpose a suitable interface retractors, if contamination is at all likely.
material such as weldable zinc rich primer, extruded • Move door glasses to fully closed position before
strip, or zinc tape. treating door interiors.
• Treat body areas normally covered by trim before
Cavity Wax Injection refitting items.
• Check that body and door drain holes are clear
Box sections treated with cavity wax are shown in after the protective wax has dried.
this section. Following repairs to these areas always • Keep all equipment clean, especially wax
re-treat with an approved cavity wax, using the injection nozzles.
access points illustrated. In addition, treat all interior
surfaces which have been disturbed during repairs
whether they have been treated in production or not.
This includes all box members, cavities and door
interiors. It is permissible to drill extra holes for
access where necessary, provided these are not
positioned in load-bearing members. Ensure that
such holes are treated with a suitable zinc rich
primer, brushed with wax and sealed with a rubber
grommet.

PANEL REPAIRS
Application Equipment and Techniques 1100mm Rigid Lance: The nozzle on the rigid lance
produces a 360° circular spray pattern combined
with a forward-directed spray. Although wax is
distributed to all box section surfaces in a single
stroke, effective and complete coverage is obtained
in long straight structures and box section cavities
by spraying on both outbound and return strokes of
the lance.
The rigid lance also provides the positional accuracy

required in shaped sections, by allowing visual
assessment.
CAUTION: Do not force the lance into

access holes when using this attachment.
1100mm Flexible Nylon Lance: This lance is

similar in pattern to the rigid version, but provides
the additional penetration required for curved
sections or in places where access is difficult. Its
main limitation is a lack of positional accuracy inside
1. Air inlet box sections.
2. Flow control (spray pattern adjustment)
3. Pressure cup (1 litre capacity). Maximum Carry out all spraying on the outward stroke of the
pressure 140PSI (9.7 bar, 9.84kg/cm3) lance. Withdraw the lance slowly to ensure sufficient
4. Gun connector coverage. Do not withdraw the lance too quickly.
5. Lance nipple connection
6. Flexible lance Ensure that the nylon tube of the lance is kept away
7. Rigid directional hook wand (forward cone from the edges of the access hole to eliminate
spray pattern) abrasion and extend the life of the tube. Take care
8. Flexible nylon lance (1100mm) with 360° spray to ensure that spraying ceases just before the
pattern nozzle emerges from the access hole. To assist in
9. Rigid lance (1100mm) with 360° spray pattern this process paint the final 30mm of the nozzle with
RED paint.
When re-treating wax-injected areas which have
been disturbed during repairs, it is necessary to use
a compressed air spray gun with integral pressure
cup and a selection of interchangeable lances.
The following points must be observed during use,

according to the attachments fitted:
• Use the rigid or flexible lance attachments with
360° spray dispersal when treating enclosed
areas, to ensure maximum coverage.
• Where openings are restricted, use the hook
nozzle to provide a more directional spray (e.g.
inside narrow or short box sections).
• Spray exposed underbody surfaces directly from
the gun less lance attachment and without
disconnecting the fluid coupling.

PANEL REPAIRS
Hook Nozzle on Flexible Lance: The rigid hook Steam Cleaning and Dewaxing
produces a highly atomised, forward-directed, fully
conical spray pattern having long range and good Due to the high temperatures generated by steam
dispersion characteristics. This combination has cleaning equipment, there is a risk that certain trim
good directional capabilities for treating short, components could be damaged and some
narrow sections, and may also be used for direct adhesives and corrosion prevention materials
spraying of inner wheel arches etc. softened or liquified.
In use, position the flat area at the end of the lance Adjust the equipment so that the nozzle temperature
at 180° to the nozzle spray direction. This will help to does not exceed 90°C (194°F). Take care not to
guide the spray more accurately when it is allow the steam jet to dwell on one area, and keep
concealed in a box section or access hole. the nozzle at least 300mm from panel surfaces.
For general spraying, move the nozzle in an arc Do NOT remove wax or lacquer from underbody or
from side to side, to ensure full coverage. underbonnet areas during repairs. Should it be
necessary to steam clean these areas, apply a new
NOTE: Ensure that all wax coating of wax or underbody protection as soon as
injection/application equipment is kept possible.
clean. Use white spirit for this purpose
immediately after wax injection operations.
Precautions during Body Repairs and Handling
Take care when handling the vehicle in the

workshop. PVC underbody sealers, seam sealers,
underbody wax and body panels may be damaged if
the vehicle is carelessly lifted.

PANEL REPAIRS
CAVITY WAX
1. Injection hole at sill rear

2. Injection hole (drilled) at sill front
3. Injection into door cavity
All areas symmetrically opposite to those shown are also treated.
See INFORMATION, Sealing and corrosion protection.

PANEL REPAIRS
SEALANTS AND ADHESIVES Ensure that ALL accessible joints are sealed
following repair work. Note that damage to a vehicle
Structural Adhesive can often result in deflection to those areas of the
body which are remote from the impact. As a result
Metal-to-metal adhesive is applied to critical joint the sealers in these areas may be disturbed by
areas during factory assembly. The material used is subsequent straightening and repair operations.
a high-temperature, heat cured, nitrile phenolic Check all joints in the vicinity of the area undergoing
which serves to bond two metal surfaces and also to repair for evidence of cracked sealer, then clean out
seal the joint against ingress of dust, water, petrol as required and apply fresh sealer using the
and fumes. This material is not suited for service following procedure:
use, and should be substituted in repair using a • Clean the affected joint or seam and re-treat any
suitable medium strength adhesive. exposed metal areas with a suitable etch
phosphate primer.
When separating a joint treated with metal-to-metal • Treat affected area with an etch-acid primer.
adhesive, it is important to avoid distortion. Heat the • Apply appropriate seam sealer as necessary.
joint gradually until the bond weakens sufficiently to • Apply appropriate colour coat (and underbody
permit panel separation. sealer as applicable).
NOTE: Spot welding through Where joints are inaccessible following the
metal-to-metal adhesive is feasible, but reassembly or fitment of components, ensure that a
take particular care to adjust the paste-type sealer is applied to such joints. Certain
transformer setting to ensure a reliable weld. DO seams also become inaccessible after the
NOT carry out MIG welding on a joint area which completion of panel repairs. In such instances the
has been treated with metal-to-metal adhesive paint process should be carried out and sealers
until all traces of adhesive have been removed. applied before final assembly.
Seam Sealers Provided access is adequate, sealer must be

applied to both sides of a repair joint. Where access
A heat cured, PVC Plastisol sealer is applied to joint is limited to one side only (e.g. box sections), the
areas during factory assembly. This material is not affected box member should then be injected with
suitable for service use. cavity wax. See this section.
Carry out all seam sealing after the application of CAUTION: In the interests of Health &
primer, and before the surfacer and top coats. Safety, always deploy an extractor unit
Ensure that all surfaces are first cleaned of all adjacent to the work area to remove toxic
grease and oil. Apply sealer materials to the joint as fumes, especially if oxy-acetylene equipment is
a bead, either by hand or using an applicator gun, being used to remove panels treated with wax
and brush well into the joint. Following application, and sealers.
smooth the sealer with a cloth soaked with solvent
such as white spirit or Shell SBP3. This will ensure
an acceptable cosmetic finish.

PANEL REPAIRS
Sealing Water Leaks Testing:
Sealing charts in this section show those areas of From the information supplied by the customer it
the bodyshell most likely to be affected by accident should be possible for the bodyshop operator to
damage and water leaks, and which could therefore locate the starting point from which the leak may be
require re-treatment in repair. They do not show detected. After the area of the leak has been
those joint areas which only apply to factory identified, find the the actual point of entry into the
assembly operations and which are unlikely to be vehicle.
disturbed in service (e.g. transmission tunnel), or
where the damage would be so severe that the A simple and effective means in the first instance is
entire bodyshell would normally be written off. an ordinary garden spray with provision for pressure
and jet adjustment, which will allow water to be
Where water leakage is involved, always adopt a directed in a jet or turned into a fine spray. Use a
logical approach to the problem using a combination mirror and a battery-powered torch (NOT a mains
of skill, experience and intuition. Do not reach a voltage inspection lamp) to see into dark corners.
conclusion based only on visual evidence, such as
assuming that a wet footwell is caused by a leak The sequence of testing is particularly important.
emanating from the windscreen. It will often be found Start at the lowest point and work slowly upwards, to
that the source of the leak is elsewhere. Use of the avoid testing in one area while masking the leak in
correct procedure will increase the chance of another. For example, if testing started at the level of
locating a leak, however obscure it may seem. the windscreen, any water cascading into the
plenum chamber could leak through a bulkhead
Tools and Equipment: grommet and into the footwells. Even at this point it
could still be wrongly assumed that the windscreen
The following tools and equipment are seal was at fault.
recommended for the purpose of detection and
rectification of water leaks: Another important part of identifying a water leak is
by visual examination of door aperture seals,
1. Garden sprayer (hand-operated). grommets and weatherstrips for damage,
2. Wet/dry vacuum cleaner. deterioration or misalignment, together with the fit of
3. Dry absorbent cloths. the door itself against the seals.
4. Battery torch.
5. Small mirror.
6. Weatherstrip locating tool.
7. Trim panel remover.
8. Small wooden or plastic wedges.
9. Dry compressed air supply.
10. Hot air blower.
11. Sealer applicators.
12. Ultrasonic leak detector.
During leak detection, the vehicle should be

considered in three basic sections:
• The front interior space,
• The rear passenger space (where applicable),
and
• The rear loadspace or boot.

PANEL REPAIRS
Sealing:
When the point of the leak has been detected, it will

then be necessary to rectify it using the following
procedure:
1. Renew all door aperture seals and

weatherstrips which have suffered damage,
misalignment or deterioration.
2. Check all body seals to ensure that they are
correctly located on their mounting
flanges/faces using a lipping tool if necessary.
3. Dry out body seams to be treated using
compressed air and/or a hot air blower as
necessary.
4. Apply sealant on the outside of the joint
wherever possible to ensure the exclusion of
water.
5. When rectifying leaks between a screen glass
and its weatherstrip (or in the case of direct
glazing, between the glass and bodywork),
avoid removing the glass if possible. Apply the
approved material at the appropriate location
(i.e. glass to weatherstrip or glass to body).

PANEL REPAIRS
SEALING CHARTS
1. Structural adhesive 7. Structural adhesive

2. Structural adhesive 8. Structural adhesive, seam sealer light
3. Putty, seam sealer heavy 9. Putty, seam sealer heavy
4. Structural adhesive, seam sealer light 10. Structural adhesive
5. Structural adhesive, seam sealer heavy 11. Seam sealer light
6. Structural adhesive

PANEL REPAIRS
12. Seam sealer light 17. Seam sealer light

16. Seam sealer light, structural adhesive

PANEL REPAIRS
21. Seam sealer light 26. Brushable sealer

22. Seam sealer light 27. Brushable sealer
23. Seam sealer light 28. Seam sealer heavy
25. Seam sealer light

PANEL REPAIRS
30. Structural adhesive, seam sealer 36. Structural adhesive, seam sealer
31. Structural adhesive, semi-structural 37. Structural adhesive, seam sealer light
adhesive/anti-flutter material 38. Structural adhesive
32. Structural adhesive, seam sealer 39. Structural adhesive
33. Semi-structural adhesive/anti-flutter material 40. Structural adhesive
34. Semi-structural adhesive/anti-flutter material 41. Seam sealer light
35. Semi-structural adhesive/anti-flutter material 42. Seam sealer light

PANEL REPAIRS
PAINT Welded Panels:
Replacement Panels 1. Remove primer from the immediate vicinity of

new and existing panel flanges, cleaning to
Service panels are supplied with a cathodic primer bright metal finish.
coating as part of the panel protection, and in 2. On joints to be spot welded, apply
compliance with the vehicle’s Corrosion Warranty weld-through zinc rich primer to joint faces of
where applicable. DO NOT remove the primer both flanges. Make spot welds while primer is
before paint refinishing. In the event of localised still wet or according to the manufacturer’s
surface damage or imperfections, ensure that instructions.
the minimum of primer is removed during 3. Dress accessible weld seams.
rectification work for effective repair. 4. Clean panel using solvent wipe.
5. Treat bare metal with an etch phosphate
Rectify damage as far as possible by panel beating process.
or straightening. To remove corrosion or paint runs 6. Re-treat repaired areas. See Sealing and
on outer surfaces, abrade the primer coat in the corrosion protection.
affected area as necessary using the following
procedure: NOTE: It is not satisfactory to use
weld-through, zinc rich primers in
1. Clean the panel using a solvent wipe. conjunction with arc or MIG welding.
2. Treat exposed areas of metal with an etch
phosphate process. Sectioned Panels:
3. Re-treat the affected area using either a
separate acid-etch primer and two-pack When replacing part or sectioned panels, the basic
surfacer, or an integrated etch primer/filler. procedure is the same as for welded panels
described above, with the following variations:
Panel Preparation
1. Remove primer from both new and existing
Bolted Panels: joint faces, cleaning to a bright metal finish.
2. Where an overlap joint with the existing panel
Before fitting bolt-on panels, ensure that all mating is to be spot welded, apply weld-through, zinc
and adjacent surfaces on the vehicle and rich primer to both joint faces and spot weld
replacement panel are free from damage and while the primer is still wet, or according to the
distortion. Rectify if necessary as described in this manufacturer’s instructions.
section, and apply preformed strip sealer where 3. MIG weld butt joints where applicable.
specified. See INFORMATION, Sealing and 4. Clean the panel with a solvent wipe.
corrosion protection. 5. Treat bare metal areas using an etch
phosphate process.
6. Re-prime affected areas as necessary as for
rectifying transit damage.
7. Treat the inner faces of lap or butt joints with a
suitable cavity wax. See Sealing and
corrosion protection.
PANELS 1
PANEL REPAIRS
Clinch Panels (e.g. Doorskins etc.): Paint Repairs
1. Abrade primer on new and existing panel joint Before carrying out paintwork repairs, the vehicle
faces, and clean using a solvent wipe. must be thoroughly cleaned using either a steam
2. Apply metal-to-metal adhesive where cleaner or high-pressure washer.
applicable.
3. Where joints are to be spot welded, apply Wash locally repaired areas using a mild
suitable weld-through, zinc rich primer to weld water-mixable detergent and wipe them clean with
areas. solvent, immediately prior to paint application.
4. Where joints are to be MIG, arc or gas welded,
apply zinc rich primer in adjacent areas but Damaged paintwork which has exposed bare metal
leave the welded area untreated. must be abraded until the metal is clean, extending
5. To retain the panel whilst clinching the flanges, beyond the area of the original damage. The bare
tack spot weld or plug weld as appropriate. metal must then be treated with an etch phosphate
6. Clean the panel with a solvent wipe. to remove all traces of rust and provide a key for
7. Treat bare metal areas with a suitable etch new paint coats. Re-treat the affected area using
phosphate process. either a separate acid-etch primer and two-pack
8. Re-prime affected areas as necessary as for surfacer or an integrated etch primer/filler, and follow
rectifying transit damage. with a two-pack paint system. Treat those surfaces
not receiving paint using an approved cavity wax,
NOTE: Replacement doors, bonnets and following paint operations. See Sealing and
boot lids must be treated with a suitable corrosion protection.
seam sealer on clinched seams, following
the primer coat.
Paint Refinishing
1. Seal all accessible exterior and interior seams

with an approved seam sealer. Certain joints
such as sill lower flange seams must be left
unsealed. See Sealing and corrosion
protection.
2. Apply suitable anti-chip primer where specified.
3. Apply a two-pack paint refinishing system.
4. Repair any damage to underbody sealers
either at this stage or before paint operations.
See Sealing and corrosion protection.
5. Apply cavity wax to all interior surfaces which
have not received refinish paint.
A. Two-pack top coat
B. Two-pack primer filler and etch primer
C. Etch phosphate
2 PANELS
PANEL REPAIRS
SERVICE CONDITION OF PANELS Valance Assembly and Reinforcement: Valance

assemblies (2) are serviced only as separate items.
Front Panels Valance reinforcements (4) are also serviced. Part
valances are not serviced but may be cut from a
complete panel.
Front Sidemember Assembly: Sidemembers are

serviced either as a bare panel (7) or as an
assembly including the front suspension lower
reinforcement extension (3) and spare wheel
platform assembly (5). Part sidemembers are not
serviced but may be cut from a complete panel.
’A’ Post Assembly
Front panels are serviced as assemblies and

separate parts as follows:
Headlamp Mountings: Headlamp mountings (1)

are serviced as an assembly.
Front Crossmember: The front crossmember is

serviced as a sidemember bracket assembly (9) and
lower crossmember assembly (10), including
subframe brackets (8).
Front Bulkhead Assembly: The spare wheel well

assembly (6), complete with spare wheel well and
upper stiffener, is serviced as one panel. It is also
available as an assembly with the sidemember
bracket assembly and headlamp mounting. The ’A’ post is serviced as a complete assembly.
PANELS 3
PANEL REPAIRS
Front Door Outer Sill
Doors are serviced both as a complete assembly Outer sills are serviced separately as a sill front
and as separate outer panels. closing (1), front extension (2) and outer sill (3).
Tonneau Assembly
The tonneau is serviced as an assembly. The rear

lamp extension (1), drain channel extension (2) and
extension (3) are also serviced separately.
4 PANELS
PANEL REPAIRS
Luggage Floor Rear Body
The luggage floor, including RH and LH

reinforcement plates, is serviced as an assembly (2).
Longitudinal members (1) are serviced as separate
items.
The rear body is serviced as an assembly with the

following parts also serviced separately: Rail
reinforcement (1), striker reinforcement (2), rear
lamp mountings (3, 7), rear body (4) and rear body
assembly (5).
PANELS 5
PANEL REPAIRS
GENERAL WELDING PRECAUTIONS • The replacement welds in the welding diagrams

are denoted by the following symbols:
For ease of reference the diagrams on the following
pages show only the type of weld used in repair
where it varies from that used in production.
When carrying out welding operations the following

criteria must be observed:
• Where resistance spot welds have been used in
production, these must be reproduced with new
spot welds in replacement where possible. All
such reproduction spot welds must be spaced
30mm apart.
• When spot welding, it is recommended that test
coupons of the same metal gauges and materials
are produced to carry out peel tests to ensure A. Single thickness plug welds
that welding equipment being used can produce
a satisfactory joint. Plug welds must be used if a B. Multiple thickness plug welds
satisfactory spot weld cannot be produced.
• The electrode arms on hand-held spot welding C. MIG seam weld
guns must not exceed 300mm in length.
• Single-side spot welding is not acceptable.
• Brazing and gas welding are not acceptable
EXCEPT where they have been specified in
production.
• Where 3 metal thicknesses or more are to be
welded together it is imperative to use MIG plug
welds to ensure joint strength.
• MIG plug welds must be used in repair joints
where there is no access for a resistance spot
welder. To replace each production spot weld a
hole must be drilled and/or punched, and a MIG
plug weld then made in its place. The number of
plug welds must match exactly the number of
spot welds which have been removed.
• Where holes are left in an existing panel after
removal of the spot welds, a single MIG plug
weld will be made in each hole as appropriate.
PROCEDURES 1
PANEL REPAIRS
Seat Belt Anchorages High Strength Steels
Seat belt anchorages are safety critical. When Body panels are being increasingly manufactured in
making repairs in these areas it is essential to follow high strength steels to meet design requirements for
design specifications. Note that High Strength Low safety and weight saving. As panels in high strength
Alloy (HSLA) steel may be used for seat belt steels cannot be visually identified by the repairer,
anchorages. and as they can be more sensitive to excess heat
than would be the case with low carbon steels, it is
Where possible, the original production assembly advisable that the following procedure be observed
should be used, complete with its seat belt at all times.
anchorages, or the cut line should be so arranged
that the original seat belt anchorage is not disturbed. While individual repairs will differ in detail, the
following Panel Replacement Procedure has been
All welds within 250mm of seat belt anchorages devised placing emphasis on ease of repair and the
must be carefully checked for weld quality, including elimination of unnecessary work. Where
spacing of spot welds. replacement of a particular panel involves departure
from the Panel Replacement Procedure, a note to
that effect is included in the relevant panel
WARNING: Body parts incorporating seat replacement operation.
belt anchorages MUST be renewed
completely if damaged beyond repair, as
the welds in these areas are safety critical and
cannot be disturbed.
2 PROCEDURES
PANEL REPAIRS
PANEL REPLACEMENT PROCEDURE
General
This information is designed to explain the basic

panel removal and replacement method. This
standard method might vary slightly from one vehicle
to another. The main criterion in removal and
replacement of body panels is that Rover’s original
standard is maintained as far as possible.
Remove Panel
2. Cut out welds using a cobalt drill.
1. Expose resistance spot welds. For those spot

welds which are not obviously visible, use a
rotary impregnated wire brush fitted to an air
drill, or alternatively a hand held wire brush.
NOTE: In wheel arch areas it may be

necessary to soften underbody coating 3. Alternatively use a clamp-type spot weld
using a hot air gun, prior to exposing spot remover.
welds.
PROCEDURES 3
PANEL REPAIRS
Prepare Old Surfaces
4. Cut away the bulk of the panel as necessary

using an air saw.
1. Clean all panel joint edges to a bright smooth
NOTE: On certain panel joints MIG welds finish, using a belt-type sander.
and braze should be removed using a
sander where possible, before cutting out NOTE: Prior to sanding, remove remaining
the panel bulk. sealant using a hot air gun to minimise the
risk of toxic fumes caused by generated
heat. CARE MUST BE TAKEN TO AVOID
EXCESSIVE HEAT BUILD-UP WHEN USING THIS
EQUIPMENT.
5. Separate spot welded joints and remove panel

remnants using hammer, bolster chisel and
pincers.
2. As an alternative a disc sander may be used.

Straighten existing panel joint edges using
shaping block and hammer.
4 PROCEDURES
PANEL REPAIRS
Prepare New Surfaces
1. Mark out bulk of new panel and trim to size,

leaving approximately 50mm overlap with
existing panel. Offer up new panel/section, 3. Prepare new panel joint edges for welding by
align with associated panels (e.g. new rear sanding to a bright finish. This must include
quarter aligned with door and tailgate). Clamp inner as well as outer faces.
into position.
4. Apply suitable weld-through primer to panel

2. Cut new and existing panels as necessary to joint surfaces to be welded, using brush or
form butt, joggle or brace joint as required. aerosol can.
Remove all clamps and metal remnants.
PROCEDURES 5
PANEL REPAIRS
Welding
5. Apply adhesive sealant to panel joint surfaces.

See INFORMATION, Sealing and corrosion
protection. 1. Select arms for resistance spot welding and
shape electrode tips using a tip trimmer.
Offer Up and Align
NOTE: To maintain efficiency, the tips will
Offer up new panel and align with associated require regular cleaning with emery cloth.
panels. Clamp into position using using welding
clamps or Mole grips. Where a joggle or brace joint CAUTION: Use arms not exceeding
is being adopted, make a set in the original panel 300mm in length.
joint edge or insert a brace behind the joint.
NOTE: In cases where access for welding

clamps is difficult, it may be necessary to
use tack welds.
2. Fit resistance spot welding arms and test

equipment for satisfactory operation, using test
coupons. Where monitoring equipment is not
available, verify weld strength by checking that
metal around the weld puddle pulls apart under
tension during pulling.
6 PROCEDURES
PANEL REPAIRS
5. Dress MIG tack welds using a sander with 36

grit disc, or a belt-type sander where access is
limited.
3. Use a resistance spot welder where access

permits. Try to ensure weld quality by using a
welding monitor where possible.
4. MIG tack weld butt joints and re-check

alignment and panel contours where
necessary. Ensure that a gap is maintained to
minimise welding distortion, by inserting a
hacksaw blade as an approximate guide.
PROCEDURES 7
PANEL REPAIRS
6. MIG seam weld butt joints.
8. Dress all welds using either a sander with 36

grit disc, or a belt-type sander and/or
impregnated wire brush.
NOTE: Brazing operations, if required,

must be carried out at this point.
Body Trim
The following panel repair operations itemise body

trim components which must be removed for access
during each repair.
Because of the unpredictable nature of accident

damage, the items listed make no allowance for any
7. Always use MIG plug welds where excessive difficulties which may be found in removal and only
metal thickness or limited access make apply to an undamaged vehicle. Damaged body trim
resistance spot welding impractical. Make plug items should then be renewed following panel
welds either by using holes left by the spot repairs.
weld cutter, or through holes punched and
drilled for the purpose.
8 PROCEDURES
PANEL REPAIRS
HEADLAMP MOUNTING Refit
Remove
1. Disconnect battery earth lead.

2. Raise front of vehicle.
3. Disconnect all ECUs.

4. Disconnect airbags and sensor system.

Precautions.
5. Disconnect alternator.
6. Remove front bumper valance. See BODY,
Exterior fittings.
7. Remove front bumper armature. See BODY,
Exterior fittings.
8. Remove headlamp. See Workshop Manual, 1. Prepare and clean panel joint faces. Punch or
Electrical. drill holes in new panel for plug welding as
shown.
2. Refit headlamp. See Workshop Manual,
Electrical.
3. Refit front bumper armature. See BODY,
Exterior fittings.
4. Refit front bumper valance. See BODY,
Exterior fittings.
5. Reconnect alternator.
6. Reconnect airbags and sensor system.
7. Reconnect all ECUs.
8. Remove stands and lower vehicle.
9. Reconnect battery earth lead.
REPAIRS 1
PANEL REPAIRS
FRONT PANEL ASSEMBLY Refit
Remove



Precautions.
6. Remove front bumper valance. See BODY, 1. Prepare and clean panel joint faces. Punch or
Exterior fittings. drill holes in new panel for plug welding as
7. Remove front bumper armature. See BODY, shown.
Exterior fittings. 2. Refit both headlamps. See Workshop Manual,
8. Remove both headlamps. See Workshop Electrical.
Manual, Electrical. 3. Refit front bumper armature. See BODY,
Exterior fittings.
Exterior fittings.
2 REPAIRS
PANEL REPAIRS
FRONT CROSSMEMBER Refit
Remove



Precautions.
Exterior fittings.
Exterior fittings.
8. Remove headlamp. See Workshop Manual, 1. Prepare and clean panel joint faces. Plug weld
Electrical. using holes left by spot weld cutter as shown.
Electrical.
Exterior fittings.
Exterior fittings.
REPAIRS 3
PANEL REPAIRS
VALANCE REINFORCEMENT Refit
Remove


Precautions.
Exterior fittings.
Exterior fittings.
7. Remove headlamp. See Workshop Manual,
Electrical.
8. Remove front fender.
9. Remove door. See BODY, Doors.
1. Prepare and clean panel joint faces. Punch or

drill holes in new panel for plug welding as
shown. Apply structural adhesive to lower
flange front section before welding. See
Sealing and corrosion protection.
2. Refit door. See BODY, Doors.
3. Refit front fender.
Electrical.
Exterior fittings.
Exterior fittings.
4 REPAIRS
PANEL REPAIRS
FRONT VALANCE Refit
Remove NOTE: Apply structural adhesive to lower

flange front section before welding.
WARNING: Place on safety stands.


Precautions.
Exterior fittings.
Exterior fittings.
8. Remove headlamp. See Workshop Manual, 1. Prepare and clean panel mating faces. Punch
Electrical. or drill holes in new panel at rear section for
9. Remove front fender. plug welding.
10. Remove door. See BODY, Doors. 2. Refit door. See BODY, Doors.
Electrical.
Exterior fittings.
Exterior fittings.
REPAIRS 5
PANEL REPAIRS
FRONT VALANCE SECTION Refit
Remove NOTE: In this operation, the front valance

section and sidemember section are
1. Disconnect battery earth lead. replaced in combination.


Precautions.
Exterior fittings.
Exterior fittings.
8. Remove headlamp. See Workshop Manual, 1. Prepare and clean panel joint faces. Apply
Electrical. structural adhesive to lower flange front
9. Remove front fender. section.See Sealing and corrosion
protection.
Cut panel to form MIG welded butt joint with existing

panel.

Electrical.
Exterior fittings.
Exterior fittings.
10. Remove safety stands and lower vehicle.
6 REPAIRS
PANEL REPAIRS
FRONT SIDEMEMBER SECTION Refit
Remove NOTE: In this operation, the front

sidemember section and valance section
1. Disconnect battery earth lead. are replaced in combination.


Precautions.
Exterior fittings.
Exterior fittings.
Electrical.
9. Remove front suspension.
1. Prepare and clean panel joint faces. Apply
structural adhesive to lower flange front
section. See Sealing and corrosion
protection.
Cut panel to form seam welded joint with existing

panel ahead of suspension lower reinforcement
extension.

Electrical.
Exterior fittings.
Exterior fittings.
REPAIRS 7
PANEL REPAIRS
FRONT SIDEMEMBER ASSEMBLY Refit
Remove NOTE: In this operation, the front

sidemember section and valance section
1. Disconnect battery earth lead. are replaced in combination.


Precautions.
Exterior fittings.
Exterior fittings.
Electrical.
1. Prepare and clean panel joint faces. Apply

structural adhesive to lower flange front
section. See Sealing and corrosion
protection.
Cut panel to form seam welded joint with existing

panel ahead of suspension lower reinforcement
extension.

3. Refit front suspension.
Electrical.
Exterior fittings.
Exterior fittings.
8 REPAIRS
PANEL REPAIRS
’A’ POST ASSEMBLY Refit
Remove

2. Raise side of vehicle.


Precautions.
6. Remove seat belt. See RESTRAINT
SYSTEMS, Repairs.

Precautions.
7. Remove seat. See BODY, Interior trim

components.
8. Remove sun visor. See BODY, Interior trim 1. Prepare and clean panel joint faces. Punch or
components. drill holes for plug welding to bulkhead, header
9. Remove header trim. See BODY, Interior rail and sill inner as shown.
trim components.
10. Remove fascia panel. See BODY, Interior WARNING: Remove ALL traces of
trim components. adhesive from joint to header rail before
11. Remove ’A’ post trim. See BODY, Interior plug welding.
trim components.
12. Remove door and header seal. See BODY, 2. Refit outer sill.
Doors. 3. Refit front fender.
13. Remove windscreen. 4. Refit door. See BODY, Doors.
14. Remove door. See BODY, Doors. 5. Refit windscreen.
15. Remove front fender. 6. Refit door and header seal. See BODY,
16. Remove outer sill. Doors.
7. Refit ’A’ post trim. See BODY, Interior trim
components.
8. Refit fascia panel. See BODY, Interior trim
components.
9. Refit header trim. See BODY, Interior trim
components.
10. Refit sun visor. See BODY, Interior trim
components.
11. Refit seat. See BODY, Interior trim
components.
12. Refit seat belt. See RESTRAINT SYSTEMS,
Repairs.
REPAIRS 9
PANEL REPAIRS
OUTER SILL Refit
Remove NOTE: In this operation, the outer sill,

front extension and front closing are
1. Disconnect battery earth lead. replaced in combination.
2. Raise side of vehicle.


Precautions.
SYSTEMS, Repairs.

Precautions. 1. Prepare and clean panel joint faces. Apply
structural adhesive at joint to front extension.
7. Remove seat. See BODY, Interior trim See Sealing and corrosion protection.
components.
8. Remove ’A’ post trim. See BODY, Interior Punch or drill holes for plug welding as shown.
trim components.
9. Remove door and header seal. See BODY, WARNING: Remove ALL traces of
Doors. adhesive from joint to tonneau before plug
10. Remove door. See BODY, Doors. welding.

3. Refit door. See BODY, Doors.
4. Refit door and header seal. See BODY,
Doors.
5. Refit ’A’ post trim. See BODY, Interior trim
components.
6. Refit seat. See BODY, Interior trim
components.
Repairs.
10 REPAIRS
PANEL REPAIRS
TONNEAU ASSEMBLY Refit
Remove

2. Raise rear of vehicle.


Precautions.
6. Remove boot lid.See BODY, Exterior fittings.
7. Remove luggage compartment trim.See
BODY, Interior trim components.
SYSTEMS, Repairs. 1. Prepare and clean panel joint faces. Apply
structural adhesive to wheel arch outer flange
WARNING: See RESTRAINT SYSTEMS, and at lower rear edge. See Sealing and
Precautions. corrosion protection.
9. Remove seat.See BODY, Interior trim Punch or drill holes in new panel for plug welding as
components. shown, and make plug welds through holes left by
10. Remove hoodwell trim.See BODY, Interior spot weld cutter.
trim components.
11. Remove side air vent.See BODY, Exterior WARNING: Remove ALL traces of
fittings. adhesive from joint to outer sill before
12. Remove rear bumper armature.See BODY, plug welding.
Exterior fittings.
13. Remove rear bumper valance.See BODY,
Exterior fittings. 2. Refit rear lamp. See Workshop Manual,
14. Remove rear lamp. See Workshop Manual, Electrical.
Electrical. 3. Refit rear bumper valance.See BODY,
Exterior fittings.
4. Refit rear bumper armature.See BODY,
Exterior fittings.
5. Refit side air vent.See BODY, Exterior
fittings.
6. Refit hoodwell trim.See BODY, Interior trim
components.
7. Refit seat.See BODY, Interior trim
components.
Repairs.
9. Refit luggage compartment trim.See BODY,
Interior trim components.
10. Refit boot lid.See BODY, Exterior fittings.
REPAIRS 11
PANEL REPAIRS
REAR BODY ASSEMBLY Refit
Remove NOTE: When fitting the rear body

assembly complete, it is necessary to
1. Disconnect battery earth lead. remove one or both tonneau assemblies
2. Raise rear of vehicle. for access.


Precautions.
7. Remove rear bumper armature.See BODY,
Exterior fittings. 1. Prepare and clean panel joint faces. Apply
8. Remove rear bumper valance.See BODY, structural adhesive to outer flanges. See
Exterior fittings. Sealing and corrosion protection.
9. Remove rear lamp. See Workshop Manual,
Electrical. Punch or drill holes in new panel for plug welding as
shown.
NOTE: It is necessary to make the plug

welds to rear valances from inside the
boot, due to limited access.
2. Refit rear lamp. See Workshop Manual,

Electrical.
3. Refit rear bumper valance.See BODY,
Exterior fittings.
Exterior fittings.
12 REPAIRS
PANEL REPAIRS
LUGGAGE FLOOR AND LONGITUDINALS Refit
Remove NOTE: When fitting a luggage floor it is

necessary to remove the luggage floor
1. Disconnect battery earth lead. front crossmember for access.
2. Raise rear of vehicle.


Precautions.
7. Remove boot lid.See BODY, Exterior fittings.
8. Remove rear bumper armature.See BODY,
Exterior fittings.
9. Remove rear bumper valance.See BODY, 1. Prepare and clean panel joint faces. Punch or
Exterior fittings. drill holes in new panel for plug welding as
10. Remove rear lamps. See Workshop Manual, shown. Replace longitudinals BEFORE fitting
Electrical. luggage floor, and refit crossmember as final
operation.
WARNING: Remove ALL traces of

adhesive from lower flange of engine
bulkhead before plug welding.
2. Refit rear lamps. See Workshop Manual,

Electrical.
3. Refit rear bumper valance.See BODY,
Exterior fittings.
Exterior fittings.
6. Refit boot lid.See BODY, Exterior fittings.
REPAIRS 13

Body Repair Manual PDF

Hochgeladen von

Dokumentinformationen

Originalbeschreibung:

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Body Repair Manual PDF

Hochgeladen von

Copyright:

Verfügbare Formate

Body Repair

Manuale delle operazioni di

Publication Part No. RCL 0090ENG

INTRODUCTION REPAIRS AND REPLACEMENTS

CAUTION: Calls attention to procedures

NOTE: Gives helpful information.

References to the LH or RH side given in this

The dimensions quoted are to design engineering

Rover are constantly seeking to improve the

This Manual does not constitute an offer for sale of

Location 6 figures= Serial number

The Vehicle Identification Number (VIN) is stamped

Vehicle identification number Q= Mark identifier

S A R R D W B G/T B/M/J A D 000001 P= Colour/Shade name

A= Country IDENTIFICATION NUMBER LOCATIONS

R= Manufacturer Engine number

B= Body Style (2 door convertible) Gearbox number

G/T=Engine Type Manual Gearbox: Stamped on a label attached to

B/M/J/X= Steering and Transmission Body number

VEHICLE IDENTIFICATION NUMBER 1

FUEL HANDLING PRECAUTIONS Fuel tank draining

General WARNING: Petrol/gasoline must not be

Whenever petrol/gasoline is being handled, drained

WARNING: No one should be permitted to

FUEL HANDLING PRECAUTIONS 1

Fuel tank repairs QUICK FIT FUEL HOSE CONNECTORS

Under no circumstances should a repair to any fuel

b. BOILING: With the filler cap and tank unit

After steaming or boiling, a signed and dated label to

Body and chassis repairs

When a body or chassis repairs involve the use of

Plastic fuel pipes are particularly susceptible to heat,

Fuel lines or tanks must not be removed whilst the

2 FUEL HANDLING PRECAUTIONS

ELECTRICAL PRECAUTIONS Having confirmed a component to be faulty switch

Connectors and Harness - The engine compartment

Switch off ignition prior to making any connection or

Ensure hands and work surfaces are clean and free

When handling printed circuit boards, treat them as

Connectors should never be subjected to forced

Prior to commencing test, and periodically during

Grease for electrical connectors

All under bonnet and under body connectors are

NOTE: The use of other greases must be

BODY REPAIRS Body repairs often involve the removal of

Operations covered in this Manual do not include

Where major units have been disconnected or

JACKING, SUPPORTING AND TOWING

1. Central jacking point - front 6. RH sill reinforced bracket - rear

LIFTING AND TOWING 1

WARNING: Do not position a jack, jack WHEEL-FREE LIFT

It is recommended that a recovery trailer or two

SUSPENDED TOW: Cannot be carried out without

Side Rear: Position the safety support under the sill

2 LIFTING AND TOWING

The rear lashing/towing eye, must only be used for

Use the front lashing/towing eyes (9) for towing the

WARNING: To ensure that the steering

Automatic gearbox models

When a car with automatic gearbox is to be towed

The gearbox fluid level must be correct before

The selector must be at ’N’.