51 Body — Equipment ‘Speci tions: . . . Page 51-0/3 5111000 Complete front bumper ~ removing and installing w/t O11 Bumper ~ front centre section: renewing Wty 121 Bumper - front wrap-round section: renewing cee WW 201 Bumper overrider: renewing 11/2 5112.00 Bumper — complate rear: removing and instaling 2 12/4 011 Bumper ~ rear centre section: renewing 12/1 201 Bumper ~ rear wrap-round section: renewing ......06.0ssers 12/2 301 Bumper joint cover ~ rear: renewing : ve 12/2 5113000 Radiator grille — centre section: removing and installing . 13/1 040 Radiator grille - end sections; removing and installing 13/1 5116000 Rear mirror — door: removing and installing 16/1 060 Rear mirror ~ interior: removing and installing 16/1 200 Storage compartment - removing end installing 16/1 360 Glove compartment: removing and installing .... vee 18/3 121001 Door stop: renewing ara 080 Door lock: removing and instaling we 20/1 120 Lock - remote actuator: removing and installing . . ae 170 Door outer handle: removing and installing... oe 23 230 Door interior handle: removing and installing 28 280 Door brake: remaving and installing - ce . 24 300 Door windaw-well sealing strip-outer: removing and installing ....... oe - 214 371 Rubber contact for celing light: renewing... 224 5123004 Engine compartment lid = adjusting . - ce 23/1 200 Lever with bracket for hood retainer catch: removing - . and installing ... seeeeseeees 23/7 210. Cable for hood reteinar catch: ramaving and instaling =... 23/2 5124050 Luggage compartment retainer catch: remaving and installing 24/1 100 Luggage compartment lock: removing and installing veeees 24/2 130 Locking bracket for luggage compartment retainer catch .......... 24/2 301 Gas spring - replacing . 24/2 341. Torsion bar springs for luggage ‘compartment 24/3 5131000 Windshield, complete: removing and installing av 001 Windshield: renewing : oo 3143 200° Rear window: removing and installing . » 31/3 5132000 Window handle: removing and installing . ceveeeeee 32/1 020 Window handle: machanism: removing and installing eo O21 040 Holder for window lift raik remaving and installing .....-...-.-... 32/1 154 Window glass: adjusting ..... we cece S2/1 170 Window glass: removing and instaling ....... 82/3 230 Knurled knob for vent windows: removing and reiting vesereeees 32/3 250 Went windaw: removing and installing .....- cece BBE 300 Worm gear for vent windaw: remeving and instahing - - 32/5 350 Window frames complete with went window: removing . and installing ...... ses 82/5 5141000 Door paneling: removing and installing 414 060 Arm rests; removing and installing ait (9.75 Ateration 51-0/15145 050 100 120 180 190 200 1-0/2 Upper section of facia trim - remaving and installing... Shelf trim — removing and installing . Padded trim an lower section of steering colurnn surround ~ detaching and attaching ....... Lower left facia trim - detaching and attaching - Lower centre facia trim ~ detaching and attaching Lower centre right facia trim - detaching and attaching . 45/1 45/3 . 45/4 o. 48/4 a. 45/4 . 45/451-073 (08 waycoas “wb “anews APOE Ieee ‘soujines POE PunGdues panBaweis pur BuquoWge PUNO ‘es Ano Tose URomE Tay pare] punches Bayer Zzee waeoreg Tmcpie aaa BuR PIANADCHA Panoduies Bajees Lorre Cooma, wnt Hae ante ade po eee Cry Teck ania OSE emOH wapai Wad vorreodde exsseypye “ata spuneduses Buyjess “sonssoupe yo 18/7 POR Teone]eane weno zon wate juourdinba pus sfuniay Apo suonesyioeds 9078 Ameration5111000 Bumper — complete front: removing and installing Unscrew ment bolts faft and right Installation instructions; Be not forget shim between body and bumper unse Remove bumper and sw bolt [1) anc nut (2) on both sides Installatian instructions: Do not farget spacer piece (31 a 5111011 Bumper — front centre section: renewing ‘Querrider ramawed — Unserav bait (1) and nut (2) at left and ri and remave esntre section. Installation instructions: De not forgot spacer piece (4) . 51.11.1271 Bumper — front wrap round section renewing — Overricler removed — Unecrew attechment mut in wheel casing 9.70 Brit1/2 Unscrew nuts (11 and 12) Remove wrap tion of bumper Installation instructions: De not farget spacer piace (3) end 3 5111201 Bumper overrider: renewing Unscrew nut (1 Remove overrider, Installation instructions: Do 7 ot forget spacor pisca. Unscrew nute (1 and 2} and remove rubber pad. Installation instructions: Ensure corract seating of underlay [3 and a5112000 Bumper — complete rear: removing and installing 3 luggage compartment floor panelling Unscrew attachmant bolts right and left (1 3h Removing and installing licence plate ght 63 26 000. Installation instructions: Oe nat forgat rubber spacer pioce (1) between bumper and body . sstallation instructions: Seal of attachment bolts betwasn the body end underlay plates with sealing ‘compound . 51 12.011 Bumper — rear centre section: renewing — Bumper joint caver ramoved — Remaving and installing rear bumper 1 12 090. Unseraw nuis (1 and 2) left and right Installation instructions: E of 1 (3) In correct . a B1—12/112/2 51 12.201 Bumper — rear wrap-round section: renewing — Bumper joint cover removed Removing and 5112 000. Installation instructions: Ensure installation angle oof spring bracket (3) is correct alling complete rear bumper 51 12.301 Bumper rear joint cover: renewing owing and installing complete rear bumper 000. ccrew nuts Installation instructions: Ensure correct seating of undoriays, :61 13.000 Removing and fitting centre radiator grille Remove and fit front right and left radiator grilles, 51 12.040. Uni « centre retaining (arrows) and iake off radiator gi . 5113040 Remaving and fitting front right and left radiator grilles Romove clamp strip (1) and cover 12). 2 Unscrew knurled . Uneeew Philips head salt-tapping screws and remowe radiator grilles, 7 3.70 simian51 16.000 Removing and fitting rear-view mirror on door A) Previous model: Turn arn Remove scrav 7 B) Present model Benes back rubber cov screw and remove Fitting instruction: Pay attention to rorrest seating of rubber qaske . 51 16 060 Removing and fitting interior rear-view mirrar : ror away to the rear /. 51 16200 Removing and fitting storage compartment Loosen screws and remove: storage way towards rear . 9.71 ModificationOn ‘touring’ and 71 models: Unscrew qaar lever knob. Remove serews at left and right Take out the floor af the storage compartment u out the trim panel Loosen the retaining bracket screw. Pull the storage compartmant back Pull the hazard wa plug off Femave the compartmant ta one side.51 16 360 Removing and fi compartment Loosen 2 and remove outer right-hand covering. . Loosen hinge securing screws Take off glave compartment / 8.71 Addition 5116/35121001 Rene ing door catch Remove rear seat. Lift side trim pane! aut of ellp and remave upwards. a Loosen screws. Note: Hold threaded plate in place with one hand. Fitting instruction: Adjust door cateh . 5121 090 Removing and fitting door lock Remove and fit door lining panel, 61 41.000. Remove Acella film as far as necessary. Loosen sec: control mee ing serews of lack remote anism: Noto: Gnly remave dear tek when in closed pasition, i.e. inner door handle forwards Detash connecting red for remote control at lock Fitting instruction: The remote contr be adjusted so that thare is 3+5 mm (0.118—0.197 play at the inner door handle . 8.705121/2 Unscrew Loosen screws for toggle spring lock. Fitting instruction: Insert spacer rol . in quide buttar, Re 5121120 Removing and fitting lock remote control mechanism. ave and fit door lining panel. 51 41.000. la film as necessary ing screws af lock remoteDetach connacting rod of remote control mechanisn 51 21170 Removing and fitting outer doar handle ind fit daar lining panel, 51 41 000, Unseraw retaining screw inside door . Lansen Philips head screw and take ‘off outer dasr handle. Fitting instruction: Do not forget rubber gasket. . 51.21 230 Removing and fitting inner door hand! Press off cover at rear and lift out forwards Lootan sera. pull off Inner handle. Fitting instruction: Do not forget cover plate between Inner daar handle anc eloar lining panel. 8.70 51212Bi— 21/4 5127280 Removing and fitting door stop Remove and fit daar lining panel. 61 41 000. Romave Acells film as far as nacossary Drive out bo wa door stog towards interior 5127300 Window well — Removing and fitting ‘outer door cover rail asen window wall cover rail by tapping lightly with a wadge of hard wood — starting al reer - and remove . 51 21.371 Renewing contact bulfer for interior light Pull contact buffer out,51 23 004 Engine compartment lid adjusting — il lock the front stop. Loosen clamp screvr (1) an tacking bar iz horizontal ani adjust wire ca facing the front a 5123 :200 Lever and bracket for engine compartment lid — removing and installing Loosen screws and remave outer left trim panel, a Loosen wire cable at clamp disc When installing: Adjust angine compartment lid — 51 23 004 a 71 Madificationand 2}, detach control cable (31 sceot with lever J c and remove b 5123210 Removing and fitting control cable for bonnet (hood) catch sen screws and remove outer left trim panel Laasen wire gable at clamp aise Qetach veire cable. When installing: Adjust ongine conypartment lid — 51 23 004)51 24.050 Removing and fitting boot (trunk) lid eatch Loosen screws, Unscreer threaded ring and pull aut boot Hid lock Remove boot lid catch ‘On “touring Pull cable away from contact switch Remove lower part of rear door catch. ‘When installing: Agjust roar door catch — 41 62.014, Remove upper part of rear daar catch. Whan installing: Adjust rear door catch — 41 62 014 9.71 Modification sia5124/2 51:24 100 Removing and (trunk) lid lock Remove and fit boot Itrunk) lid catch — ng Instructions: Nove fitted pasitias On “touring Remove lower part of rear door catch — 51 24 050. Unscrew threaded ring with 6079 box spanner. Take out the lock When installing: Note installed position — slot faring downwards with lack clasod 51 24 130 Removing and fitting striking for boot (trunk) lid catch, Loosen screws. Adjust striking plate . 51 24 301 Gas spring — replacing Support the rear door. Dotach the keeper st the spring pivotfamove the qas spring complete with bracket Lift out securing rember. Remove bracket 5124 341 Torsion bar springs for luggage compartment lid — renewing Remove fixing nut + the left and right supports 12) . Remove bolts at let . When installing: Note the installed position of the torsion bar springs. 7 9.71 Addition51 31.000 Remawing and fitting complete windshield Remove windshield wiper arm Remove filler sttip and using a lip extractor. detach the lubber window spal carefully from the body. . Start at one of the top comars and push windshield with hands.or fest If necessary. aut of body. . Fitting instruction: Renaw porous rubber seal Nota: To avold damaging the glass use soft glass holding device. Pull an rubber seal : Insert filler strip in rubber seal. . 9.705131/2 Fit length of string ar wire, appran. 3mm (14 ") dia., inta rubber seal. The two ends of the string should overlap at the bottam by about 30cm (1 ft). . Unitorrnly fill ruber lip: all raunel with joint mastic *) Place preassembled windshield on windshield aperture and bold firmly te prevent slipping to one fo. Pull rubber seal over body web using = During the fitting procedure use suitable ped or flat af the hand to bring windshield into co jan by knocking in regular pul See Technical cata5131 001 Renewing windshield Remove and fit windshield, 61:31 000, Check rubber surround far re-use and renew If neccessary In tha ease of a broken windshield ramove glass splinters from dafroster nozzles and intariar, Insert new wineshield into windshield aperture with @ number of rubber moulding sections The clearance (Al batman windshield and bedy aperture must bo appras. 6.5} 7 mm (0.28 + 0.276") 51.31 200 Removing and fitting rear window Remove filler strip and using a lip extractor, detach the rubber windaw seal carefully from the body. . Start at one of the top corners and push rear window with hands, or feat if necessary, out of body . jing instruction: Renew porous rubber seal Nate: To avoid damaging the glass use soft glaze holding dawles, Pull an rubber seal Z 9.70Insert filler stip in rubber eal Fit Length of string or wire, approx 3mm (1/8") dia., inta rubber seal The two ands af the string should overlap at tha bottom by about 30 em 11 ft.) jormily fill rubber ip all round th joint mastic Place preassembled windshield on windshield aperture and hold firmly 10 prevant slipping to ene side. Pull rubber seal over body web using string. During the fitting procedure use gultable pad or Tat of the hand to bring windshield ints carrect position by knocking in regular pattern, . Hy See Technical data 6131/4On “tauring’ models Remove the cable for the heated rear windawr. ‘Take out filler strip and carefully remove the rubber 1 the body with a lin-type pullar, Beginning at one of the lower corners, carefully press oul the gla wae with the rubber Surrout Note: To avoid scratching, use a salt cover over the Fid the mew rubber surround. Thread a cord or cable approx. 3 mm 10.12 in.) in thickness through the rubber surround. The cord ond= should overlap by approx. 30 cm (18 in.) Lay the glass together with the rubber surraund on to 1 cutout for the window and hale! firmly te prevent sliding sideways. Beginning at tho bottom, pull tuber surround aver the ade of the bodywork using the threaded card. The glass fs brought into the e position by avanly tapping it using a ped or the palm of the ha Fit the fill Seal the glass with Ter ip into the rubber surround. Sealing Compound 2322 . 8.71 Addi51 32.000 Remaving and fitting window erank Press off cover plato and lift out. Loosen screw andr swith thrust washer, Fitting instruction: When the windavy knob on the window crank must paint down mave window crank slosed the ds, 81.32.020 Removing and fitting crank mechanism Remove and fit door windawe, 51 32 170 Loosen screws and take out ecank mechanism 51 32 040 Removing and fitting retaining bracket for window lift rail Romove and fit door panel, $1.41 000, Dismantle retaining bracket from i Fitting Instruction: Push retaining bracket upwards, Both guide rallers must locate on the guide rail 6132 154 Adjusting door window Remove and fit door lining panel, $1 41.000. Slacken window retainer at lift rail. Fitting Instruction: Pus retaining bracket upwards, Both guide rollers must locate on the quicle ral a.70 si—aaytUpper acdjus Note: Only adjust nt in Larigitusina’ diraectisn, Adjust th anil sete tops s0 tha he windaw be wound Up. they locate on the waldad ndow must lovete 5132/25132170 Removing and fi Remove and fit auter cover rail for window woll in door 1 21 300, Remove and fit retaining brackst for window lift 5132 040, Loosen screws: 7 Open windew approx, 15 © tilt farwards and detach lift . run betwen the two plastic washe fitted batween lift are and lift ra : 51 32 230 Removing and fitting handwheel for quarterlight out cower (A) with a wire from the ft hole 18) . 9.705132/4 Loosen se we andl remove handwhael 51 32250 Removing and fitting quarterlight ave and fit daar lining panel. 1 41.000. Datach Acolla film as far as nacessary Fitting instruction: fi tick on sc with spacial adhesive #) Slacken retaining screw on worm geae Open quartertight. [A = approx 4cm (1.6")) = *) See Technical dataPush quarterlight firmly dawnea out of hinge and then pull out u 51 32 300 Removing and fitting worm gear for quarterlight Remove and fit a rterlight, 51 92 260 Loosen retaining screws Fitting instrwetion: Whan assombling push worm gear firmly upwards. 51 32 350 Removing and fitting window frame complete with quarterlight Remove and fer cover rail for window wall in door. 51 21 300. Re and {it door lining panel. $1.41 000. Detach Acella film as far as neo sary H} Soe Technical data 2.70Remove bottam ser Fitting instruction: Adjust quarterlight frame so that it ocalas neatly on dor aperture, 132/6851.41.00 Removing and fitting door Ii Remove and fit inner door handle. 61.21 230 Fomove and fit window crank. $1 32 900 Remove and fit handwhoel for quarterlight. 51 32 230 Romove and fit arm rest, 81 41 060 Litt doer lining panel out of remove upwards, . Romave springs of window crank and handwheel ing instruction: Fit spring of window crank with large coil diameter facing the Acella film, . Check Acolla film and renow if necessary Stick on with special adhesive") . 51 41.060 Remawing and fitting arm rest Loosen Philips head screw. : ") See Techni: 970 BattLift aut caver plate, Unscrew Philips head screvrs, Loosen bottor screws51 45 050 Upper section of facia trim — removal and fitting Remove windshield — 51 31 000, Remove instrument board — 62 21 000 Unscrew the main light switch. Lift aff the cover from the knobs for the heater blower svriteh, Unscrew nut and remove the knab, Remove bezels. Pull out switeh to rear The cables remein connected Unsere the knob from windshield wiper switch. Unsermw bevel and withdraw the swith to the rear The cables remain connect Remove the cable fi ratte lighte Installation note: Redyyellow cable = positive Brawn cable earth (around), Remave wim trom the lower left hand sidle of the facia Remove hese ein trom tha left hand demister a 9.71 Addition sisrim from the lower right hand side of the Remove hose clip from the right hand demister outlet, Remove nuts from studs (1) and (2) Withdraw screws (3) and (4). Romaye the trim trom the upper section of the 4 roust rest in holkters, When installing: Fising51.45 100 Facia and shelf trim - remaving and fitting 5145050. jon — 32 31 020. Choke nected, Remove storage compartment ~§1 18200. Pull off heater kas . Remove fixing serews (1) and (21 . Remove screws (3) to (B) Remove fixing screws (8) to 112 Remove facia and shelf trim 8.75 aneauon5145 120 Padded trim on lower steering column surround - detaching and attaching Loosen tha serews and detach the padded trim . 5145 180 Lower left facia trim - detaching and attaching to 4) and take off trim 5145 190 Lower center facia trim - detaching and attaching Detach and attach the padded tir oa the lower stearing unr surraund ~ $1 45 120, Jan the sorews and take off the tn 5145 200 Lower center right facta trim - dataching and attaching Remove and install the center oddments compartment — 51 16200, Loosen screws ancl take off the trim,