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Chapter 12
Bodywork and fittings
Contents
Bonnet - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Bonnet insulation panel - removal and refitting . . . . . . . . . . . . . . . .26
Bonnet release cable - removal and refitting . . . . . . . . . . . . . . . . . .11
Boot lid lock barrel - removal and refitting . . . . . . . . . . . . . . . . . . . .18
Boot lid - removal, refitting and adjustment . . . . . . . . . . . . . . . . . . . .9
Bumper mouldings - removal and refitting . . . . . . . . . . . . . . . . . . . .36
Bumpers - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Centre console - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .42
Door - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Door exterior handle - removal and refitting . . . . . . . . . . . . . . . . . .13
Door interior trim panel - removal and refitting . . . . . . . . . . . . . . . .22
Door latch assembly - removal and refitting . . . . . . . . . . . . . . . . . .15
Door lock barrel - removal and refitting . . . . . . . . . . . . . . . . . . . . . .14
Door striker plate - adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Door weatherstrip - removal and refitting . . . . . . . . . . . . . . . . . . . .16
Door window frame mouldings - removal and refitting . . . . . . . . . .31
Door window glass - removal and refitting . . . . . . . . . . . . . . . . . . . .23
Door window regulator mechanism - removal and refitting . . . . . . .24
Exterior mirror - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .39
Facia panels and trim - removal and refitting . . . . . . . . . . . . . . . . . .41
Front bumper - height adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .34
Front seat - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Front seat air cushion - removal and refitting . . . . . . . . . . . . . . . . .45
Front seat belts - removal and refitting . . . . . . . . . . . . . . . . . . . . . .47
Front spoiler - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . .37
Degrees of difficulty
Easy, suitable for
Fairly easy, suitable
novice with little
for beginner with
experience
some experience
Specifications
Torque wrench settings
Front seat belt buckle to seat frame . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seat belt retractor bolts (front and rear) . . . . . . . . . . . . . . . . . . . . . . . . .
Other seat belt anchorages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear seat back hinge to body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear seat back latch striker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front seat retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front seat frame-to-slide bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear bumper mountings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front bumper adjuster lockbolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 General information
The bodyshell and floorpan are of pressed
steel, and form an integral part of the vehicle's
structure. Various reinforcing and mounting
components beneath the floorpan are made of
HSLA (High Strength Low Alloy) and REPHOS
(rephosphorised) steels, which have superior
Fuel filler lock barrel - removal and refitting . . . . . . . . . . . . . . . . . . .21
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Headlining - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . .38
Interior mirror - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .40
Maintenance - bodywork and underframe . . . . . . . . . . . . . . . . . . . . .2
Maintenance - upholstery and carpets . . . . . . . . . . . . . . . . . . . . . . . .3
Major body damage - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Minor body damage - repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Motifs and emblems - removal and refitting . . . . . . . . . . . . . . . . . .33
Overhead console - removal and refitting . . . . . . . . . . . . . . . . . . . .43
Radiator grille - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .27
Rear parcel shelf - removal and refitting . . . . . . . . . . . . . . . . . . . . .50
Rear quarter window moulding - removal and refitting . . . . . . . . . .32
Rear seat belts - removal and refitting . . . . . . . . . . . . . . . . . . . . . . .48
Rear seat components - removal and refitting . . . . . . . . . . . . . . . . .49
Seat belts - care and maintenance . . . . . . . . . . . . . . . . . . . . . . . . .46
Side mouldings - removal and refitting . . . . . . . . . . . . . . . . . . . . . .28
Sliding roof - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . .10
Tailgate - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Tailgate latch assembly - removal and refitting . . . . . . . . . . . . . . . .19
Tailgate lock barrel - removal and refitting . . . . . . . . . . . . . . . . . . . .17
Tailgate strut - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . .20
Tailgate window mouldings - removal and refitting . . . . . . . . . . . . .30
Windscreen and fixed glass - removal and refitting . . . . . . . . . . . . .25
Windscreen mouldings - removal and refitting . . . . . . . . . . . . . . . .29
Fairly difficult,
suitable for competent
DIY mechanic
Nm
51 to 64
25 to 45
25 to 45
21 to 25
40 to 60
25 to 32
25 to 32
21
21
strength-to-weight
characteristics
compared with conventional steels.
Extensive use is made of plastic for
peripheral components such as the radiator
grille, bumpers and wheel trims, and for much
of the interior trim.
Interior fittings are to the high standard
expected in a vehicle of this class, with even
the basic level models well equipped. A wide
range of options is available, including air
conditioning and leather upholstery.
Difficult, suitable for
Very difficult,
experienced DIY
suitable for expert
mechanic
DIY or professional
lbf ft
38 to 47
18 to 33
18 to 33
16 to 18
30 to 44
18 to 24
18 to 24
16
16
when
2 Maintenance - bodywork and
underframe
The general condition of a vehicle's
bodywork is the one thing that significantly
affects its value. Maintenance is easy, but
needs to be regular. Neglect, particularly after
minor damage, can lead quickly to further
deterioration and costly repair bills. It is
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