Download Saab 900 Convertible 86-94

Saab900
SERVICE
MANUAL
SAAB
8:5 Convertible
Irt t985- t990-
028 Technrcaldata
Saab900
108 Specialtools
800 Technicaldesclplion
810 Bodyshel
SERVICE
MANUAL
812 Topassembly
830 Spoilerassembly
843 Windowglass
8:5 Convertlble
t;,
M i986- r99r -
844 Weatherstrips
and seats
851 Inteiorrrim
852 Rearseat
| ,-,
899 Alphabetical
seclionguide
om&3Fl.m!andconpoMbarcd.ah
blidinged@l*roh'iglibhdo
6.n$sjoh€pddo'gp€.ilc|ong
UnKt3
[email protected]
ri6 tho Sl sydo.n.
lshoul lh. s.'vl6 Mmur m h
Fdl)slra.1oni|br}i''m.€|unib'
qrvs rn bEdd and m. @p*[E sr unn.
Th€ l.ro$iq synboEed dbt€vralffi e
u!d:
St untt
Equlvaleniunli end
3ymbol
m
rnd'0n)
&
N
'{m
b'
r 0l.4
cc
polnd {bl
ldnd.lo€ (bn
poind.rqE r.d (rbrn)
Polid.rde Fl lqu@ hdl (b[tf)
(aF lbtr.d.bdr tdl
o
o
us rhurd$.n (k qr)
(rrs .nhEtral.d|dd
Ussalhn(ussrD
Converalonftctors
1 k0 = 220 |b
1N=023lbl
1Nn=07rbtfr
1 b{ - 14.sblrlf
lF€l=o07b.ll|=1'05l|qql
1 USg.l = 0S3 Uxsdr
1 US rrqd = 0.43uKqr
qc-cF.32)r5/l
llb=0,451€
Martel code6
no 6d6 Bid b mnd .p.df€fon8
o
o
Technicaldala 028-1
Technical
data
Hydraullcs
lor convertiblo
top
worlungpressure
ol pump
hin 2s (36s)
Iighr€nin9Iorque hosefinings
5 . 1 4 2{ 3 . 3 , 4 . 5 )
Chas.is no. H7003109
Chass'sno N7003200
oneards
Recommended
creaningagents
Soapandwalef Forstubbohslainsor din
useSikkens
FeducerM600as perthema
Sraples
roronerabncrayer
I s ( 03 S ) p a d
n o 6 93 5 7 r 2
12.7(0.50)panno 69 34 245
a
3M SuperWeathersttip
Adhesive
3M SuperW6alherslfip
Adhesive
Contactadh€sive(LoctiteBtackmar3AO,
LoclileSuperglueor oqulvalent)
Betasealadhesile
kil, pan no.
{45)3007119
Fenll parl no. (45)3016045
data
028-2Technical
SeglantToofab.lcands€als
Sirarler255 panno (45)3007 127
SealanlToPlab c.nd seals
tyre pressures(coldtyros)
Recommended
1.2
G100
2.0 (29)
22 132)
2.0 (29)
2.4 (35)
21 (30)
2.3 133)
2.1 (30)
25 (36)
l.30)
(3s)
2.2 132)
2.5 (36)
2.1
2.!
1-2
1-2
0.210
2.1 (30) 2.3 (33)
24 (35) 2.s (36)
24 (3s) 2s (36)
O
O,
L
a,
Speciallools108-1
Specialtools
I
Press!resensor(included
+t
olo FastModilm B1-5324
285
662
Pre3suresensoradaplor
a 29 28 1 5
ooublesidedadhesive
hp€
Technicaldescnptron
800-1
Technical
description
T o p. s 8 e m b l y. . . . . . . . . . . . . . .
T o pt r a m ea s s e m b l.y. , , . . . . . . . .
r o pc o v e r
..... ..........
Head|ining ......,,........
H y d 6 u 1 i c. s. . . . . . . . . . . . . . . . . .
sears ........,
... .........
a001 Adiustrnents
.... ......
300.1
T o pa s s e m b t y. . . . . . . . . . . . .
3002
Seals . ........
.... ..
300.3
o @ . w t n d o w g t a s s. . . . . . . . . .
3 0 0 - 3 R e a r q l a n e n i g h. .l s. . . . . . . . .
800-4
Top assembly
The lop assembly
consislsol a top fane as.
sembrya top cove.and an innerhaadinino
The top 's operakd oy an etecr'catrycoi.
lrolledhydraulic
sy.tem.
'rh€
iop lrameconsislsol lvo side rails,each
ol which compriseslhree seclons a lfont a
middleand a rearsec. tion.
The seclions are held togeher by hinges.
whichallowrhe side rallslo lordas lhe bp ts
Four crossmembers,somelimesknown as
bows run belveenlhe side railsand are each
idenliliedby a number,no. 1 beingthe cross.
memberd$e lrontoi lhe lrame
Bo0-4
BOO-4
800.7
3oo3
3oo.g
description
800-2T€chnical
!p. it is lockedlo lhe wind
meansol a lalchingmocha.
side, atached lo lhe no 1
Th€ lop cover is in two pad6i lha top covor
iGelland a rearccreenpanel
The kont ollhe lop coverls gluedontolh€ no.
1 crossmembe..and lhe trailinq edge is
siapledto a slrelcherlhal is rilered onto the
body.Thetop is alsogluedto the rear seclrons
t-.
The .ear screan is glued to lhe rearscreen
panel, rhich is slapled lo the no. 4 cross
m€mber and ro lhe strelcherilsl rofrard ol
lid. The lop s€cton
lhe luggago.cohpanmenl
ot the raa.screan panel, betweenthe top ol
lh€ r€a. screen and lhe no. 4 cfos6memb€r
is iast€n€dby a zip to allowlhe rear screen
to be loweredlor increasedvenlilalioninside
Whenlnzipped lh€ rear
loweredand not allowed
Th€ r6ar screencan be .eplacedwilhoullhe
needlo ,emovelhe lop cov€r.
Two variantsor the lop cover are n use on
ca.s withchasss no H700319sor ea.rie.tne
lab c is made by cambria,whdeas on cars
wilh lal€r chassisnos fie top labricls oade
Alter trinming or culting,lhe edges ol lhe
Cambrialabric hust be lused by use ot 6
heatgun lo preventlraying
Siaptes are available in lwo l6nglhs, lhe
long6. on6s being used when lwo or mor€
layersollabric needlo be slapl€d.
0_
t-.
Technicaidescnprron
800-3
Headllnlng
The h6adlining
ls secur€dto the und6rsides
or the rou.crossmembers.
on fte no. 1 and
no. 4 crossnembersit is h€tdanptaceby
bothdouble,sided
adh€sive
iapeandsc.ews
andon $6 no.2 andno.3 crossmembers
by
m6ansol plaslicrglain€rslrips.Ih€ bdckol
the headlining
is securedby pressstuds.nd
Hydraulics
Th6lop is raisedandloweredby h€an! ot a.
.lectricallycontrolred
hydraulics
system.The
setoo pump and moio. are tocai€don the
ightnand side, undernoath
th€ rear seat
Plastic hoses run tlom lhe pump to the htro
setuo cylinders,which ar€ atachedto lha
operatngmechanism
lor lhe top.
The hydrauticsysten is precha.ged
al $e
ractorywilh specialhydGuticfluid 9a.t no.
(45) 3014604.Pleasenorelhar rhis is rh.
only ttuid lhal may be !sed. Eartierpar
ricurars
staring
rharATF ud or eng'neortmay
be us€darelhusno longer,alrd
A bypassvalveis tittedin lhe ci.cuitbolw€en
rhe PUmpand lhe nghlhands
enabrelhe lop Io be operatodmanuaty The
vaNeis accessiblebehinda lap in lhelim ar
lhe back ollhe ruoqaqecompanoenr
To preventthe pump ftoh overheating,an
overloaddevce isolalesit aulomaticatty
it it
has been runninqtor more than 10 - 20 se
condswithlhe top lulryup or down
.A
descriplion
800-4Technical
Seals
The seal on the A pillar is gluedlo a retainer
scfew€donlo lh€ p'llar Ai lhe bonom.lheseai
'5 herd'n praceby rhreelasle
sided adhesiv. tape.At$6top,lhe slrrpis se'
cured by one lastBnerand co acladhesive
The lop has a seal al lhel.od one on eilh€r
side and lwo atlhs reat.
The seal at $e tont is gluedand screw€dto
on eith6rslde
$e no 1 crossmombersand,
oruedb a retainerlhal ie screwadlo the side
;ails ot the top lrame.Sealdnlis appliBdatlhe
The iniemediataseal on eilherside is glued
ro a s€al retainer sc.ewed onlo lhe middle
The .ear seals 8re gl!6d, scr4€d and
secured by li€s lo lh€ side rail r€ar seclions
These seals also setoe as quid6 lor Ine
t,
I
Adiustments
malcan
Thiss€clionexDbinslhe adiusltneds
quaF
rea.
windows,
top,
door
lo
lh€
be made
Th. tenE. lore a.d all, and lated and
rererio
ve,lical,whenappliedto adjustm€nE
to
lhe
car'
ment
relaliv€
adju
ll shouldbe nol€dlhal adiustmenlol one com_
ponont6an afier lhe adiushenl ol oth€r com
t
L
i
P.rr P@iton o. r.ising toP
The oark Dosilionon raisinglhe top. i€
lh6 oosilionin qhich the top sloF bolore
belnolarched,is adiusledbv meansor
bala;c'n9.linkcams locaradinside lhe
bp, adjacenlto lhe top ol $e quaner
Technrcal
descnptron800-5
on belng raised,lh6 l€adingedqe ot he
lop sholld slop in lhe park poslion, 20 30 mm (0.79 . 1 13 in) above Ihe wind
screen rrame. The rronrot rhe rop must
alsobe parallelwilhthe lrame
To adjusrrheguidepin,whichinhrbits
ta.
€rar movemenr
olhe lop.toosenthenul
Lalchinqmechanlsm
hoo*s
Io adjusl rhe heiohr ot rhe tar.hing
mechansmhook. slackenott lhe Tod
rotale $e hook One
complelelurn or lhe hook increasesor
decrersesrs heqhrldependngon which
wayrt rsturned)by 1 mm (0.04in)
Pressdow. on thetrontcornerot lhe lop
lo ensurethatno playis presenl
in rhe hinge beMeen the
Ironl and middlesecuonsol rhe s'de ral
to bringlhe iionl se.lion or the siderait n
line (parallel)with lhe door windor and
desc plion
800-6Technical
5 ToP .ssembly lold€d po3ilion
To adjust$6 endposition
or lhe lop when
loldeddown.slack€nofi lhe nurcon lhe
rear $op on the lop framemechanism
whenlhe topis down.
A.p€cial qause(asshown)mlsl be used
L
t
Posilionlhe gaaqe as shown and lhen
adjusl lhe stop lo rhe co.iecl posirion.
fl,'
conect pasitionlot slap bftctol
T€chnicaldescription800-7
As a geno€lrule,atts6atshust be gtu€d'n|o
pos'rionu5in93M superweaher.ho Adh6.
sjv€,wirh.ny adjustment
b€inqnad; b€tore
NoLelhatrheropor lhe Atilar s€atmuslbe
gfuednlo posi0onusinoa contactddhesNe,
such as Loctileglackhax3a0.In tis case,
$e s€ar musl be cor€c y positionadbetora
[lo adhesive
is applied.No olheradtush€nl
ol lhe A'pillarsealcanb€ made.
1 Top a3!.Ebty tronr .€61
rh€ lale/atpositionrng
ot tl€ tra't'ngends
or |ne rronl se.l can be adusl€d bt
roosanhglh6 nutson th6 botd securina
lhe soal r€tainers. Foreand,aft adjusim€nlotlhe s€almustbenade betoroth€
lop as$mbly stde3€ats
Adjusrmenr
or rhetalerarposilroning
or the
s'deseaEcan be nad€ by slacleninq
on
lhe nuls on lh€ bolts securinqlhe seal
rerarners.
Fore.and.aft
adjuslmedot rhe
s€armlsl bo madebetorelhe adhesivo
W
lop assemblyrearse.l
verlicaladjuslment
ot lhe rear seat can
b6 madeafterlh€ nutsand o havebeen
r@sened
andtheadhesiv€
bondbroken.
A*
Stl
descrjption
800-8Technical
wh€n adrustinqlh€ door shd@ check tle
ot lhe itonr 3eclionol the Fid. tail
adru3tmenl
1 Io adjusl lh€ heiqht ol lh€ lront ol lhe
window glass, loosen lhe screw n $e
2 To ad)usrrhe heiqhlol ihe rear end ol the
glass, loosBnlhe s6rew in lh. rear qhss
3 The heighlol lhe lrailing6nd ot the door
Ihe rear
can also be adjusledby undoing
qlass
linmechamsm.
nlt on thewindow
Technicaldescriplion800-9
For$and-afi adjGrment
4 To adiusl 1116loreand,atl posilion ol the
window glass, loosen rh. glass stop
=Jlfa
5 To adjuslhe lat€ralposilionol the window
grass,roosenlhe bonomol $e rear guide
channel.As irom chassis.o, K7021110,
rh6lronl guidechannelcan be adjusl€din
Qu.rterlighrs
1 Loosenthe scfews in the kont and rear
800-10Technicaldescription
Fo.€-6nd-afiadiustm€nl
mechanism.
2 Undolhenutson lheglass.lift
3 Undolhe secutng nuts lor l-\e glass.li,l
h€chanismand ium lhe sluds in lhe
appropriate
dteclion.
\
-4
4 Undolhe nul securinqthe glass lo lhe
glasslinmechanism
and lum the slud in
direclon
lhe appropriare
Body810.1
Body
310.t
Additionalstrengthenlng
As on 000-.ees saloons(sedans)
and hal6h
backs,the Convedbbbodyis a monocooue
To compensale
lor lheabence ora rioidraot.
add'tionar
srrengihen,ng
has be6nproitdedin
lhe lormol sleelmemborsanda toad.bea.ino
bondedwmdscreen
-rh€
strenglbening
componenb
areastolows
I
3 Anchorage
lor seatb€llguide
Corn€.plateon radiator
lop crosshember
2 Anchoring.ocket
onwhe6tar6htora-piuar
3 Side{anelsrenglhene.
4 Enendeda pi d 0owheelarch)
5 Topcrossmehbdon tindscr66ntrane
10 Upp6rsidemember
11 Torsionboxon reanaxte
tunnel
12 Sill.r€inlorcingmembor
13 Torsionboxunderreafseat
7 SecondaryB pilar (ti ng poinl ror top
810-2Body
Bodydimensions
are
The diroclio.sin whichthe measurements
madeare givenin,ihe Directio
Table, with rel€rence lo lhe coordinale
Each coo.dinaleoiginabs rrom a daum
(o) line oatun line xO cannotbe used In
practiceand is lhererorenol shown
x{oordinale = Daum line lor IongnudinaL
DatumIno YO. This is ihe canirerineol the
body, dividlngthe shel into leil and righl
haves T.ansversedmensionsare spoc!
led belween lvo measuring points To
measurolhe dimensionon one side onlv
mark oul the Yo line betveenlhe holes as
shorn on lhe drawinqand then halve $e
dimensionand lolerance
Y coordinate= Oatum lne lor fiansverse
(lenlo rlqht)
measu16meils
=
Z.coordinate Dalum line lor v€nrcal
The ligure lollowinq lhe coordinale in lhe
corumndenoleslhe lolerance,as rollows:
1 = Oesisndinensionin coordinalesysFm
2 = Ackal measuremenl qeneany a
diaqonalmeasuremenl
3 = Tolerancelor besl rit
(hc)= Dimensionto be measuredrrom hole
Oatumline zO The line runs alongthe rod
n the body betweenlhe roor pan ano sde
oanel.Measlremenlslo be madebelow$e
zO ino a.e indicaledbv a negafve value
(i.e.$e valuels prelixedby a I sign).
ttem Flg-no, Ohenslon,
aumperbrackel(hc)& lronlholelor
Oislancebelwee^lrontXl and rear
Xl
Wishbonered hole(hc)& lfonlhole lor
X1
1 5 0 6 . 0 1 (45 92 9 1 0 . 1 6 ) Fronlholelor splng link (hc)& tailedge Xr
2
2
3
zo & edgeol lrontcrossdenber
zO I bonon edgeol bumperbracket
( 4 1 . 3 3 1 0 A ) Holeslor bumpotbrackel(hc)
1064.012
( 4 2 . 4 4 0* . 0 3 ) Width:betweennnerwheelarchpane
1073.012
1 2 2 3 . 5 ! 2( 4 3 . 1 6 1 0 A )
3,3
13
15
Outorboltholein kont crossmenber
{hc)& rearholein stenglhenerunder
Oulerholesin kont crossmember(hc)
HoLesior rackand piniongear (hc)
2 1 3 75 1 2 ( 3 4 1 5 t 0 . 0 3 ) B6aroule.holeslor wishbone(hc)&
lronlhoLolor sping Ink thc)
( 5 6 . 2 4 1 0 . r 2 ) Fronihoreror springInk (hc)& Yo
1301.513
Fronrhorelor sorinq ink (hc)& iront
hoL6lor Paiha.d{odbrackel
21
Y1
Diag 2
Y1
olag 2
Dneci2
Direct2
Body810-3
Item Flg.no. Dlmensron,
mm (in)
Fronlholelor sonnor'nkthcl & c6nlr€.
hnehrouahPaihaft.rodbr;ckel
zo (hc)& Panhard
rodbrackol
zl
Rearholelor Panhard{od
(hc)
brackel
& edgeol recessin lloorpan(ret.
Fronlholelor Panhardrod
brackellhcl oiag.2
& konlhorelor RHsprinqunk(hc)
1 0 6 0 . 03! { 4 1 . 7 3 ! 0 1 2 ) Holesrorspringrink(hc)
Fecessin reariloo.pan
22
3.10
3,10
2
2A
29
1240.O
!3147.24!0.121
YO(hc)a lne lhrough
horein coUision
Aperlure
lor rearliqht
cluster
22
ZO & lop olcrossmemberat YO
ZO & top ol lie plaleal YO
ZO & cornerar l,arledq€or ru9gage.
21
21
21
zo& waisrlinear lail4dgecorner
zl
1 3 2 1 . 5 i 4( s 20 2 . 0 1 6 ) DistancebeNeenhingemounlidgs
1 3 2 10 r 4 1 5 2 . 0 0 1 0 . 1 6 i w dth ot lailodge ol ruggage.
-2 (-0.3)
H n q e p i nh o l e( h . ) & c e n l r eh o t el h c t a t
2,7
33
Centrehol€in rear rroorpan (hc)&
boflomedaeol channelinrearscroon
23
Centrehore(hc)in rroorpan (yO)&
co.neron lailedge ol luooaqe.
0aq.3
Cornerob
n i l e d q eo r a p e r l u r(oh c l&
36
3,9
Fronlhole'n 'nner*he€larch panel
lhc) a bcalinShoe in bul[headchannel
a9,rr
Fronlholeror rack-ando'nronoear lhcl Diag.2
3 bofom or bulrhead.h;nner am'dwav
belweenholeslor wip6rspindtes)
Dislancebotweenrront2 hotein inner
wheel'arch panel& outerhol6lor
3,11
Fronlholein nnorwheerarchoanel
(hc)&moununs
rusonwinq(hbl
Mounlinslus on w'ng(hc)3 locahns
horeIn bu rhead channet(hc)
810-4Body
Item Flg.no. olmenslon,mm (ln)
40
3,9
41
42
1l
5
45
5
46
5
al
3
A43 5
843 5
49
1
so
3
51
s
52
S
53
911
54
55
56
57
4
34
4
1
53
1
59
2
60
61
62
polnls
Measurlng
556.011 (2133!0.04)
Locatngholein innerwheel'archllange
(hc)& localingholein bulkheadchannel
{hc)
1340.013(52.7510.r2) D stanceb€leeenlugson winqs(hc)
1 3 1 . 5 1 1 ( 5 . 1 a 1 0 . 0 4 ) D 6 l a n c eb e N v e e n h o e s Yi ol r l f o n t
ens ne mountns(hc)(lales(varianls)
40015(1s71002)
F H b o r h o r e( h c ) &Y o I n e
1990!1(7.33!004)
Z O & s l e n c e (r m u r i l e r ) h o( lhec )
172011(677i0.04)
B o r r h o r(eh c ) r obr u n p e rb r a c k e(rx o )
& nUIon enginemounllng(hc)
517.011 (20.3s10 04)
Widlhbetweenrearenoinemounling
holes(hc)
7 3 0 1 1 ( 23 7 1 0 0 4 )
r m e r n a r d i m e n soi o
. o n te n g i n e
i in
.0 (.0) (ea.ryvarants)
mountinq
7 3 9 0 1 2 ( 2 9 . 0 9 1 0 0 3 ) L e f i r e &e n g n m o u n l i n(gh c ) &B H h o l e
in rrontenginemounlLng
7 5 1 . 0 1 2 ( 2 s 5 6 1 0 . 0 3 ) R H r e a re n q i n em o u n t i n(ch c ) &l e l th o e
rn rronl€ns ne mounhq (hc)
55.5i1 (213i0.04)
a o t h o l ei n b u m p elrh c ) & h o l en i r o n t
c,ossmomb€roc)
197.012(7 7s 10 03)
Fronlho e in 6ck.and.piniongear (hc)
A verlicalpanol bukhead(nollo
n9 crease,
sr.en9men
6 6 00 1 3 ( 2 5 . 9 3 1 0 1 2 ) Y Oo n w i n d s c r e ekon g e & l o po r
exhausfpiperunner(edqear bulkhead)
2175r 2 (3 5610.0a)
YO ar v ndscreenllange& lop edge ol
ste€rinq.column
mehber
63612 (2503! 0 03)
Oistancebelweenw ndscreenedgesat
nange
1 r 8 0 0 1 4 ( 4 6 4 5 1 0 1 6 ) D i s l a n cbee l w e einn s i d €os l s i l l s
1 3 3 6 . 0 ! 4( 5 2 . 5 9 1 0 1 6 ) D i s l a ^ cbee M e e no u l s d ee d g 6 so l s i l s
1 5 00 1 2 ( 5 9 0 1 0 0 3 )
Z O & t o po l s i l
(
6
9
.
5
4
1
0
1766.512
3 ) S u m p ehr oe { h c ) &r o c a l i nhgo r ei n
wrndscreen
rame (ncj
Dbtancebelweenocalingholesin
8000 I 1 (31 50I 0 04)
rame
1 0 7 3 5 1 2 ( 4 2 . 4 4 r 0 . 0 3 )z O & L o c a l i nhgo l ei n w i n d s c r e er n
{ncl
1
1 4 s 9 . 0 1 2 { 5 9 0 2 1 0 1 2 ) L o c a l i nhgo l en w i n d s c r e er rna m e( h c )
poinr(hc)on
& bertanchorage
secondaryB Pillar
1 2 7 . 1 0 1 4 0 1 0 r 2 ( 7 0 9 1 1 0 . 0 4 ) L o c a t i nhqo e i n w i n d s c r e el rna m e( h c )
& lronthol6in spinq Ink
1,6
1259.0!2 (49.5610.03) W dlh betweenocatingholes n
secondaryB pilars (hc)
onect 2
Y1
Y]
Yl
z1
x1
Y1
Yl
oaq l
Diag1
X1
x2
Dnecl2
Dnecl2
o recl2
Y1
Yl
21
Y1
21
oned2
Oirect2
Yr
Body810-s
Item Flg.no. Dlm€nston,
mm (h)
2 9 2 2 0 r 2 ( 1 1 s . 0 4 1003 ) Buhpe.holee(hcl& rocarnohotern
socondary
B pillarlhc
zo & ocatinghoreinsecondary
B pilar 2 1
2 3 1 75 1 3 ( 1 1 0 . 9 2 ! 01 2 ) Bumper
hoe (hcla be[ anchoraoe
l25S.0r r (495610 04)
p o i nlih c ) r ns € c o n d aBr yp l l a r
Dislanc€
b€MeenbelranchoEoe
- ooints
in secondary
a pilars(hc)
ZO&lop laceot secondary
B pittar
21
Distance
guidepr^horesin
beh{een
1 3 6 02 1 2 ( 5 3 . 5 5 r 0 . 0 3 ) Maximum
diagonatd
stancebetween
1,2
insides
ol windscre€n
lrame
ZO& topcomefat konrot sidepanel z l
2 s 1 3 . 0 1 3( 0 3 . 9 3 1 0 . 1 2 ) Bumper
hore(hc)&rronrcorner
or side
Dislance
bireen topcornersat trontot
2
2
gollofrcorneral tronlol dooraperlure
& topcorneral rrontot sid6panel
Botlomcomer al rearotdoor apertlre
Diaq 3
& topconer ot windscr66n
lrame
Bohomcoheral rearoldooraDenure
&lop rivethotetorA-Dittar
trim
a€llanchor.aeoo'nlonsecondarv
B
pillar{hc)Abbl horerorrearspoi]br
widlhberween
bolhores(hc)rorrear
73'7
Beltancho.aqe
arrear seat(hc)
3239.514
Ben
anchoraqe
020.s01016)
at r€arseal(hc)3
Diagonal
between
r6a6eatbelr
anchorage
poinr(hc)8 bel anchoraqe
cars wnhhree.point
b.l ,ittedi^ roarseal,
chassisno.J7005072
onwards
810-6Body
11118S
"9
a
-3
-F:
a
rft
gi
t
iq
P
P
fl
\.l
Body8l0-7
8s78s
810-8Body
811TaS
I
Topassembly
812-1
Topassembly
312.1
412-21
412-25
312.36
81242
41242
S e r u co y i n d € 6 . . . . . .
B y - p a svsa l v e . . . . .
B l e e d i n g t h e s y s l.€. .m.
Measuring
lhe pressure
Lalching
handteassembty
Skikerplateassembty . .
412-43
312.43
312-53
Top cover
1 Remove
lhe headtining
(s€epaqe8j2,21).
Fenove lxe spo'terassembte
t3e€oao6
430.1)
Lowerth€toptolh€ midway
position.
i
Pullawaylhe cornorsot
renove (hescrewat lhe
I
812-2Topassembly
Aemov€ the fluls secuino lhe seal 16.
iainerlo lhe lronl seclionol the siderail.
ReFov€ lhs sdews in lh6 l6adin0 edge ol
tie sealand remov€lhe seal.
Lowerlhe topcomPlelery.
i
Pullawaythe welt cord (lheloldedsl p ol
labric along the teadingedge ol lhe top)
rrom $e no. 1 crossmembetilh€ w€lt
Topassembly812-3
9 Benov€ all lhe staples
slip an.l lh6n r€nov€ Iha
10 Pull away$€ iop cover
E
12 Dill out the rivelsin the
812-4Top ass€mbly
13 Ca.elullywilhdrawth. cables nom h€
€nv€ropasi. tne slde ol lhe lop cov4 and
leave lhsm hanoinokon the rear re
14 Femoveth€ acom nutsand snlp ofi the
lies holdingthe rear seatsin ptace Fe
rd
!d
15 Pullawaylhe top coverkom the siderail
r6arseclions(labic gruedto rairs).
t/
v,
16 Plll up lhe lop coverside [aps, release
ihe hooks lrom the llaps and hook ihen
Topass€mbly
812-5
17 Befrov€ lhe nnish€r 6lip tom the tail
ry
t
13 Unsc.ewthe leaturesllip €nd caps kom
l9 Pullofitheleaureslrip.
Ma.k the let and right
mrnrumr€lainerslip and
812-6Top assembly
staples holdinglhe lop
.i
24 Undo the scr6ws secu.ing lh. anlibar.
l@ningstripslo lhe no.2 and no. 3 cross
nohbers (he $ips are in lhe pockeEin
Topassembly812-7
Wilhdrawtho anli-baliooninq
slrips lrom
To fli
1 9an withrhe rop lrame.ssembtytotded
Faise lhe kame ass€mblyand [n lhe lop
cover inio posrlioi Insedlhe anti,balloon.
ino sliips in lhe pockelsin fie cover.
812-8Topassembly
s6cute lha ends ol the anti,baoonino
skips lo the no. 2 and no. 3 cross.
m€mbe.sby insgninglhe screwsin lhe
Ensure thal lhe pockets do nol gel
Insen$e lop covercablesin thepockets
usinga hookedweldingrod lo pul lhem
Rais€lhe lop assombly
about50 cm and
sgcurethelronlrelainer
lor 6achcabteby
m6ansota.ivel. use v€tswithpanno.
Insenlhe hooksinlo the 6y6totson the
r
Topassembly812-9
3 Fil lhe spacers,pan no. 8292492 or
8292799, as appropiiate,
into posilion
on thewindscreen
lrame.
I
Closelhe lop, enqagethe talchinghooks
but do not closelhe handles
10 Clamplh€ lop coverlo lhe no. 4 cross.
memberby meansol a w€ldingclamp
The stbhing alongthe seamsand the
prepunched
hol6sin lh€ covermuslbe in
line with lhe leadingedge ol $€ cross.
11 Gluethesideflapsollhe toplo thecomer
or lhe no 1 c.ossmember
using3M super
Weather$riP
Adh6slve.
3M Slpd Weathe.stripAdh€siv€sholld be
used aor all gluing ol the lop cover uness
812-t0Topass€mbly
12 Slretchthe cov€r over
memb€rand qlue it to
c.ossmember
lo tix lhe
13 Femovelha w€dingclaopiron lhe no
l
l
15 T.im lhe side napsby meansol a knileor
ll the lab c is ot Canbria mak€, use a
he6l gun lo ruse lte edges lo preventih6n
Topassembly812-11
16 Gbe m€ side flapsto th6 no. I cross
m€mber.Fold the tab c
T.im the lab.ic atongthe edgeot the no. i
Cul away the top tayer ot tabric betueen
':i
8l2.12Topassembly
20 clt throuqhanycr€as€salonq,l. l€nglh
andsmoorhrhehbnc down.
21 CutofilhesurpLus
seamarlheedge.
22 Plac€|he wehcord in posilionon lhe no.
Theloreandalt posi(onis detemlnedby
.ligninq lhe s€am wilh lh€ ironl edge ol
lhe crossmemberAlso ensurelhat the
midpoinrol rhe cord is equadisranl
Lom
23 Op.n up lh6 bo!@nllap ol lie w€[ cord
andslapleil to $e plasft skip.sta ng In
b6 middleand workingour lowardslhe
6.ds. Usa lhe long staples,pan no.
693428s.
The long slapres, parl no.
u6odtor staoringlvo or noro
Th€ shorl staples,parl no.
lsed whenonlyone layeroa
Topassembly812-13
24 Gtu6lh€top iotdot ti. wettco.donto$e
25 Gluerhowelcordends.
26 Applya beadot adhesive
sear jnlo posiuonand
onb lne sealretainor
8t2-14Topassembly
28 Fil ols scr€wssecurlnO
|nesealtolhe no.
29 Flllheko scr€wsin thestripr€tainer.
30 S€al [h. ends ol the stip usinq Sikallq
255 (3OO712J).
31 Placelh€ space6,pan no. a292492ol
429?7S9.as appropriale,
an he windscreenlram€.Rais€lhe top and enoage
lhe lalchinghools bul do not close$i
Topassembly812-15
tabric by puljng il down
lhe back and gtuethe top
T
:
$
abngrheoursjde
edgesor
Placeth6 rear s€atsin Dosrxon.
ltohr€n
|ne acornnutsand rirrheI'es Use;abb
u e s p, a n! o . o 0 ) 7 s 7 1 3 9 s .
In order nol to t€avesharDedoes ftal
courddahagerhe rabnc dd noicul lhe
€ndsol lhe tiesbdlJckthemin instead
812-16Topasssmbly
sc.eenkom lhe sl'ap and
36 Plac6 a proteclive cover
rid.
luqgage.omparlrnent
usinga drin.centrelhelop
conrrehole in tne no. 4
Str€tchthelab c by pullinq
rear ol lhe car and use
staple6
to lir il intoposition.
"
To ensurethatthetopcoveris nol pulledoui
carryod eachol $e lollowing
o, alignm€nl.
sreps(up to and includingsrep4s) on both
sid6s ol lhe car belore going on lo lhe nen
coler 6ide llaps and
edqe ot lhe labric is
edqe ol rhe .ea. screen.
witha coupl€ol slapl$.
1
3a
Topassemb
y 812-17
39 Removelhe staptesin the side panels
srerchlhe tabricaqainanduse a couDte
oJslaplesto hotdit in ptace.
t0 Remove
rhesraples
tromrhemiddteofihe
no..4cfossmember
srelch thebp,abric
ano secure by means ot a coupteoi
srerch lhe coverby putinqit towards
the
rear or the car and siaoteil to lhe no. 4
crossmemberslapti.9 shouldbe done
aronglhe cenlrellnobetween
the seams
a(ernarrno
berween
therighrand en sides
41 Slretchrhe cover lowardslhe rear on
erlherside shpte the fabic ar rhe oul
lhe no 4 crossmember,
ourboard
ol rheseams
42 Removelhe staptestromlhe sidepanels
,esrerchthe tabrtcand sbpte n position
usrnga coupreor sraptes
812-18Topass€mbly
43 Pull down the top cover side flaps lo
slr€lchthemand daple the tronlpan ot
the sideilapsin posilion.
oo notstaolein
lhe holesin thesrr€lcher
44 Pulldownandstretchlhe innertabricand
Applya bead ol adhesilealonqlhe line
.laples in lhe no.4 crossmembe..
Topasssmbly812 19
47 Wilh lhe lelt and .ighl ma.ks codeclty
ori€nlaled,s.rew lhe lealureskipr€tainer
rntoprac€on the no. 4 .rossmember.
43 Apply a bead ol adheslve atong
49 Presslhe tearlre strip
screwon theendcaps
50 Trim lhe edgeslo removeslrptus tabric
ll lhe labric is ol Caob.ia make, use a
heal gun Io luselhe edgeslo p.eventhen
812-20
Topassembly
5l Piercea hole in Ihe labric lor subsequenl
ins6rlonor lhe siud lor lhe sid€ sectionot
lhe spoilerassombly
53 Removethe spacersiromrhewindscreen
trameandraiselhelop assembly.
check thallhe top comesb rost 20 30
mm rromlhewindscreen
lrame.
li adjuslnenlis necessarys€6 page300
T
\I
check the adjuslnenl ot rhe lalching
hools by lalchinqrhe top in positionand
lhen pr63in9 downon the lro corn6rsol
lhe iop. No playshouldbe present
It adjuslmentis necessary.see page 300.
5.
Topassembly812-2i
54 Adjuslthe positionot lhe
agarnsl
|nedoorglassand
secunnq|nesealreIainer.
q
55 Firlhe screwssecurnqlhe anx.baoonrna
slripsinsidethepocretson lh€ no 2 an;
no.3 c.ossm€mbe.s
56 Fillhe spoilerassembty
(seesoctionB3O)
s7 Filihe h€adlininq
(seepageB12.Aa).
Headlining
1 Feleaselhepresestudsandvetdo tasle
nss sekcu.ing
lhe h6adtining
sid6flapsal
812-22Topassemb
y
Undolhe zip, reloas€lhe slrap and lower
Pull away the headliningrrom fie ad.
hesivelape holdinqit in placeon the no 4
crossmemb€rand let il hangkee
Mark lhe posilionol lhe
no. 3 dossnember and
Topassembty
812-23
Mark$€ position
ot thestripon lhe no.2
crossmefroer
and6aseftrestripofi.
Remove
lh6 screwstromlhe tinishef$ip
on fio no.1 top.assembty
cros.nenb€r.
Rel€asethe talchinghandteand refrove
h€enn6her st4 (securod by adhesive
812-24Topasssmbly
To lll
Lift $e headlininginlo positionand press
lhe plaslic relainingst p onto lhe no 2
crossmemberol lh6 top assembly En.
slre the strip is posilionedconlrallyby
lininq!p the ma.ks mad€ beiorethe slriD
ll a new headlining
is beinqinshtted,en
sor€ lhal lhe retainer$rip is equldistanr
lromeilherendol tho.o.2 crossnemh.r
using double,sided
adhesivelape,pr6ss
lhe headlining
into positionon the no. 1
crossmember
andsc..w lhe ijnlshersrlp
intoplace.Tak6carelo aliqn$e linbher
Presslhe plaslc relainerstrjpinto posi,
lion on lh6 no. 3 crossmemb6r.
Ensure
lhe slripis positionod
c€ntBllyby tininqup
lhe mads made belorelh€ 6trip was
I a n6w headliningis being instaled,
ensurethatlh€ relainerstripis 6quidi5tanl
kom eilherendot lhe no 2 crossmembe..
Press lhe headtiningonlo the doubt€sided adhesivelape on lhe no. 4 crossmembe. and screw lhe melal skip inlo
position.Note thal lhe strap tor the rear
screenis rerainedby meansonhe middte
Topassembly8i2-25
Hangthe ,ear scr€€nlromthe st6p and
I
r3
Secur€lhe headlining
side panelsat the
r€ar by neans or lhe p.ess srlds and
Setu.e the Veldo laslenersatong lh€
Rearscreen
To ensure tral lhe ,ear 6creen remains
posrtioned
equidislanl
irom eith6rside, lhe
comprerescr€6n assembty,inctlding the
paners6curedby a ziplo tha no.4 topjlam.
qossmember,
6usl be reptaced.
I Bemoverh€ sporrerassembty
{see pase
330.1)
2 Flt th6 spacers pan no. 82S2492or
4292799, as appropriate.
in th. wind
812.26Top assembly
Engaqe the labhing hooks but do nol
closelhe lalchinqhandles.
Rgmovathe linisherkon tho taitedgeoi
Bemov€all lhe stapleslroh rhe lail 6d9e
F6movethe leaturestrip
theno.4 dossnember.
Topassembly812-27
7 Bemovelhel€.tureskrp.
T
Ma( the endsoi lhe atuminium
retainer
skip to showwhichis lei and whichis
riahl,andrefrovotheslip relain€r.
Removethestapleslromlhe no 4 c.oss
1 0 Fotd back the lop cover and mark lhe
posilionot the siay pad. Removethe
$apr€ssecuinglh€ siaypadto theno.4
11 Removelh. stapleshotdingtheiop panel
or lh€ rear screen lo lhe no 4 cross-
812-28Topassembly
12 Unzipthe taslenerand rel€as€lh€ stEp
lor lhe r€ar screen.Unpluglhe eleclrical
connectorlrofr the scre€nand pull lhe
leadsourol rh€labric.
Tont
1 Usinq a salsquare,
Marklhe midwayposilionalonolhe no.4
crossmembe..
Thisshouldbe in lin€wilh
lh€ r€taining
screwlorlhesfap
Unziplhela3rener
on thenewscreen.
Topassembly
812-29
Align th€ lop panel ol the rear sde€n with
the mark on lhe no. 4 crGsmember.The
lop €dge ot the panel husl also be
alignedwiththe lomard .dge ol the no 4
crossmomber
sraplerhepanerintop.s.
Th6 long slaples, pan no.
usedror slaplinqtwo or mor€
The snon siaples, parl no.
used when only one layer ol
padwithlhe marksand
Place a proteclive cover ove. the
lugga96{ompanm€nl
lid.
Feed lhe eledrical l€ads throughlhe pa
neland Plugin lhe connoclor.
Hang lhe rea. screenlrom lhe stap and
812-30Topassembly
Foldth€top cov6rbackdownovorth€no.
slretchrhepanellabncby pu 'no it down,
arcnlnqlh€ norchwirh lhe hote ln trle
luggage€omparth.nl
lid. Ftr th6 p.net in
posalion
by m.ansol a coupleol staples.
Slretchlhe bonomflapso.6itherstdeand
Rehove the slaples lrom the middt€ ot lhe
panel,str6Lh lhe panelagaindnd secur€
by n€ans ora coupl€ol staptes.
't2 Staplebe rear panetand
sideflapsinro
posilion, wo*inq oltyeards trom the
Topass€mbly
812-31
14 Pullth6 staypads rtghtand siapteth.m jn
15 Centrolhetopeoverby inse.ting
a dritlin
lhe hole in the middteot lhe no 4
fiossmember. slr€tch the cov6r by putl
inq it down, lowards the r€a. ot the car
andtjx lt in position
by m6ansota coupt6
To onsurethatne top coveris nol pul6d out
or alionhenr ca.ry oul 6ach ol rhe lollowing
sleps (up lo and includinqslep 2s) on both
sides ol the car beloregornqon lo fie n€x1
16 Slretchlhe lop cov6r side panets,6nsur
rng thal fie edges are Daral|etto the
edgesor lhe rear panel.
F the panetsin positionby mednsot a
812-32Top assembty
17 Sttelchthe top cover on eiher side bv
pullinqil downand lowardsthe rear,anA
s€cur€by meansot a coupleoi slapres.
1 3 Femove lhe stapl€s in
19 R€movethestapt6s
kon lhe middleotrhe
no. 4 crossmembe.,
slrotchhe cover
.gain andsecureby m.an6ola coupleot
20 sLelch lhe cove. by pullingil lowardslhe
rea. ol lhe car and slapleil b lhe no. 4
crossmember srapling shourd be done
alonq lhe cenlre.linebehdeenth€ s€ams,
6rlernaung
betweenlh€ righl and len sides
Topass€mbly812-33
21 Skelch ha cover bwards lhe roar on
6ifi.r side. $apte the tabric at the od,
Doard6nds oa lhe no. 4 c.ossfrember.
outroardol lhe seams
22 B€movethe stapleskoh the sidepanets.
resrdch the {abricand staplein position
usrnga coupJ.or slapres.
23 Pull doqn the lop cover side ttaps lo
srolch lhem and slaplethe trontpan ol
lhe sideilapsin position.
oo notstalteii
thehol€sin thesrer.her
24 Plll downand st.etchrh6tnnertabic, and
812-34Top ass€mbly
25 Pull down and slrelch rhe side ilaps,
staplinglhem inlhe ordershori
26 Applya beadot adhesive
arongtherineol
slaplesin theno.4 crossmember.
(
(
27 Wilh lhe leit and qht marks cotrectly
orienhted,screwrheleatureslip reiainer
inlopraceon lhe no
23 Apply a bead ol adhesive along lJle
t
Topassembly
812-35
29 Pressthe lealurestip inro positionand
sc.ewon lh€ €ndcaps.
l0 Trm rh€ed9e5lo removesurplusrab c
3l Bemovelhe spacersrromthewndscreen
trameandraisethelop assembly
checklhal lhe lop comesto resr20 . 30
mh lromlhew ndscreen
iiame
ll adtustmenl
is nece$ary.see paqe300
Check lhe adJustmentol lhe alching
hooks by lalchinglhe lop in posilLonand
lhen pr6sing downon the lro cornersol
lhe top No playshouldbe p.esenl.
lr adjustmenlasneoessarysee paqe 300
5.
812-36Topassembly
Panelsol lhe headlining
33 Fitthespoirerassehbry{sees€cio.330)
Hydraulicsystem
1 Removethe rearseal cushion(soepage
3s2-1)
2 Removelhe rearseatbackrest(seepage
3s2r)
3 Femovelhesde rim (see paqe3s1.1)
4 Releaselhe handbrak€(lo put slackin the
cab e ov€r lhe sefro pump)
5 Openthe bypassvalve.accessibiebehind
lhe llap on the FH sde at the back ot the
luggagecomparlmenl
Beleaselh6 clips securinglhe hydrauic
hoses lo the rear side panel on eilher
R
il
I
e
Topassembly812-37
7 Rsmovethe pin{eraininq
ctip (sph pin)
trom the piston rod on €iher side. Nole
lhe positions
ol thewashersandspacers
and wilhdraqthe clsvice pin on eifier
close lhe bypassvalve.switchon h€
,gnitionand. by meansot lh. switchtor
thelop,lully.etractth€pislons.switchofi
undo Lhe s€cu.i.o bolrs lor the setoo
Laftlhe setuo pump oil ils sealingand
pluglheco.. nectorslroh therelays.
812-38
Topassembly
11 label lhe conneclorsand disconnecllhe
l€adslrom lhe pump
12 Bemovelhe mosture batrioron eilher
I3
lhroughtheapenures
in
Pass lhe cylinderon the FH side undeF
neah the tuellinesand handbrako
cable
Lill out rh€hydraulicsyslefrcomplet€.
Label rhe braclel lor each cyrrnder(lgrrl
I lefi)and pulrhemro ono 3ide
Top assembly812-39
To tlt
1 Bleedthehydrautic
systemlo expsla0 ai.
(eee Page312-44)This must be done
beloreft6 systemis insta0ed
in thecar
Ensurelhalhe p'stons.re ru y relacled.
Pass lhe RH s€rvo cylinderand bypass
varveund6rlhe handbrakecabteand tuel
Plug in lhe pump connectors,nolinglhe
maikrngs to ensure that lhe ioht con
neclorsare pluggedtogelher
812-40Topassembly
Pluo the connectorsonto rhe reays Pass
lhe pump undernealh
lhe handbrake
cab e
and presslhe rubbe.busheson lrrepuhp
Mountthe brackeltor the BH cy 'nderonlo
the cyinder. ensu.inglhal lhe hose con.
nedions are Iowafdsthe rea. ol the car
Pass lhe cyinder throughlhe apenu.e n
Pul lhe cvlinder'nto posrtronand tghren
lh€ se.urin9bolrs g.ininq a(cess rhrodoh
lhe apedurein lhe panel
\
0p
Topasssmbly812-41
Mount lhe bracketon the oher cylinder,
agaln€nsuing lhat lhe hose oonnections
are towardsthe rea. ot lhe car
1o Pass the cylinde.lhroughlhe rear aper
Note lhat lhe hydraulc hos€s shouldnol
90 lndernealhlhe handbrakecable.
Put the cylinderinlo posilionand righbn
lhe secu nq bolls,gaininqaccesslhrolgh
$e apenurein the panel.
12 Pul back fte moislurebariers on €ilhef
1 3 Passlhe bypassvalvethrouqhlhe ape.
lu.e in lhe rearsidopanelandsecureil in
Securethehydraulchosesin lheirclips.
15 Releaselhe lalchnghandleslor lhe lop,
lo tacililateadiushentol lhe seruocyin.
812-42Top assembly
16 operalelhe pumplo bringlhe pistonsinto
$e lullye{ended position.
Aeconnect $6 rods by insarlng the
crev'cepin and securinqwilhlhe spll prn
worh on one pistonal a ime
17 Felil lhe sidetim (s€6page351,2).
13 Fi he backest (soe page3s2.2)
1S Fn lhe searcushion(seepage3s2.1).
20 close lhe ratchinghandtesror thebp
Servopump
Rehovelhe hydraulicsystBmkom lhe car
Labd ba hose conn€clions to indicab
which is towardsth€ lront and which is
lowardslhe r€ar,and removehe pump.
To ilt
Reconnectthe hoses lo ben respectve
litlingson the new pump
5.1 - 6.2 Nm (3,3- 4,5lbl fr)
F€inslallihe hydraulicsystemin rhe car
Hydraulichoses
1 Renove the hydraulicsyslemlrom Ihe car
Nole and mark $e positionot the hoses
and lhen dlsconnecllhem ifom the cytm
Topassembty
8i2-43
Whenfaplacing
the AH set ot hoses the
bypassvalvemustbe rranstefted
tromlhe
To ll
1 Bsconnecr
|he hosesto lheir respecve
lningson thepumpandcyt]nder
5-1.6,2 Nm (3.8- 4.s lbt tt)
Reinslallthe hydraurcsyslemin the car
Servocylinders
1 Removethe hydraoicsysremtromthe car
2 Disconnectthe cyindertromlhe hoses.
1 Roconneclfte hoses lo rhe cytnder.The
liohlercololred hose shoutdbe connecr
ed lo the tittingnearerlhepisronrod
5,1 - 6.2 Nm (3.3- 4.5 brn)
2 Reinstatllhe hydrauic syslemin the car
T
Eypassvalve
Removethehydraur,c
systemtron thecar
Femovelhe bypassvatve
fit
I
Fillhe newbypassvarve
s.1- 6.2Nm(3,3- 4.5bt n)
Feinslallthe hydrautrc
syslemin th6 car
812-44Topassombly
Bleedingtho hydreullcayatem
To .void possible danage lo painMoA o.
lpholslory. [|. hydraulicsysiemmusrbe br6d
Removolh€ hydrauhcayslemlrom the car
Prac6$€ pumpon lh. rcrkbench.ndlho
.yllndersinsldea kay on $e lloor.
Filllhelluid resetooir,l€aving
lhe pluqoll.
fiuid.panno. (45)
us€ sp€ciarhydrauric
3014694.
Olsconnectone ol the hoseslrofr on6 ol
Allowlhefluidlo,un outunil
lh€ cylinders.
lhe hoseis lull.Aecon.eclthehoseio hs
F€p€alth€pr@€dlrelot lhe oth€rhoses,
loppingup lhe.eseNonas necessary.
I
Topassembly812-45
Conneota power suppryto the pumpand
run to bing lhe pislonslo lh€k end ot
Keep lhe .eseryoirtoppedup withttuidlo
ensure thal lhe lluid never r6.ches the
Fun lhe pistonsto lhe opposinqend ol
3
I
Fepeatlheprocedureuntilthesysl6h has
a smarramoud ol an in the systemwil
nol afiecloperalionoilhe lop.
Checklhe levelin rho r.setuoirandtop up
as necessaryFil the plug.
Retorque
all hoseiininqslhat havebeen
3,3- 4.5Nm(5.1.5,2 |bl n)
Wipeclean the hosesand hosefininOs.
Operata$e pislonsa numberol limes
andcheckthalfiereareno leaks
812-46Top assembly
13 R6lum the pislonsto the lutty ret.aeted
14 Reinslalllhe hydraulicsyslemin the car
Measurlng
tho hydraullcpressure
Hydraulrclluid mlst nol be allowodlo come
withupholsleryor painlvork.
(topulslackin lhe
Release
lha handbrake
cableoverlhe setoopump).
Femovelhe rcaFseatcushion(seepage
852-1).
check the levelot hyd.aullctluld in the
sysl€mandtopup as necessary.
Check to see whethe. lhere is an
€xcessiveamounlol air in the systemIt
so. lhe syslemmusl be bled belorethe
pressurecan he freasured(see paqe
Top assembly812-47
Oisconnecl
$e hoseslron lh€ l€€ pieces
b |ne rear or $e pump.Pruglho open
€nds usinq|ne hosa unionconlainodin
Place abso6.nt pdpe. underneabUe
Puhplo soakup anyspiltlluid.
prec€and connecladaP
Connoclth6 olher end ot rh€ hose to lhe
812-48Top ass€mbly
the ABs'system iesle. to lhe
lho pressuresensorto ihe ABS
presslre
12 SetlheABSleslerlo measure
13 Moasure
rhep.essure
as tollows
. stan the car and pressthe swilchlo
.
Holddownlhe swilchunlillheove oad
prot6cror
breaksthe ci.cuit Nowiead
komlhe AASlester
ofi lhe prassur€
I
I
ilinhum worring pressore:25 bar (365p3l)
The presenceol aif insidelhB adaplorfining
pr€ssu@
lo spurious
€adings.Bunlhe plmp
opposib dnecion lo erp€l any ak bubbre.
Disconnect
theaBst€st€r.
1 5 Di.conn€cllha pr.$ure sensotlrom tle
I
1 6 R€hov. he adaplorkom thepump,tiltino
dr6pumpto avoidlluidspillaqe
{
Topassembly812-49
17 Screwon lhe tee pi€ce.
l8 Disconneotthe hose unionand reconnecl
lne noses b the pump Make sure the
noses run undernealhlhe handbrake
cable. Press$e pump homein its mounl.
5,1- 6.2 titm{3.3.4,5 tbt ft)
19 Prr bach rhe searcu6h'on{s6e page 3s2.
Latchinghandleassembly
OpenUe tophattuayandremovethetiont
screwm lh€ sealrebiner
812-50Top assembly
Ma.kthe positionol ihe sealretainer
and
r€movelhe lwo securingnuls.swivelIhe
Remov€lhe lwo nuls and lhe Phillips
screw securinglhe latchinghandleas'
semblyto lhe lronlseclonol lhe side6il.
Removethe screwsecuringlhe latching
handle assemblylo lhe no 1 cross
Top assembly812-51
Bemove lhe lalching handte pivot boll a.d
li{loll lh€ l6!chinghandt€a6sembty.
Translerlhe bol( washerand bush lo the
10 fit
Lifi lhe latohinghandle assembtytnto
posjtion.insertthe pivol bo[, bush and
wash4andtlghten
lh€boll.
Fil lha t*o screws securingthe tabhing
handle .ssembly to the no. 1 doss-
Fit and tghlen the tuo nuls and the
Phillips$'ew s€cunngthe ass€mbyro
me ltonlseclionollhe sidarail
812-52Topassembly
scr€win lhe screwal thelronlor lh€ s6al
Pressthe sealinrolhe relaiier slrip
Threadlhe remainingnuts onlo lhe bolls,
Topassembly812-53
I Faise lhe lop Align the soal wilh lhe
marksand tigfien lho nuls
g
10 check the adjuslmenlol the larchinq
hooksby latchinglhe lop in posilionand
thenpressinq
downon lhelronlcornersol
lhelop.No playshoudbe present.
ll adiushenlis n€cessary.
seepage300.
5
Strikerplate
812-54Topassembty
Romovethesrrrrerpralesecunng
sc'ees
Pullourlhe laslenerro rel€asethe toDol
cut awaylhe searand removelhe slriker
Topassemby812-55
To tll
1 Rehove all lraces ol old adhesivelrom
lhe cornerol lhe windscreenlrame
I
Remole all taces ol old
Pul back he slrikerplateand securo
meansot lhe retaining
screws
I
812-56Topassembly
Apply conlacl adh€siveto lhe A.pilar s€al
andpushin lheiastener.
l,
2 s s ( 3 0 0 7 1 2 7a) r o u n d
Use a spalulato removesurplusseat.ni
Spoilerassembly830-1
Spoilerassembly
F e a ra s s e m b l y . . . .
Sideassembly
(Chasslsno. 17011109a sa le4
1 Aemovethe rearseatcushion(seepage
3s2-1)
2 R€movelhe rea.seatbackesl(s€epa96
352r).
3 Femovelhe siderrio (seepaqe4511).
Savelhe washerstlom the
as lhesewillbe neededin
spoiler(wh€reapplicable)
B€moeethe nul rrom the lronl secuing
... ..
3304
830-2Spoilerassembly
Renovethewinqnutlromlhe rearlaslening (accesslhroughlhe lap in lhe lim in
sidelhe llqqagecompanment)
The spoilerassemblymusl b€ oasedofi gent
lylo preventthe paintlso beng damaged.
Caretlllylifi ofthe spoile,assemby.
Save the cable in the rear mounlinghoe
as lhis will be needed n ihe finincol a
newspoile.assembly(wh€reappicable)
Carelullyremova all lraces ol adhesive
and dirt kom the paintwork
4i
Spoilerassembly830-3
Rohove all lraces ol old adhesive and dirl
rromlhe spoilerassembty.
1
Makesure thatlhe rlbber wash€rsand
cabreallhe rearlasr6ning
arein plac€.
rr a now spoilerass€mbly
is beinqtited.
lne rubberwashersand cabl6 musr be
ransleredto then€wone
Po.itionlhe spoilerassembty
on lhe car
and screwdownlighllhe wingDuton the
830-4Spoilerassembly
Fir and lEhrenlhe nut on rhemiddtestud.
7
Filand liqhlenlhe nut on the ko
slud
8 Fil $e side kim (seepagea51.2)
9 Fit the backesl (seepaqe352.2)
10 F I lhe seal cushion(see page352J)
Chassisno. L701110
onwards
Savelhe washerslromthe
as lhesewillbe neededin
spoirer{whereaPPlicable).
Rgmove
thekonrsecurngnur.
Spoilsrassembly830-5
Femove lhe wing nll liom the rear
lasl€ning(access Ihroughlhe llap in lhe
l m insidelheluggagecompartnent)
Beleasethe spoilersectonal rhomiddle
Tnespoilerassohblymustbe easedolt qenr
ly to prevenlthepaintwo(beingdamagsd.
Caretully
m otrthespoildassembly
Savethe cablein Ihe .ear mountinO
hole
as this will be n€ededin lhe fininqol a
(whereapplicable).
newspoirer
assembly
830-6Spoilerass€mbly
To lll
1 Carelulyremoveall tracesor adhesive
anddinlromlh€ paintqork.
--------,
Bedove alllra.es ol ordadhesiveand dn
rromlhe spoirerassemby.
Mak€ sure lhal the rubberwasheG and
cable al fie reariasleningare ln ptace.
rr a new spoilerassemblyis beng fted,
the tubber washersand cable musl be
t ansteredlo lhe newone
Spoilerassembly830-7
5 P.ess$e spoitersecuon
Fil and lighlenIh€ wing
Filandlaslenurerrontnut
830-8Spoilerassembly
Rearassembly
1 Opan lhe luggageaomparlmonl
lid and
where applicabre,unplug lhe connedor
lor lhe sioplightinrhespoiler.
2 Rehove lhe rubb€rplugs.lolowedby lhe
spoile,reiainingbollsand nuls
use a heat gun lo aliow lhe rape to be
pllled away.Take care not to apply loo
much heat as lh6 can damagethe painl
work or spoilerassembly
Thespoirerassembly
muslbe easedoll !enr.
ly to prevenlthepainhrork
beiig damaged.
CarellllyLnofi lhe spoLler
assembly.
To flt
Removealltrac€s olod adhesiveanddi.l
rom lne luggaqe.omparlmenr
lid.
'1
I
Spoil€rass€mbly830-9
Fomovealllraces olold adh€siv€and dirl
lrom lh€ spoild assembly
I
II
ApprySikattex
255around
Lilt the spoiler inlo positionand. where
6pplicable teed fte wirng loom ror lbe
stoplighlthrouqhrhehoe in lbe id
Open the lid Tighlonthe nuts and botts
where applicable,plug on lhe conneclor
r
Windowglass843-1
Windowglass
Fearquan€ightwilhstidinq
B € a r s c r € e.n. . . . . . . . . .
Windscreen
1
Femovelhe windscreenwrpers.
843-2Windowglass
F6mov6 lhe lalchinqmechanismsl ke.
Femoveihe lwo screws
Windowglass843-3
Unpluqfte connectorand removelne
r€atoiewmnro. and paddodLim.
--=--.-
Femovethelower,slee.iqrolumtrcovar
10 Bemov€the sp€alargriLles.
Femole lhe lwo scr6ws in lhe leading
edqe otthetop ol the dash
/@ffi
843-4Windowglass
12 R€movelhe two s.curi.O screwskom
undernoalh
lh. olovecomparthent.
13
1 5 Pullthe dashpanelloeard, pushrhea.
pirrarkifr lowardsthe rrontot rhecaf ion
bothsides)and.enoveit
Windowglass843-5
16 Femov€theqin.tscreen
moutding.
17
piec.s at lhe botom
13 APply lape .ound the ed96s ot
wrndscre€n
b protecllh€ paintrort
l9 Insenone end ol a cudinq*ire iZmelres
lono)lhroughhe adh.Biveh one ot |he
corn€6ol lhe windscreen.
843-6Windowglass
20 Anacha logql€lo eachendol he clning
2l Pllllhe wirealongthe glassunlillheglass
is lree alllh€ wayround.
Litl oll the windscreen.
acton, as lh€ healgene
will cause lhe wire to
To fit
wndsc.eenuse adhesive
plus one rolill {45)3016
Trim lhe bead ol adhesve on lh6 lrame
(and on th€ romovedglassil it is to be renfled)b a maximumlhicknes.o,2 mm.
Old adhesiveadh6rin9ltmy providesa good
Remove all loose adhesivelrom lhe pahr
wo|k and glass.clean the surlaceslhorough
ly with a slilable cleaner and apply prlm€r
(althouqhnot lo ordadh€sive)
Touch !p the painNeork
lhat wit be co.
Postuon
lhe spacersat the bonomol tne
i
Windowg ass843-7
Do nor allowlha clea^erro dry naruralyas
st6ak5ot areasewillb6lel1.
Alwaysuseclean,lintrreerags
appry maskinqtape aroundthe inside
Position
thelape 17J1 mm rom the side
edgesol lhe glassand 23!1 frh kom
thetopandbonomedges
1 7r 1 m m | 1 7! r m i
Applyprimr lo Ue edqeol lhe qras5
Checkth€ lit ol the froutdingrolainerstrip
ll lhe shape ol the srrip do€s not malch
$at ot ihe windscreenthe slrip musl be
b€nllo lhe corect shape
Insena bngth ol bonner.r€iease
cabte insjde lh€ r€tainingslrip lo p.eventits be
cominodisronedduringbendino
P..ss the stip onto lhe windsc.eenafter
8438 Windowglass
F( lhe windscreenmouding.
E
A P P yi h e a d l i e s i vaes r o l o a s
Keep rhe gun perpendicurar
to lhe
scr€enand applya beadot adheslve
lo the Fmed surracearonglhe edge
ol the relain€rsrrip checkthallhere
Windowglass843-9
10 Lifithe qlassinlo position.
alieninqil with
A gap ot al leasl 2 mm musl b€ main.
tained betireenlhe r€tainerstip and lhe
Al lhe lop ol lhe s6.een. the su.lace ol
tne glass mlsl lie belween1.0 and 2.5
mm ansidelhe edgeot lhe trame.
a
a
11 To preventlhe windscr66nlrom slipping
oul or posilion,use adhesivelape to hold
the qlass in plac€ unlil lhe adhesivehas
a
a
12 use a sparula
lo shoolhoutlhe adhesive
s|an at ihe bonomcornerol oie ot lhe A
pillarsand workupwardsacrosslhe lop
ot lhe screenand downto the come.on
4'
3
843 10Windowglass
13 Removethe maskingtape trom lhe inside
14 Li lhe edqe or the froutdin9mtdway
aronolhe lop ol rheotassandpourwater
overil Checklor leaks
.E
15 Do no frore work on lhe car un[ rhe
adhesivehas hardened.
'rhe
hardenno lime ror lhe adhesive s 15
hours To prevenllhe bondbeingbrokenand
the qlass lrom movina lhe car musl nol be
Do nol sam the doors,luqgagecofrparhenl
rd or bonnel(hood) knockfie car of rol I
The windscreenmusr nol be touchedberore
the adhesrvehas hardenedproperty
16 Pullrhe dash paiet totu6rdand inslaltthe
A.pirraftr'n on eitherside.
Windowglass843-11
17 Pre53in th€ lssrenerslor rheA.pllarrnm
ta Push lhe
)
dash panel back inlo position.
checkinglo ensurethatlhe spindl6lorth€
tefrpeaturs conlrol is still ptoperlycon
)
1S Fil lhe scres at lh€ oulboardend unde.
nealhthe dashpanel.
)
)
20 Fil the lwo screws undernealhthe glove
843-12Windowglass
21 Fit lhe Mo sciews al the back or th6 dash
22 Beconnectlhe
speakers
andtilthegri es
Iaslener and rit the Mo
lhe slee.ing.column
cowl
3
Rslillhe paddedtrim.plugin lhe connec.
|or and scr€wthe reatoi€wmnrorback
Windowglass843-13
25 Femoveall lracasol adhesivelrom the
lop cotne.solthewindscreen
kame.
26 Removeall taces ol adhosivelrom the
23 Ferl lhe sun vrsorsand cal.h brackels.
843-14Windowglass
adhesive lo lh6 a-prlar
30 Apply sikaile! 255 (3007127) lo seal
3l Usea sparula
ro r€movesurptus
seaanl
I
32 Fitlhe undscleen w'pe's.
Windowglass843-15
Doorwindows
1
)
)
Bemove$e dooFl|m pan6r.
)
undo lhe .elainingsc.ewslor the doo.
)
843.16Windowglass
Disconnectlhe irnhrod rromthe handle.
Removelhe mo6rurebar'er.
Removethe 'nboardw'ndows€al
Femovethe kont and rear sropstor the
grass.(Lowerlheglasslai enoughlo oain
W ndowglass843.17
)
)
Litt up the glass.lGiing
ca.e nol lo damage$e
)
)
843-18Windowglass
To{it
1 Lowe.the glasslntoposition,
takingcare
notlo damagelheoutboardwindow
seal
Slide lhe glasslifichannelinto position
and Ighl€n be screwsthat secu.eth€
glassin the friddlemounting
Relil the slop rollerson th€ lronl and rear
Adjusl lhe heightol the glass by moving
To gain access to the mounlingson the
glasscariers, raiseor lower$ewindow.
Windowglass843-19
carelully9d ba6kthemoisture
bafior.
)
)
6
Firrhe h6nderela'n'nqscrews
)
)
Fil lhe inboardundow seal(mouldrns).
843-20Windowglass
10 Fetit the i.im inserlpanel
Rearquarterlight
glassand
regulatorassembly
352-1)
352-1).
rhe r€a.sealcushion(seepage
the r€arsealbackresl(s€epage
rriesider.im(seepa9e35r-1)
rhe secunngscrewsror lhe co.
lhe bell guide.Slidelh€ cover
1
Windowglass843 21
a
a
Remove
lh€ securing
bottstorthequaneF
right bracketassemblyand lift on the
Bemove lhe quanenighloulboard seal
The tonl ol lhe searis 9ruedIn place
I
843-22Windowqlass
I Rehove lhe secunngbolls ,or the requta.
10 screwin lhe studslo makeit easierlo titl
11 Lft oul lhe glass completewith requtaror
12 Undo lhe bolrs secunnglh€ glass to the
Windowglass84323
13 Fenove fie clip and rubber seal These
will have lo be translered to lhe now
qlass(whereapplicabLe)
ll,
ru
Applyglycerol(glycein)tothetubberstrip
andsridelheskiponro$e rerainer.
Apply primer to lhe {rip retainefand
apply a bead ot aelasearalong lhe
groovein rheslripr€tain6r
Press the slrip retainercomptetewirh
tubberstripodlolhe leadingedgeol lhe
glass Faslenlhe clip and seaLthe bp
withSikatlex
255(3007127)
r
flI
Lil)
U
Posilionth€ qlasson lhe
843-24Windowglass
jnto
LlnIhe glassand .egulatc,r
assembly
posilion.This is easierit the studsare
scrowedrn andthewin-dowis in lhe tut/y
Feoonnecllh6 eleclricalteadslo lho molor, notinghowtheyare laballed
Align lh€ ollboard seal lor the
use conlacladh€sivebelween
ing and lhe seal at $e door lo
W,ndowglass843-25
-
a
11 Realigi the belr guide. ensuring{ral the
localino5tudenoaoes
-bohlhe hoLe,n lh€ bo
dy.andxehren
lh;
Tighlening
torque:
24- 40 NmOZ7" 29.5tbtit)
,
t
a
13 Adjuslthe tit ot lhe gtassretatveto Ihe
lop€ssembry
sealsand the edge ot the
doof(seepage3009)
14 Carerulry
'€li[he mo'sture
batr'er.
Filrh€sidetrim(seepaqeas1-2).
(seeoage8s2-2).
l 6 Filrheback.esr
(seepage352J).
1 7 Fillhos6arcushion
Wealherstrips
and seals844-1
Weatherstrips
andseals
Top.assembly
rronrseal
Top-assembly
trontseal
)
g
Undolhs screwssecurang
lha s6allo
rronladgeorlheno.1 crossmember.
I
F
844-2Weatherstrips
andssats
Toatt
1 Removo.ll faces ot otd adhesivetrom
lh€ no. 1 crossmember
and s.at retai,
Applya beador adhesive
atonothetengrh
Detween
th. toFassehbly
ouidepins.
arign $e seal and ghrenlh€ relainino
Apply Skan€x 2ss (3007127)ro s€al
Wealherslrips
and seals844.3
Glue lhe seal onlo lhe seal relainerson
Rememberthat any tore.and.afiadiuslment musl be hade beiorelhe adhesve
,
Faise the lop and adjusl lhe rore,and-aft
Sideseal
844-4Wealherslrips
and seats
To ih
Femoveall rracasol otdadhesive
anddin
tom lhe seal retai.er.Applya bead ot
adhesive
aloiq lhe sealretainer.
Pressthe newsearInlolhe sealrelainer
adjusrthe endsol rhesea so tharlheytil
snugryaqainsr$e adjacenlseats This
musl be done belore the adhesive
Rearseal
Rehove lhe acorn nuls. snip rhrouQhlhe
and seals844 5
wealherstrips
itt
ADOrya bead ol adhesivealonglhe new
;rl. put lhe seal 'n Plac€and LoossY It
E
Adrusl lhe end or lhe seal so $al ir lirs
snuQlyagamsrlhe adtacenls€al Fil a
n€w e and lightenthe acon nurs
Do nor cul ofi lhe end ol lhe le bul luck il
inside (sharp ends can chale against$e
A-pillarseal
Pul oul lhe laslenersec0rin0
1I
844-6Weatherskips
and seats
careiullypll the seal awayirom the A
pirrar,pry oul lhe lhree tasteners
ar lhe
botlomandredovelheseal
2 Apprya rensrh{about 4 cm) or doubte.
slded adhesivehpe pan na. 7814662,
over lhe bp one ol lhe lhree tasbners
ljse a piece ol sandpaperb roughenthe
E
Wealherslrips
and seals844-7
lhree tastenersar fie bor.
and pressthe seal onlo
A p p l y . b e a do l a d h e s , v e
Adjuslrhesealso lhal I lils snugy agaiist
lhe seal on lhe lop assembLyApplycon
lacl adhesivelo lhe lop or the seal and
Interior
lrim851-l
Interiortrim
3 5 11
Side lrim
I
Removelhe s€alcushion
Benovethebackresl(see
Feoovethe speakerrifr
o
A p i l a rr rm . .
....
3513
851-2Inlerior
lrirn
Removeihe tim rela'n'ngscr€ws
Unplug lhe speaker conneclorsand ill
1 Lilt lhe lrim inlo positDn and r€connecl
Ensurelhai the rubberdoo. seatdoes nol
b6.ome lrapped behi^d lhe lrtm and
tightenth€ lrlm relan ng screws
Plug on lhe connectortor ihe tight and
press rhe ighl finng inlo lhe ctios Fett
Inl€rior
rrim851-3
Applyadhesivelo the rubbercover pisce
and pressil inlo position.
d
Rerirlhe back.esl(seepaqe352-1)
6 R6litlhesealclshion (see pag€3522)
A-pillaririm
'
ii#1i,.fri
stkerprare
(see
assombrv
2 Romovelhe low6r,steering4otumn
cowt.
7l)l
a- -=4
?]N .---_
il\
Femovelhe speaker
9r'rret.
J8t
I
trim
851-4Inlerior
tiro secling screwslromun
Femovetherasreners
rorrhea.pilarrr'm
Inlerior
trim851-5
Plll lhe dashpanel,otuard,pushlhe Apillartim lowa.dslh€ lrontoi the car (on
bolhsides)andremoveit
To tit
i
Plllthe dash panettoRard and hsta[ $e
A.pilla.tim on eilherstde.
Pressin lhe lasr€ne'sror the A.p tar lim
Push lhe dash panel back inlo position,
checkingb €nsurethatrh6spindtetor lhe
rmpralu@ @nlol is st'[ propertycon
Fil lhe sc.ew al lhe oulboardend under
451-5 hteriorlrim
Fi! the Mo screwsund€rneath
Ihe glove
Fitlhe twoscr4s al thebackot thedash
Reconnecrlh€ spealers6nd t lhe grLles
Press in the laslend and lil lhe rwo
screwsholdnglhe sleering.column
cowl
Frt [te st ke.prateass€mby(see paee
312-551.
I
Rearseat852-1
Rearseat
352.1
352.1
Rearseal
o
I
1 Bemovethe lour botts in lh€ mslal strip
arongthe leadinaeda€o, the cushion.Lift
the cushionout olthe car
ftt
Put back lhe seat cushionand tght€n lhe
lolr bolls ln the leading edqe ot the
1 Fenove the s6arcushon(see above)
2 Removelho Mo bortssecurng lhe botom
852-2Rearseat
Removolhe l*o bolls 3ecuangthe lop
the backest and lill lhe bac*.esl out
To lll
l-itt the baokesl into position and lighlen
lhe secoring bols al lhe bollom ol lhe
Tl9hlenthe securinqbotlsat the lop ot the
Belillhe seal cushion(see page 3521)
Alphabel
calseclionqurde899-1
Alphabetical
sectionguide
T€chncal descriptioi
Bemoval
Fining ...
.....
Femoval
Finin9
3513
3 5 15
S p e c i al o o s
..
Measurinqpressure
1 0 31
Adjushents
310-2
3101
310.1
023-1
3 1 23 6
Specla loos
i4easuringpressure
3005
103.1
ouarlerlight
Femoval
F i n i n q. . . .
adjustmenl
....
34323
Technicald€scrplion
412.25
300?
34315
Redoval
Fning
Adtustmenl
Techni.aldescription
B e m o v a l. .
....
Fining
Adjushenl
Seadlining
Technicaldescription
Removal
FininQ . .
Technicaldala
Technicaldescrplion
F e m o v a l. .
3003
Canbriatop,coverlabnc
B e m o v a l. .
Fining
312.43
Latching handle assehbly
Technicaldescrplion
Femoval
Fning ...
Adtustmenr
Techn.aldata
Technl.aldala
Technrcaldescription
Technicaldescrplion
F e f r o v a l. .
F i n i n g. . . . .
Beedin9
Adhesive lape
Techncal description
023.1
300.3
Fining . . .
pressure
Moasurinq
Specia loos
Measunnqpress!re
Bodyshell
Techn.aldala ..
Techncatdesc ption
Femovallifiing . . .
T o . h n i c a l d a l a. . . .
400.3
41221
Femovaltifiine
adjusrmenr ...
a2a2
899.2Alphabetical
sectionguide
Tochnlc.ld..cription
R g h o v . | d n i n g. . . . .
a003
T * h . i c a ld a i a . . . . .
T@hnicald€scpnon
B € h o v a ln/ h q . . . . .
023-1
300-3
8t242
T€chnicaldescription
F i n i n g. . . . . . . . . . . .
Adj$rmenr . . . . . . . .
300.1
8007
R s m o v a.l, . . . . . . . .
Fiting,...........
851-1
65t-2
Spacors...........
103-1
Speclal
tools .......
102.1
F e m o v a ,l . . . . . . . . .
F i f l i n g. . - . . . . . . . . .
:::1'::1$Gr
430-2
Spoll.r sld6 assombtv
(dhaslls.o,L7O111rb
F e m o v d. . . . . . . . . .
Fltinq ,...........
330{
4306
S l a p l eg u n . . . . . . . . .
108t
S p e c i a t l o o. .t. . . . . . . . .
T € c h . i c adla l a . , . . . . . .
T o c h . i c adle s c p o n . . .
801-l
o28-l
400,2
st otcher..,,.........
Slrlkerpl.reassembty
800.2
R a n o v a l. . . . . . . . . .
F hn g . . . . . . . , . . .
028.1
400.2
,
300.1
ToP.lr3me
crossmemb€rs
.....
.
.
30Gl
4005
Tyrepr6$urss
t pholstory
, o2a-2
........
B € n o v a l / i n i n.g. . . . . . . . , . . , .
. 451.1
.....,........
430.3
Spollersld6 a83€hbtv
{chasslsno.L?orI t0!
.
,
Toptram€assembly
..........
Remova|fting
R . m o v a l { f t i n g. . . . .
400-1
812.1
.4127
Adjush€nl ...,....
Sklerrlm
.
.
...
412€3
81255
l€chnlcar
data.........
02&1
T€chntcat
doscdpiton.. .
Topass€mbly
gur.leplns
a0Gl
Adiustm€nl,..........
3005
R e n @ a |. . . . . , , . , . . . . . . . . . .
Filtng..,.,.-.......,,,....
. a43t
Wolkshopinfolmation
Us€rfeedback
SMB.SCANIAAB
SaabCarDivision
Workshop
Infomation,
AFSVE
961 80 TROLLHATIAN,
Sweden
Telefaxphone
no.:+46 520 84370
Comments/suggestions
$of eidrccadoewo shopsery
ceM
Bybning6ha€youvdsmrhismanuarrluwt beherpjngusromainbina
highsraidadin
NotedM any.omnenb o, sugee$ions}tu mayhe ona sheerof pap€l
pageandenduslrurue6atlheaboEaddess
ForaeatoronEnience,youa€a
s*dcdne
ro sendyo( connenrs byrax,us nerh
!
,
e
n
a
ra
I