Door handle and lock components - removal and refitting
Door exterior handle
1 Remove the door trim panel (Section 11).
2 Peel back the waterproof sheet as necessary to gain access (see illustration).
13.2 Peel back the waterproof sheet for access to the door handle
3 Undo the two screws and withdraw the handle from the door (see illustration).
13.3 Door exterior handle retaining screws (arrowed)
4 Disconnect the control rod and remove the handle.
5 Refitting is a reversal of removal.
Door interior handle
6 Remove the door trim panel (Section 11).
7 Remove the interior handle securing screw, then manipulate the handle from the door and disconnect the lock operating rod (see illustration).
13.7 Remote control handle retaining screw (arrowed)
Refitting 8 Refitting is a reversal of removal, but ensure that the lock operating rod is correctly reconnected. Refit the door trim panel with reference to Section 11.
Door lock and cylinder
All models except Cabriolet Removal
9 Remove the door trim panel (Section 11).
10 Peel back the waterproof sheet as necessary to gain access.
11 On 1986 models onwards, remove the exterior handle as described previously in this Section.
12 Disconnect the control rods from the lock.
13 To remove the lock cylinder, pull out the retaining clip and seal and withdraw the cylinder (see illustration).
13.13 Door lock cylinder retaining clip (arrowed)
14 Remove the lock by extracting the three securing screws and lowering the lock sufficiently to permit the cylinder lock rod to clear the lock housing (see illustration). Turn the latch around the door frame and withdraw the assembly through the rear cut-out in the door.
13.14 Door lock retaining screws (arrowed)
Refitting 15 Refitting is a reversal of removal.
16 From late 1984, Cabriolet models were fitted with revised door locks. Due to it no longer being available, if an early type of lock is to be renewed, the later type of lock must be fitted as follows.
17 On models with central locking, disconnect the battery negative lead.
18 Remove the door inner trim panel with reference to Section 11.
19 Peel back the waterproof sheet as necessary to gain access.
20 Disconnect the control rods from the lock.
21 To remove the lock cylinder, pull out the retaining clip and seal, and withdraw the cylinder.
22 On certain models, the lock is secured to the door with rivets. Drill out the rivets, or remove the securing screws, as applicable.
23 Withdraw the lock from the door, and where applicable remove the central locking solenoid from the lock.
24 Remove the plate from the inside edge of the door.
25 If the lock was secured to the door with rivets, the door must be drilled as shown, in order to accept the securing screws for the new lock (see illustration). Apply suitable corrosion protection and repaint the area around the holes.
13.25 Drill the door at the points indicated when fitting a new lock to early Cabriolet models
A Existing holes
Note: dimensions given in millimetres
26 Remove the shaded area of the new threaded plate, as shown (see illustration).
13.26 Remove the shaded area (A) when fitting a new door lock threaded plate to early Cabriolet models
27 Where applicable, fit the central locking solenoid to the new lock, then fit the threaded plate in the door, and fit the lock. Tighten the securing screws finger-tight only at this stage.
28 Reconnect the control rods to the lock.
29 If a later type lock is being fitted to a model which was previously fitted with an early type lock, a revised lock striker plate must also be fitted. Where applicable, fit the new striker plate and tighten the securing screws finger-tight.
30 Close the door once to achieve correct alignment between the lock and striker, then open the door and tighten the lock and striker securing screws securely.
31 Refit the waterproof sheet and the door inner trim panel with reference to Section 11.
32 Where applicable, reconnect the battery negative lead.
Heater unit - removal and refitting
Removal 1 Disconnect the battery negative lead. 2 If the coolant is still hot, release the pressure in the system by slowly unscrewing the expansion tank cap. Place a thick rag over the cap to pr ...
Hydraulic unit (ABS) - removal and refitting
Note: A new gasket must be used between the hydraulic unit and the bulkhead on refitting. Caution: Refer to the precautions in Section 1. Removal 1 Disconnect the battery negative lead. 2 Depre ...
Manual steering gear - removal and refitting
Note: A balljoint separator tool will be required for this operation. Removal 1 Set the front wheels in the straight-ahead position. Ensure that the steering lock is engaged and remove the igniti ...