Windscreen, rear window and fixed rear quarter windows - removal and refitting
1 With the exception of the cab rear window on P100 models, all fixed glass panels are direct glazed to the body using a special adhesive. Special tools are required to remove the old glass and to fit the new glass, therefore the work is best entrusted to a dealer or replacement glass specialist.
2 The cab rear window on P100 models can be removed as follows, although it is advisable to entrust the work to a specialist.
3 Remove the six Torx bolts and nut/washer assemblies, and withdraw the safety grille from the rear of the cab.
4 Prise out one end of the trim insert from the window rubber, then pull out the remainder of the trim.
5 With the aid of an assistant, carefully push the glass and rubber into the passenger compartment.
6 Remove all traces of old sealer from the glass, rubber and cab aperture.
7 Commence refitting by pushing the window rubber into the aperture, ensuring that the trim panel and body panel engage in their respective grooves in the rubber.
8 Working from outside the cab, enter the bottom edge of the glass into the rubber, and hold the glass against the rubber while an assistant working from inside the passenger compartment pushes the rubber over the glass.
9 The trim insert must now be refitted to the rubber, preferably using a suitable windscreen trim insert tool. If no special tool is available, the trim can be refitted by prising open the rubber lips and pressing the trim into its groove, although this is likely to prove difficult and time consuming.
10 Refit the safety grille to the rear of the cab on completion.
Crankshaft front oil seal - renewal
Note: A suitable puller will be required to remove the crankshaft pulley. A new crankshaft pulley bolt, and a new lower timing chain cover gasket, must be used on refitting. 1 The crankshaft front ...
Manual transmission oil level check (Every 12 000 miles or 12
1 With the car on level ground wipe the area around the filler plug, then unscrew the plug using a socket spanner, or on later versions a suitable Torx or Allen key or socket bit, as applicable. A ...
Exhaust emission control system components - removal and
Carburettor engines Spark delay/sustain valve Removal 1 Disconnect the vacuum lines at the valve and remove the valve from the engine. Refitting 2 When refitting a spark delay valve it must be ...