Body

(excl.Air Conditioner)
Repairsand
Maintenance
 Content of Manual

Group 8Or General page

Specifications 1
F l o op
r an. ... .... ... .. 2

Group81: Body
Design 5
Checkingfront end 1
Replacingbody parts lo

Group 82: Front End, Hood and Fenders

Design 17
rront ferde's r8

Group83r Doorsand Trunk

19
Doors 21
Door windows
W r . o o w c r a n lm e c h a n i s m ...... .... .... ... 25
E l e c r ' , clay O p e r a r e dW i n d o w W i " d e r s 26
t'u'r LE. 2421?44 a-d 262 264 28
T a i C d t e .2 4 5 a n d 2 6 5 . . 30
SLn Roo' 31

Group 86: Bumpers

B u - p e r s. . . . . . . . . . . . . . 54
lmpactabsorbers 55
Bunper moud,1gs 56

TP 11410/1
2000.2.79
 Specifications

Group80

General

Specifications

Vehiclegeneraldimensions and weights

applyto all models242-244245 and
Specifications
262-264 265 unless otherwise stated.

't92.6'
L e n g t h. . . . . , . . . . . . . . . . 489 cm
wdfi................. 171 cm 67.3"
Heghr,curb weightjexcept245-265 56.5"
245-265 . . . . .. . . .. . . .. 146 cm 51.5"
W h e e l b a s. e. . . . . . . . . . . 264 cm 1o4"
T r a c lf r o n t. . . . . . . . . . . . 142 cm 55.9'
T r a c kr e a r. . . . . . . . . . . . . 135 cm
Turnrngcircle{belweencurbs) 9.8 m 32.5',
Culb weight (depending on typdl
242................... 1291-1389kg 2844-3060 lbs
244................... 1 3 1 G - 1 4 1kO
s 2886-3106 lbs
245 . . . . . . . . . . . . . . . . . . . 1394-1485kg 3071 3271 lbs
262................... 1425-144O ks 314O-3180lbs
264.. .... ... ... .... ... 1435 1465 kg 3160-3225 lbs
265................... 1480-15OOks 3260-3305 lbs
GrossVehicleWeight (GVW):
2 4 2 ,2 4 4 . . . . . . . . . . . . . 1830 kg 4030 lbs
2 4 5. . . . . . . . . . . . . . . . . . . 1950 kg 43OOlbs
2 6 2 ,2 6 4 . . . . . . . . . . . . . 1900 kg 4190 lbs
1950 kg 43OOlbs
Capacityw€ight:
E x c e p2r4 5 a n d2 6 5 . . . . . . . . . . . . . . . . . . 920 lbs
112Olbs
265................... 990 lbs
Pemissibleaxleweight,frontl
242, 244, 245 855 kg 1885 lbs
262, 264. 265 930 kg 2O5Olbs
Perm|ssible axle weighl rear:
242, 244 and 262, 264 990 ks 2180 lbs
245, 265 1 1 8 0k s 2600 lbs
lvlax.trailerweight 908 ks 2OOOlbs
Max. hitch load 75-90 ks 160-200 lbs
Cargospacs,245 and 265
L e n g tw
h i t h . e a rs e a tu p . . . . . . . . . . . . . . . . 1 1 3c m 44.5"
L e n g tw
h i l h r e a rs e a td o w n . . . , , . . . . . . , . 188 cm 74.O"
Maxrmumwdth 133 cm 52.4"
H e i g h t. . . . . . . . . . . . . . . . 84 cm
Volumewilh rearseatup . . .. . . ... . . 1.5 m3 53 cu-ft.
Volumewhh .€ar s€at down 1.9 m3 67 cu.ft.
Cargo,openang; maximumwidth 1 1 6c m 45.7"
max'mumheight 78 cm 3o.1'

Group80
Geneml
 eEo?

o
o

o
o

O€)
Floor plan

Group80
General
 :1--=
-.
. rF_-l
'-.r ., ;1

I \

A = 1O2Ot 2 mm Distancebetween holes {@ 9 mm) for strut attachment.

B = 855.5 t 2 mm Distancefrom strut attachmenthole(o I md centerto hole(o 16 md in firewall
(diagonallymeasured).
C = 236 t 2 mm Distanceffom strut attachment hole (@ 9 mm) center to front end of fifewall
flange-
D = 162 ! 2 mm Distancebetweencenterlinesof holes{O 10 mm) for imoact absorberattachments.

Group80
Geneftl 3
Specifications

A =412):2 mm = distance between center lines of holes (O 10 mm) for impact absorber attachments.

SpecialTools

999 (SVO)
5 123 Fixture, andreartrailingarm6t-
sidemembers
5126 Gaugerod, side members6nd front cross
member.L,sedwith Fixture5123 and Gauge
5127.
5 127 Gaugesidemembers andfrontcrossm€mber.
Usedwith Gause Rod 5126

@
r4(io I
5125

\{]-r' 2499 Fixturefor windshieldinstallation

5124 Fixture,wheel housing.Usedin conjunction

with FixtuG5123 andAbutmentPlate5125
5125 Abutmentplate/gauge plate.us€din conjunc-
tion with Fixture5124.

Gtoup80
4 Genenl

Group81
Body
Design
The vehiclehas 6 unitizedor integralbody, which
meansthd body and frameare composedinto one
The body is cornposedby severalsheetpanelsweld€d
together to a strong shell.
The body couldbe dividedinto severalsubsections:
floor,sid€s,roof,front fendeq hood,doorsandtrunk
tid.
For fronl fendersand hood see croup 82.
For doorsand trunk lid s€e croup 83.
Heat iansfer from exhaustsystem to body is being
redocedby three hsat protectionshields.The galvan
ized steel sheet shieldsare attachedat tho joint f?e-
w€llfiont floor as wsll as abovellont and rsar mufft-
Hot dippedgalvanized(rinccoated)stoelis usedfor
many criticalsheetmetalcomponems. Thesecom-
ponentsare normallysubjectedto high weatherex-
posures.Thereare numerousadditionson the front
Body dest:gn
iii,gt".
Vehiclesequippedwith catalyticconverters are pro
videdwith extmheavyfloor insulation abovethe ca-
talyticconverterand ihe heatprotectionplates.The
catalytic convertersystem increasesexhaustsystem
foam rubberprovidesnoiseinsulation.
Self-adhesive
A splashguardunderthe front enginecompahment
alsoactsasanenginenoisesuppressot Somemodets
withautomarrctransmission
arealsofinedwith a noise
screenunderthe engineand t.ansmission houshg.
end:wh€slhousins, sprinsdfiiisinss,
;nneranaouter
coverfor thedriveshafisupport,jacksupports,
heat
shieldgfront splashguard,noiseshieldand lower front
panel b€neath the grille.
Group80
Genenl 5
Bodydesign

Thefloor soctionis the sahe for 6ll modsls.

Th€rearfloor panelsfor 245 and265 are reinforc€d
with a frame A, above.

Roof sections

N
Group80
6 Genenl
 Bdy alignment

Checkingfront end with tools 999 5123, -5124, =5125, =5126 and
-5127

1,
2.

NOTE:Do not force fixture into position.tt may be
distonedand mis€lign.
1. CleanareasoI thesidsm€mbers wherethefixrure
suppon block {4) are supposedto land.
2. Attachthefixtureadaprors { 1}tothesidemember
gaugeholes.Do not tighren.
3. Placethe fixtureunderthe vehicle.
4. Litt the fixturerearend and hook it on the act-
Attach fixture 5123
5. Lift the fixturelront endandattachthe rear guid€
studs{2)to the sidemembsrgaugsholes.Lower
thefixturesupport lsgsandadjustheightFosition.
6. Thef6ceat the fronrguidestuds(3)shouldabut
the sidemembers. The front guid€studsshould
7. Attachr€tainingscrews.t the rear guidsstuds
t2t.
8. Tightenthe adaptorsThefixtureabutm€ntblocks
shouldtouch the side memb€rflanges

Group81
Bdv 7
Bdy alignment

A2
Checkside members
1. Check that side members align at front guide
|rr-l l-',rl
t] fl -t r 2. Installr€tainingscrewsat front guidesruds.Us€
llLr front axle member retainingscrews
Align front guid€studsin side membergauge

Max. misalignment permitt€d:guidestudsmall

diameterwill enterhole.
No misalignmsntguidestudla€e dlameterwrll

A3
Check position ot control arm brackets
1. Attachcontrolarmrsarbrackets to sid€members.
Spare parts can be used for this checL
2. Adjustgaugeson fixtureand checkbracketfit.
The gaugesare providedwith a slot which in
dicatestolemncepermitted.

A4
Check wheel housingheight and sido align-
m€nt
1. Installgaugsplat€5125inoneofthewheelhous-
ings.
2. Attachlixture5 124 to previously
installedfixture
5123.

Group8l
Rody
 Bodyalvnment

MAX;T01. A5
Check wheel housing position, using gauge ol
{ixture 5124
Max. tolerance p€rmissible:
of gaugewill enterhol€o{ gauge
Side:shall cliametsr
plats5125.
Zero toleranc6:
Sid€:largsdiameterofgaugewillenterholeof gauge
plate5125.

0-r01.

\2620

A6
Checkalignmentof sidememberfront sedrcn
,'-/,,--...= Attachgaugerod 5126 to mainlixtur€5123. Placa
gauge5127 in impactabsorberattachment.Ch€ck
side memberalignment.
MaL r66dings p€rmitted: 0 mm and 4 mm
Zsro rsading: 2 mm

A7
Check alignmont of front cross membel
L Placegauge5127 on gaugerod 5126. Check
alignmenlof front memb€r.
Max rddings p€rmitt€dr O mm and 4 mm
Z€ro reading: 2 mm
2. Checkother side.

Group8,
Bdv I
Body alignment

Instructionson how to use specialtools 5123 to 5127 when

replacingbody parts
This Instructiondeals with a collsion dam€ge whrch B1
l
requ res replacementof those pans screenedin i Lus-
Uncover
1. Removebaitery.
2. uncoverfrontend.
3. Removesheetmetal pans screenedin illustration

YEIY?

Modifiedand adapted,rhisinstrucrion couldbe used 4. Removeboth f.ont fenders.

for most other fronl end collisiondamages.
B. Frontside memberand wheelhousins
C. Sde membertie plate
D. Jack supportmember
5. Removeengineand transmlssion.
6. Removefront axlemember.Femovespringdrc
7. Uncoverwheelhousinsto be replaced.
plate.
Rightside:savetype designation

B2
Removesheet metal oanels
1 . Cut loose Iront member kom side mem-
'wheerhousinS
be' whrh shou'dnol be.eplaceo.
2. Removeside member tie plate and jack support

3. Firct drill out spot welds from inside of car, as

shown in illustration.Then cut loosefrom under

Cut looseouterand innercowlside lie platesfrom

5. cut looseside member/wheelhousingfiom firc'

ll
Removeside member/wheelhousing.
6. Removenicksand buns from surfaces.
'7.
Straightenas necessary.
8. Grindall connectingsurfaces.

Gtoup I I
10 Body
 Body alignment

-Checking body alignment(wheelhousingand front membersnot replaced)-

(Oper-
Fixture5123 mustnot beforcedintoposition. The fixturemust not be installed
when srraightening
ations 15-23). membersor wheelhousings.In thosecasesfixture
Forcescausedistortion
andresulting
measurementer- front pan shouldbe released.As alignmentgoeson,
fixturefront end can be raisedto checkalignment.

Prepare
Use a scrapefto clean inside of front side members
(intemediate and rear parts)

Attach fixtures
Attachmountingbrackets (A)for fixture5123 tOrear
endsof side members.
Let mountingbracketshang loose.
Fit fixture5123 undervehicle.Raisefixturerearend
and hook it to mountingbrackets.

Align
Raisefixture front end and guide rear guide pins into
the holes of side members.
Lower support legs and adjust height.
NOTE: the front guide pins should not be used.

Attach
Installattachments€rewsat rear guide pins.Then
tightenmountingbracketsA.

Group81
Eody
Sody alignment

B7
Checkfit
1. Thefixturesupportpadsshouldnow abutthe
flangesof the side memberc.
lf necessary,lower fixtoreand align members.
2. Checl rhar lhe srdemembersabursurfacesar
front guidepins.
3. lnstallaitachmentscrewsat frontguidepins.Use
front axle memberattachmentscrews.

88
Checkclearance
guidepinsin holerin sidemembers,
1. Installfront
see Fis.
Maximum cl€arancel
Small diameter of guide pin fits in hole of side

Large diameter of guide pin fits in hole of side

Whenevernecessarylower fixture and straighten

Attach tmiling arm br6cketto side member, in-

termediatepart. Spare parts can be used when
checkins.

89
Check fit
'1. Adjustgaugesandcheck{it of the brackets,
see
Fig
The gaugesare providedwiih a groovewhich
indicatesdeviationpermitted.
NOTE:the bGcketsare somewhatadjustable,
2. Whenevernecessary,lower the fixture and
straighten,alt. replacemember.

Bto
Attach fixture
1. Attachfinure 5125 to wheelhousing
2. Attachfixture 5124 to fixture5123.

Gtoup81
12 Body
 Bodyalignmmt

MAX;TOL, Maximum tolerance: 811

the smalldiameter Checkposition
of ths gaugefits
Use gaugeon fixture 5124 to checkpositionof wheel
in the hole of
nousrng,
fixturs 5125

O-TOL, Z€ro tolsranca:

the largediam€t€r
of the gaugefits

fixture5125

Bt2
Straighten
Whenever necessary,
removsfixtureandstraighten

A pullchaincanbeattached
to fixture5125,seeFig.

Bt3
Attach fixtures
'1. Attach gauge
rod 5126 to fixture,see Fig.
2. Placegaugs5127 in bumpershockabsorberar-
tachmentandcheckpositionot sidememb€r,ses
Fis.
3. Whenever necessary,
lowerfb,aureandstraighten

4. Removefixture5124, fixturs 5125 and gauge

rod 5126.

GroupI I
Bdv 13
Bdy alignment

Preparationsprior to installationof new sheet metal parts

Bt4
Preparewelding

Kp
Applyweldprimerto ail groundsurfaces.

815
Drill holes
Drillapprox.5 mm holesin ths sheetmetatpartsit-

R16
Connect parts
Connectsidemsmb€r parLjacksupport
intermediate
andtrailingarmbracketas shown.

Installingnew sheet metal parts

Whsn sver necessary,straightenths floor and the fire-

wall to achieve corect alignment. Parts positioned
by helpof fixturesmustnotbedisplaced.

R|7
Position parts
Positionthe parts ass€mbledaccordingto opstation
B16.
Firtailingalm bracketagainstgaugeon fixture5123,
6nd tighten.

Group8,
14 Rody
 gdy alignmmt

Bt8
Position fixtur€s
1. Poshion whoelhousing onfixture5 | 23.Us€front
axlememberscrewsto fit it on fixture.
2. Position fixture5125inwh€elhousing andfinure
5124on tixture5123.
3. Attachgaugerod 5'126to fixture5123.

Bt9
Wheel housing
\\ to correctposition.
Adjustwh€elhousing
1\, \ Apply a coupleof smallweldsto connectwh€elhous-
ing member and side member.
:{-- -_\. ;,

820
Front cro6s member
1. Rais€and positionfront crossmsmbsr.
Wdd member to position (weld holes).
2. Wdd whs€lhousingand wheslhousingbracket
to firewall {weld holes).
3. Adjust cover plat€ into position.Welct it at the
bumpe. shock absorberattachment.

Group
8l
Bdv 15
Rodyal4qnment

821
@o@
W€ld holes
1. Wdd holesof oLrter.nd innertie platesto ioin

2. Wdd holes and s€ams of ti€ plat€sto conn€st

them to wh€elhousingand Iirewallside.

|]28ll

R22
Trailing arm brack€t
t. adjustthe trailingarm bracketpo-
lf necessary.
sition,seeFig.below.Thegaugeon fixturs5123
hasa groovewhich indicatesdeviationpemitted
Next,applya coupl€of smallwsldsto attachboth
ends of the side member interm€diateDart.

W6ld holes
1 . Wdd holesto connectjack support memberto
sidemember,intermediat€ part,androckerpanel,
2. Weld,from insidevehicle, sidememberinterm€-
diats pan, tie plate and jack supportmember

Rsstore
t . Removeall fixtures.
2. Wdd seamsai both endsof sid€ member,in-
termediatepart. Grind as necessary
3. Weld seamsandholssof baterv shelfandsuo-
port to sid€ memberand wheelhousing.

Re-installation
t. Installwhe€lhousehandware.
Rightsids.emem-
2. Installfront axle memberand springsnd strut
3. Install€ngin€and transmission.
4. Applysealingcompoundroundthe wheelhous-
ings and on the t€nder attachmentsurfac€s.
5. Installhood and front fenders
Installlsfl andighr sideplatsE,
floorplats,c€nte.
suppon and cover pl6t€.
7. Installfront €nd components,
Install the battery.
9. lnstallremainingparts.

Group I I
16 8dv
 Design

Group82

Front End, Hood and Fenders

Design

The hoodconsistsol an ouler and an innersteelsheet

plate, bondedlogethsr.The undersideol lhe hood is
coveredwilh soundabsofbingmatodal-
The hoodis hingedattho backon lwo hinges.In closed

io posilion lhe hood is s€cur€d by a lock on the lrcnt

s€ction.The lever for the hood lock ls operatedby a
contol undemeah the dashtload.
The fronl lenders are Dressedin ong oiE@.
G lle and headlight rimsare madein ABSplasticand
retainedby spring locks. S€s right.

Gtwp 82
Frcnt Eti, Hod and FetdeE 17
 ServiceProcedures

Replacing grille The hinges are adjustedup-down by slackeningthe

1. Depressand turn the spring locks 90o. Lift up lock bohs, 1 below, moving the hood to position de-
the spring locks. _ sired and locking the bolts again.
2. Pullthe gilleforwards untilfreefrom uppermem-

Remove the grille.

3. Transfer springs to the new gille.
4. Posirionthe grille.Positionspring locks,depress
and tum. Checkthat ihe locksaresecurelylocked.

Frontfenders

N
Adjusting h@d hingss

The hood contact atthe front coners can be adjusted

by screwing the rubber stops in or out.

Removing front fenders Qr

- four bolts to the brace
four bolts at rear end. accessiblewhen the front

three bolts to fiont section

- e,ght bolrs from the inside ol $e wheel housing

Hood l@k

Hood and hood hing€s

To remove rhe hood, remove the bohs retainingthe
hood to the hinges.
The hinges are attached to the body by two bolts
on eachside.All bolt holesare oblong to permit hood
position adjustment-
The hood lock upper and lower parts are adjustable
lengthwiseby moving them in the oblong bolts holes.
The lensth of the lockingpin can be adjustedby loo-
seningthe lock nut turning the locking pin to length
desired and locking the nur again.

GtuupA2
18 Frcnt End,HoodandFenders
 Design

Group83

DoorsandTrunk

The doors are built up of an innerand an outer ptate,
flsnged and spot-welded together. Hinges are fitted
to the inner plate. The doors are adjustablelongrru-
dinally,verticallyand laterally.Thedoor locksare ired
to the doors wnh screws. The door handle on the
outsadeactuatesa leverwhich lifts tbe lock pin of the
door lock by a pull rod. The cloor opener inside the
car is attached to the inner door plate wilh screws.
The handletransmitsthe movementto a lever which
lifts the locking pin by link rods in the lock. On rhe
front doors ihe lock mechanismis fined in a cyhnder
under the door handle.

Frontdoors

7-6
I-1

Group83
19
Design

The rear doors are equippedwith child'proof locks.
The locks incorporatea latch which prcventsths door
frcm being opened frcm the inside when the latch
The door latches are $eel and woldsd to the door.
Thewindowwindersconsistof lifringarmswith tooth
ed segments.The window runs in sliding grooves In
the inner door ol6te and is set to thB d€sir€dDosition
by lifting alm lrom th€ tooth€d s€gment with the
assistance ol a helos arm.

Rear doors
244 / 264 and 245 / 265

rp8?
I t8p ,"

fr$fI itt tt
7S i-.-n

1$

?1 6
tl

| 0,0 r332!

Grcup83
20 DooBand Trunk
 Doors

ServiceProcedures

Doors
Removing/installing door stops
Replacedoor stop = Op No- 83106
Remove door panel according to instructionsunder
"Removrnq In_er handec ard upholsrery" fhen re-
move the bolt between the door stop and post, and
remove the rubber seal.

o 3-
Doorwindow crank

Bemovelock button and screws ar the top edge

of the uphostery. Bemove the door upholstery
by rnsening a screwdriveror simiar under the
upholsteryedgeand carefullyprying outwardsso
that the uphostery

Removing/installing front doors

Femove the boh between door stop and door p llar.
Doorstop Removerhe boltsbetweenhingesand door,accessbte
when ihe door is opened.The door can then be re

After this, remove the three boks securingthe door

stop to the door- The door stop can now be taken
out thrcugh the upper opening in the inner plate of

Installationis in the reverseorder.

Removing inner handles and upholstery

Replacedoor window crank = Op. No. 83402
1. To remove the arm rest in the front door, take
out the two plastic plugs with a na(ow screw-
driver and remove the anachingscrews located
on the inside.Then tum the plastic ring ar the
front edge of the arm rest severalturns to the
left, push the arm rest foMards and the hook
at the front edgedisengagesleavingthe arm rest
ro De removeo.
Remove the two retainingscrews for the rear

2. Put a finger on the insideof the crank and press

Front door
the latchesholdingthecover. Pry loosethe cover,
using a screwdriver.Remove Phillipsscrew and 2. Foe ior the lock cyinder anachlng sc.ew
3, Hole for rear view m iior installation

Gtoup83
Doorcand Ttunk 21
Doors

In order to remove the hinges,the panel in front of

the door hasto be removed.When this hasbeendone
the three bolts are removedand now the hingescan

The door and hingesare installedin ihe reverseorder.

Since the holes in the hingesand in the attachment
between the door and hingesare oval, the door can
bo adjustedlate€lly. The door can be adjusted up, down
and lengthwisein the atlachmenrberweenthe hrnges
and door post. This is possiblesincethe holes in the
door post are larger than the diameter of the bohs.
Shims to adjust between lower door hinge and door
are availableas spare parts.

Bemoving and installing rear doorc O

See the corespondingsectionabove.

Removing front door lock

0
Op. No. 83406 = replacedoor lock
1. Follow operations l-3 under "Removing inner
handlesand upholstery.
2. ffemovethe lock cylinderby its attachingscrew
which is fittsd in the rearedgeofthe door.
3. R€movethe lockingfof the pull rcd lockingknob
a n dt a k eo u t t h ep u l l f o d .
4. Removethe locking for the inner door opener

5. Removethe lockingfo. the outer handlepulr rod.

6. Removethe three retainingscrcws lor the door
lockandthelock.
The retainingscrcwsare locatedon the rearedge

Lock,frcnt doo6
I
Removingouter handle,Jront doors 2.
3.
Op.No.83404= replaceouterdoorhandle
1. Crankup the window to closedposition.
2. Remove innerdoorhandle andupholstery
accord-
5.
Pullrod for lock button

6, Coverfof outsr h€ndle

Screwsfor oul€r handle
0
ing to previousinstructions. Relurnspringior ouier handle
3. Crankdown the windowuntilthe rwo retaining 9 . Pullrod for ourerhandlo
screws7, Fig.right are accessible.
Removethe lo.
11.
4. LJnhookthereturnspring8, Fig.rightandlift out 12_
1 3 . Rerlrnsping for innerdoor op€ner
the handleand coveras a unit.

2. Screw in both the attachingscrews7.

Installingouter handle,lront doors
1. Placethe handlein positionin the door and move
rhe pull rod 9, below, in the lifting arm for rhe
handle,
3. Checkto makesurethe lockfunctionsproperly.
lf necessaryadjustthe lensthon the pull rod 9.
4 . Installthe returnsprjngL
5 . Put backthe door upholstery and re-installthe

Gtoup 83
22 DooB and Trunk
 t, Le€ for remote conrrol
2. L€w for cl ld sfety door l@k

4. Ftll .od for outd handl€

6. Cov* for our€r handle

7. Scr€ws for outer handlecover
8. Rstuh lpring for our€r hsndle
9. P'rll rod lor lock button
10. Inn€rdoor open€r
11. netum s! ng for inE door op€n€r

Removing rcar door lock Removing outer handlg, rear dools

Op. No. $4m = rcplacedoorlock
l. Carryout operations1-3 und€r"Removinginn€r
handlesand upholsrery".
2. Removeths lockingtor the pull fod lockingknob.
3. Removs the locking for ths inner door opener
4. Removsth€ lockingfor the outer handlepull .od.
5. Remove the retaining scrcws for ths door tock
and rcmovethe lock from the door. Th€ attaching
screws for the lock ars placed on rhe rear €dgs
l. Windupthewindowtotheclos€d position.
2. Removsthe innerhandleand uphotstery accord-
ingto previous
instructions.
3. unhooktheretumspring8.
4. Unscr€wthe screws7. and lift out hsndteand
covsrasoneunit.
Installing outgr handlo, rear doors
1 . Placsthehandlein poshionin the doorandmove
rhe pull rod 4 in the tiftingarm for the handte.
Scr€w in the attaching scr€ws 7.
Checkto make sure that there is a clearancsA.
ot 1L1mmll /32!.1/32") betweenthe pu rod
eyslstand pin in the lock lever
Installrstum spring8, and checkthat th€ tock
is functioningproperty.
5. Installdoor upholsteryinnerhandte.

Strikor platos
The striker plate is madeof ste€land is install€dwith
6 floatingnut plateTh6strik$plateis adjustabte since
th€ holesin th€ body sre larg€rthan the diamster of
the attaching screws
Th6 v€rtical pqsitionof rhe stdker ptate is controlt€d
by closing th€ door, with th€ outside handl€ Dutt€d
out whsn the door latch should slid€ con€cdv into
the latchplate The strikorplateshouldhavean inward
Sirikor phte inclinationof 1.5o tor ths front doors end 2.5o tor
A. Front door 1.5o 8. R€8rd@r Z5o ths rear doors, s€e Fig. left

Group83
D@6andTrunk
Doors

Bemoving front door window

1. Crankdown the windowto its lowestposition.
2. Bendout the cover,removethe screwand rhe

3. Remove the arm fest and the door panel.

Remove the large sheet of water protection.
4. Removethe lock spirngsand the washerson the
irside of rhe regulatorarms. Bend the regulator
arms outwards and separaterhem from the w'n-

5. Ramove lhe window by hfl'ng and tu,nrng ro-

wards the vehicle as shown:

Window dihonsion, r€ar door 244. 245

A = 169a2 mm = 6.654"-$.i32"
B = 90d+1o

2. Lower the window with the acute angled corner

fi6t and turn it at the same time as shownl

Door window removal

Door window installation

1. Installthe window in the window channelaccord-
ing to following two Figs.

Q'

o
3. Checkthat the window is aligneclin the windo\,!

Fit the regulatorarms in the window channeland

install the washeG and the lock springs.
5. Install the water protection springs.
6. Installthe door panel,the arm rest and the win-

242 andlront door244, 245

Windowdimensions,
A = 2612 mm = 10,275"-10.443" Removal and installation ol rear door window
B = 89o+1o See the corespondingsectionabove.

Group83
24
 Doors

Removal of door window crank mechanism lnstallationof window crankmechanism

Op.No.83504= Replacefrontdoorwindowregulator
1. Crankdown the windowto its bottomposition.
2. Removethe doorpanelandthewaterprotection

3. Removethe lockspingsandthe washerson the

insideof the regulatorarms.Bendthe armsout
wardsandremovethemfrom the windowchan-
nel.
Bemovethe clip 1, Fig. below, at one of the reg-
ulator arm's retaining points in the door.
5. Remove lhe door window crank mechanismre
taining screws 2l

Window mehanisn

I Installthe crankmechanism.
Do not rightenrhe

2. Installthe regulatorarms firsi in the door and

thenin thewindowchannel with thewashersand

3. Clankthewiodowtoitsupperposition andtight
Front door interior
en the crankmechanism screws.
4. Installthe water prorectionsheet.
2. Window mechanismrelainingscrews
5. Insrallrhedoorpdnel.the arm restandthe win

6. Removethe crankmechanism
as shownl

Rgmoval and installation ot rear door window

mechanism
Op.No.83502: Replacereardoorwindowresulator
Proceedin the sameway as describedabove

Window m€.hanism r€mov.l

Gtwp 83
Doorsati Trunk 25
Doors

ElectricallyOperatedWindow Winders

BATTERY

Er@
.lcNltlo sllTltt
l
FUSElOX SB - black

EI{ERGIZIN6
8E!AY GN - green
GR - gray
BL - blue
BR - brown

SIIITCH,
StlITCH, RTGHTSTOEI{INDOI{
LEFT SIDE I{IIIDON

RIGIII STDE
I,IOTOR
LEFT SIDEIIOTOR

Adjusting stop positions, front window win- Rundown th€ windowio the stop poshion.Chsck
ders that the lifting arm does not bottom in the slide
fork Adiust if necessarythe stop lug so that rhere
L Removedoorpanelandths waterproofing sheel.
is a clearanc€ of approx.1/32" {1 mml.
2. Runup the windowto the stop andreleas€rhe
Restoredoor paneland wat€rprootingsheet.
stop lug usinga 5 mm seGcrewwrsnch.Run
up the window as lar as it can go. Adjustthe
stop lug againstthe tooth segmentand tighten
up the lock bolt.

Stop lug, upp€r pGition Adjosting lo@r stop position

Group83
26 DooB and Ttunk
 Replacing window winder or motor, frcnt 10. Securethe windowwinderin a viseandremove
the motor from the winder.
Figuresin bracketsapplyto replacement of winder.
1. Removedoor paneland wat€rprootingsheet.
2. Run down the window to the stop position.
3. Release the liftingarmsfrom the windowrailby
pushingloos€the s€fetybracketsandremovethe
washers.Then lever the arms towards you,
4. Removethe windowby liftingandturningit to-
wards the vehicleat the sametime,

Finng window winder in vi$

(11) Remove the window winder from the vise.

NOTE: Take care not to jam your fingerswhen
releasingthe vise since the window winder s
spring loaded.
(12.) Tensionthe spring on the new window winder
to the bonom and place the wrnder in the vise.

5. Disconnectfie battery ground cable.

6. Removethe under-dash panelandthesde oane,
(at the Iront door pillar,.
7. Removetheluse boxanddisconnect thecontacF

o
T6Nioning window windor spring

Mounl the motor on thewindsr. Removethe win-

Ssmovinqtu$ box 1 4 . Position winder and motor in the door.

Run the wires through door and door pillar.
1 6 . Fit the liftingarm wirh washerand $fety bracker
in the door slide rail.
th€ liftingarm from the side €il in the
9. R€lease

Removethe windowretainingscrewsand take

ths winder out of the door.

Group83
Doorsand Trunk
17. Lift the window into ihe door with the pointed
part f rst and th€n turn it slighny away from the
TrunkLid.242/244 and 262 / 264
The trunk lid is moufted on two hinges,which are
attached by two bolts io the inner pate of the lid
and with ihree boltsto the pillarundertherearw ndow,
The trunk lid is counterbalanced by a spring support.
The trunk lid is removed by removing the two bolts
on each hinge and liftng it off.
When replacing,ihe lid is firsi openedfully. lt is then
lowered slightly and clamp 2739 appliedand rhe lid
openedfully again,after which lhe sping suppon can
be removed.When installinga new spring support,
p t p s st o o l 2 / 4 4 , s u s e d a s s h o w n I n l g . b e l o w I
order to nstall clamp 2739.
suo-2739
*t--l
tsl
Toolslor sprangsupport
Gtoup 83
2A
Make sure thai ihe window entersthe slot in the
guide rails.
18. Fir the lifting alms for the window rail together
with pastic washers and safety brackets.
19. Reconnectconlacts and install fuse box.
20. Install side panel and under dash panel.
21. Connect the battery ground cable.
22. Adjust window winder stop positions,as descrb
ed under "Adjusting stop positions.
23. Fit waterproofing sheet and door panel.
I
l]
InsralLin the reverseorder,
When removing hinges,first remove the spring sup
pon as described.bove.The lid isthen removedfrom
the hinges and the h nges ffom the body.
The holes in the part of the hlnges atrached to the
trunk lid are oval in ordef ro pefmir longitudinaiad-
justment. For verticaladjustmentthe hotesin rhe pan
of the hingesattachedto the bodyareovat.
0
I
q
lock for trunk lid
Lock cutch, fitted in lid
2. Lock mechanism,fitted n rear secton
3 . Lock knob, fhred in rear section
 Trunk lid

Ths lock (Fig, below) is instaled in th€ rear ssction
and is releasedby tuming the tockabteknob. The tock
catch on ths lowor €dge of rhe tid is adjustabts in
order to permit variation of the ctosing tension of the
lid.
The lock knob is r€moved by taking out the hors€shoe
clampwith piiersinsid€th3 trunk. The tock knob €n
thenbepullsdout backlv€rds.
To removsthe lock removsth6 tock knob and nen
ths tlvo bolts und€rthe upperdgs ot ihe r€€rsoction.
Ths lockis sdjusrablelongitudinay sincethe bott hor€s

-'--'\T

i,
r
ar
I
22

11
e2-

Gtdlp 83
D@rs atd Trunk
Tail gate

Taif Gate, 245 and 265

{(

0.(

The tail gare on the 245 model is suspendedby two

hinges screwed to rhe roof. To r€move tail gats, first
remove upholsterypanelon inside.Then rc66ve left
license plate light and disconnectwne.
Disconnectalso the other outgoing wires from their
connectionsinsidethe tailgate. The gas springisthen
disconnectedat its attachmentin thetailgate. Remove
{t(
the screws for the hinge attachmentsto the tail gate
and lift off the tail gate.
To instauth€ tall gate: Lift up the tail gate and insert
the wi,es. Positionlail gale and screw on $e hinges. {{
lf the gas sp ng was rcmoved, install at and adjust
play where attachedto th€ body. lnstall licenseplate
li9ht,wire and upholsterypanel.
The tail gate lock must be removedfrom the inside.
Insidethe tail gate, the link rod to the lock plunger

a
Tail garelock 245l265
3. Lalchingdevicelor inneropener
4. ControLfor larchingd€vice
is removedand also the screws for the lock The lock
can then be moved to the left, from where it is raken
out of the taal$te. The lock cylinderis removed by
looseningthe lock screw inside the rail gate.
To remove hingesfor replacement,detach the head-
lining at the rear (see under "Replacingheadlining").
Disconnectthe wire at the joints under the hinges.
Removethe screws secuing the hinges to the roof
and the tail gate. Remove the hinges.

Gtoup83
30 D@rsand Trunk
 Sun Roof
Removing cable
1. Open the sun roof and releasethe clips seclring
the roof upholsteryat the front end. Then move
the uphostery back to leave an opening.
2. Crank the sun roof forwards and slacken rhe
screws at irs fo I ardLhmenis I and - 1
Bend the leaf sp ngs 10 to one side and remove
the rcinforcingplates13 at the rear attachments.
3. Bemovethe wind deflector2.
Bernovethe intermediatepieces8, cover stfip 3
and holdersabove the drive. Releasethe front
guiderails6and pulloutthe cables5.
Installing cables
1. Insiallthe cablesso that the attachmentsfor rhe
sun roof come opposite each other, and .r the
rear end of the roof opening.Screw on secur€ly
the front guide rails.
2. Instal the intermedlatepieceq holdersand cov
3. Insrall rhe wind deftector.
Scrcw on the roof securelvand our back rhe leaf
Sun r@f A. Rear attachment lvhen r@f is o@n
t_
2.
3.
Crank housingwith crank
5. Clank the sun roof fo.wards until it is comptetety
closed and check that it is level will the root.
To adiust verlically.use the front adjustmert 7.
and the lifis at the rea dojushenr 12. Atsochecl
that bolh the lifts sland straighrup when the root
6. The crank dnd hoLsing4. Tur. the c'anx ro the
stop positionon the removedgearhousing.
7. I n s r a ltlh e h o u s i n ga n o c r 6 1 k .T h e c r a n t s h o u t d
now poinl straighrforwa'ds in the vehrctewher
the sun roof is completelyc osed.
8. Put back the upholsteryand test rhe function oi
Beplacing sealing strip
The sun roof must be iemoved in order to replace
the insulatingstrip and sealingstrip there. See points
1 and 2 under"Bemovingcable".
When rcpacing the insulatingstrip round the roof
openingof the sun roof, all that is requiredis 1o crank
the roof backto its rearmostposition.
B. Rdr attachmat whon rool is closod
8. 11.
9. 12,
to. 13.
Gtoup83
Mouldings

Group84

SealingStrips,Glassand
ExternalTrim Mouldings

Sealingstrips When installing,begin by placingthe clipsand locking

The sear,ngsrips dre securedby slopweldedfastening
The sealing strip is removed by pulling it outwards,
when the ridgeofthestrip releasesfromthe rail.When
attachingthe sealingstrip,one of the ridgesis placed
in positionin the rail, the other ridge is then pressed
down into the rail with € wooden putty knife. This
is moved along the rail as shown:
them by pressinginthestud inthe middle.Themould-
ing is then pressedonto the clips.
Removingwindshieldmoulding
The windshieldmouldingis fixed by clipsp€ssed into
the slits in the windshieldopening in the body. The
mouldingcan, for example,be suitablyremoved with
a steelputty knife.Insen the knife betweenthe wind-
o(
shield and moulding opposite a clip, see Fig. below.

O,r(
Then Iever the moulding loose.

In$tallings6alingsrrip
O,(
Removing
trim moulding
@(

Trim mouldings
Waist mouldings
The waist mouldingsare attached with plastic clips.
The mouldingsareremovedwith a wooden puttyknife
with which they are carefullyleveredoff. The clips
can be removed by carefully pulling them off w|th
Installing
Installthe windshieldmouldingby pressingatin bet-
weenthe body frame and the clips.To ensurethat
the mouldingcoincides with the cornerioints,install
in the followingorder.
First installthe lower mouldingwith a cornerjoint
on. Theninstalla side mouldingalsowith a corner
on. Finally,installthe remainingmouldingtogether
with cornerson to the body frame.

Group84
32 Glassand Mouldings

Removing trim moulding for rear window
1. Remove the mouding from the rubber strip by
Insertrnga moistefed nylon puty knife;nd mov
ing it all roufd between the strips (do not pult
off the trim moutding).
2. Pushover the loin ng piecesro o.e of the ha ves
of the mou ding.
3. Remove the trim moulding by evering out rhe
ridge of the rubber strip from ihe trim moutding
with a moistenedwooden porry knife. Retease
thetrim mouldingin the midd ewilh anotherplny
knrfe as shown.
Removingtrim moulding
Lever off the moutdingcarefutlywh te reeasing
the .ubber strip with the other putty knire.
Installing trim moulding for rear window
Moistena 4.0 mm (5/ 32") leathercord in soapsoturion
or paraffin and place it n the groove of the ruDDer
strip for the trim moulding.
Place one half of the trim moulding tn position and The solderinsircn shouldbeon 2OOw' Ths tip may not be
so thick thar it @n come in contact with the gtass.
holdrtiherewhilepullingtheLeathercordoutupwards
over the moulding so that ir is pressedagainst rhe
rubber strip as shown:
Installingtrim moulding
Windshietd
Pushover thejoinifg piecesand repearrhe procedure
w r r h t h e o r h p r h a r o f t h e - o L d r . q . aso t, T p o s o n
oi the joinlng pec€s over ihe joints.
Windshield
Removing windshield
Op. No. 84302 = replacewindshietd
1. Placeproiectlvecoveringov€r the hood anctrronr
2. Remove the windshied wiper arnrs.
3. R e m o v e t h e x t e r n ar lr i mm o u t d i n gS. e e " F e m o v -
i n g w i n d s h i e dm o u l dn g " .
a. U n s . r . w L 1 ei n e r c o v e, g s r p c a r d , e a r v i e w
5. Cut the windshied loose wirh a wa.m sotderng
Insertthepoinrof the iron berweenthe windshietd
and the body.from the /nsideof ihe vehice. Then
d r.w the soldering ron round the windshietd.The
windshieldcan now be pressedout by hand.Cur
off any remainingsrrafds with a knife.
6. Clean the body (also ihe w ndshtetd if h is ro be
re instaled) of any rape.
Remove any defecriveclips.
Installing windshield
1. Injectsealng agent lnto the hoes where rhe new
c l p s a r et o b e i n s t a l l e dU. s e P u m pN o . 2 1 0 j 6 3 .
2. Install new clips.
3. Cleanthe conlact surfacesfor the rape on Dooy
and windshield.Use ethyl or merhyt acetaie for
the ceaning. Be carefulnot to touch the ceaned
4. Coat the clips wirh sealing agent No. 686275
so ihattheagent forms a smoothbridgeberween
the c ps and body for the buty tape to seal
against.
Group 84
Glassand Mouldings 33
5. Coat adhesiveon the cleanedsurfaceson the
body and windshied. Coat an edse betw€en 18
aft 2'l nm \3/4 and 7/8") in width round the
windshieldmeasuredfrom hs outer edge. Apply
the adhesivetwice to ensuretoral coverage.Any
adhesivespill on the body or glasssurfacescan
be rcmoved with methyl acetate.The adhesive
can be app ied within 5 minutesafterthe cleaning.
Installboth ihe spacerson the lower edge of the
windshieldopenins.They should Liebetweenthe
2nd and 3rd clipfromeachwindshieldpost.
Butyl tape joinl
2. Spacef
Installthe butyl tape on rhe body not less than
10 minutes and not more rhan t hour aftef the
adhesivehas been applied.RolLthe tape round
the whole of the windshieldopening wirh the pro
tectivepaperon.The ioint shouldbeoppositeone
of the side posts and the joinfs ends should be
The tape is best cut with a heated knife.
Placethe tape edge to edge with the spot weld
flange. The tape profile may not be altered by
stretching.The protectiv€paper is removed im-
mediately before the windsheld s lnsla led. Be
careful not to soil or touch the adhesivesurface
a. Use a glasslifte.for installingthewindshield.Two
man are required10 instalthe windshield,h must
be carefullylocated in the openins before being
placedagainstthe tape. Oncethe windshieldhas
beenplacedin position,adiustingpossibilitiesare
then very small. The wndshield must not lie
Grcup84
34 Glassand Mouldings
Usingfiiture 2a99 1o installwindshi€ld
9. Installthe fixturc 2890 and pressthe windshietd
{;
firmly in position. When the outer plane of the
windshield l i e s 1 1 1 - 5 m m ( . 0 4 1 . 0 6 " )f r o m r h e
outer €dg€ of the body, then the windshieldis in
the cotrect position,Let the fixture rernainabout
10. lf the btltyl tape is squeezedoutside rhe wind-
I
shieldon its inside,cur offthe projectingpart with
Note lf any part of the painted edge on which
the butyl tape is installedis seen through the
windshieldfrom the outsideof the vehicle,apply
sealingagent 686275to these points. This is onty
requircdfor light coloredvehicles.
11. Install the outer tim moulding, see Instattins
windshieldmoulding".
12. Inslallrhe innercover sr ps ano rFarvicw mirror.
13. Installthe windshieldwiperams.
r) (
Rearwindow
oD. No. 84312 = .ep'dce rea, w,ndow t
Removing rear window
1. Removethetrim mouldingsas describedin oper-
ations I -3 under"Renrovinsrearwindow mould-
ing.
2. Removethe cabes forthe electricallyheatedrear
3. Faledserhe rubber srnp bolh from rh€ rear wr"
dow andsheetmetalby insertinga wooden putty
knifemoistenedin syntheticwashingsolution(the
putty knife should be moistenednow and then
duringthecourseof thework)betweenthe rubber
strip and rear window and between the rubber
strip and sheet metal respectivelyand moving it

4. Start removingihe rubber strip in the upper lefi
corner. Levef the rubber sfiip over the edge of
the sheet metalfrom insideand at the same t me
carefolly p!lling out the strip from oursidewrth
a pair of wide-nosedgips. Then carefullypull off
the stip by hand al round and remove the rear
Removeallsealingcompoundfrom thesheet me
tal. lf it has drled on, first carefullyscrapeoff rhe
sealng compound and then wash clean wnh
naphtha.Check that the sheet meta edge is not
defomed. lf the sealingcompoundhas not dned
o n c l e a .r h er u b b e rs r p w r h - d p h l h ao. r h e r w F e
Installingrear window
1. Moisten the outer edge of ihe windshield and
insralltherubberstrip startingal one of the corn-
ers. Adjust the strip so that it lies coiiectly all
2. Install a cord (preferablyterylene)of a suitable
sizein the grooveofrhe rubberstripforthe sheet
metaledge,beginningatthetopcenterasshown:
Placing@rd in rubberstrip
3. Place the rear window in positionwith the rubber
s r r i p l s l d l l e d W F d l n q w o r k i r gg o v e - . c a r e l u l y
slike the rearwindowaiew blowswilh lhe palm of
lhe hand so hal il ma"e. good corlad all round.
Thencarefullypull out the cordfrominside.Thiswi
cause tl^e ubber slrip to -c.eep over the 5heel
0 melaledge as shown:
hstalling rear window
Reat window
I
It may sometimesbe necessaryto adjustthe po
stion of the .ear window whh the palm ot the
hand. lf the cord is difficult to pull out, rh s nray
damagethe strip, n which casethe rear window
shoud be struck from insideor oursde wirh the
pa m of the hand if the rubber strip does noi
''creep
overtheedge of thesheet melsl properly.
4. Check that the rubber stip sealswell al rolnd.
ll necessaryadjusttheposhionof the rearwindow
both vertca y and laterallyby striking with the
palm of the hand.
5. Sealthe joints belween the rubber strip anctr€ar
window and rubber slrip and sheet metal with
sealingcompound using a 9un with a flar nyon
nozzle.Make s!re that the sealingconrpoundfi Ls
the joinr wel. Scrape off surpus seallng com
pound and wash rear window and sheet meral
with kerosene.Cleanthe rear window and sheet
metal around t with polish.
6. Installthetrim mouldingsaspreviouslydescribed.
7. Installthe cablesfor the eleciricallyheated rear
(tarl gate) window-
Rearquarterwindows
See the correspondingsectlon under"Rear window'
Rearquarterwindows,242/ 262
To remove the glass in the rea. quader windows on
rhe 242/262 model, open frrst rhe quarter winclow
and remove the screws securingthe quarter window
opener io the body.
Removethe window from rhe fronr atrachrnentsby
t n s t o p e n , _ g , r9 0 o a n d a r r h e s a m e - e p u l n 9 t o
Group84
GlassandMouldings 35
Desisn

Group85

Upholstery,InteriorHeatingSystem{excl.Air Conditioner)

For Air Conditioner, see: 240 models, TP 1 141 1

'11412
260 models,TP

Front seats Th€ front passengerseat is retainedby four brackets

each with three positions.Thesearc the same as for
the drive/s seat but tools must be used to change
O(
The inclinaiionof the seat back is accomPlishedby
a gear system. lt is inva ably adjustableby tu,ning
the hand wheel on the outsideof the seat. The seat
is providedwith an adjustablelumbarsupport,the ten-
sion can be adiusted by a knurled knob loc?ted on
the outboardsideofthe backrest.
I
on the 2 door models the front seats can be folded
fo ard. There is an automaticlatchingdeviceon the
outboad side of the seat. lt is rcleasedby a lever.
The front seatsare equippedwith non-adiustable head

C, I
(

Front sear

The front seats are built up on a tubular frame. The

paddingconsistsof a soft rubbe. maierialand foam

The front seat c6n be slidedfoMards and backwards

to desned positon after the loop hande on rhe seat
front has been lifted.The sealrallson both sideshave

There are lwo levers,each with three positions,for

positioningthedriver'sseatverticallybothin front and
rear. Ths means that also the cushionangle can be The resfiaintscan be releasedand pulledupby pushing
in the lock iabs khrough the upholstery).

Group85
36
 Design

Headlining
242 / 244 and 262 / 2641
The headlinng consistsof mo! ded glass woot wrth
a plastrccover on th€ und€rside.

Glasswool headlinins242.
El.ctrically h6ated driv6r'6 3oat
It is made in one piece and cannot be folded. lt is
heldin positionby the sun visor,rearview mifior, curve

0 Somemodelshav6an electrically
controlledby a lhermostat.
heateddrivefsseat
h a n d l e a n tdh r e e p l u g s a t t hrec a r e n do l t h e h e a d l i n i n g .

244 / 265
Thetoalcurrentdrawis 60W Thethemostal olts outat Tbe headliningconsistsof plasticfabric stretchedon
26"C(78')andculs in al 14rc (57.). root bs. lt is securedin retainersfitted on the lpper
limit ofthe bodysides.

Ventilation
Roarseats
242./24/and26?./N 242 / 244 and 262 / 264:
Rearseatcushionandrcarseatbackarc madein pot- The ar ventsare locatedunderthe rear winduw:
yurelanfoam, mouldedon a frame of wireswhich
stabili?e
thefoamandretaintheuphotsrery.

245 / 265
Bearseat cushonand rear seat backare designed
as the front seats,but the frame is wood.
The rearseatcushioncanbe foldedfoMard anorne
back rest down to provideincreased cargospace.

Door upholstery
The door upholsteryconsistsof woodjiber sheeting
llned with non-wovenpaddingand coveredwith
upholsterymateial.h is securedto the doorby clips.
The arm restsare madeof mouldedplasticand are
screwedto the innerplate of the door.

Covering Ior Iirewall and floor

The sidesof the bulkheadare tinedwith mittboard.
The firewallis coveredwith setfadhesiveinsutating
material.The floor is coveredwhh textitemais_
Vehiclesequipped with catallic converter
haveexrra
hea\,1insutationabovethecatalyticconverrerandthe
heat protectronshieldsas the catalyticconvener t_
2.
sYsre- r-.raaseselhausrsyner tempersture:, 3.

Gtoup 85
37
 245 / 264
Theairventsarelocaiedundertherearrightsidewin-

1,
2.
3.

ServiceProcedures
ol
Front seats Fit the new heater pad in $e seat back.
NOTE:theheaterelementbarbsshouldpointtowards
Replacing heater device for drive/s seat

Oi (
the padding.
1. Disconnectthe seat pad electricalwires at the Hook the plastic hooks to the suspensionmat lower

2. Removetheseat,completewith slidingrailgfrom The heater pad electdc wires should be routed towa.ds
the inboard side ot the clshion. Fit and attach front
3. Bemove the screws acc. to Fig. below, and rc- upholsterytorcarupholstsry,usingfour clamps.
move the seat cushion,

Seat cushion heater pad

Placethe seat cushionon a table, upside down, Re-
move the cover plate.Cut and removethe clamps at
the rear end of the cushion
Pull out the heate. pad.
Fit the new heater pad in the seat cushion.
NOTE:rheheaterelementbarbsshouldpoint towards
the padding.

Ret.ining bolis
The heaterpadelecric wiresshouldbe routedtowards
rhe inboarclside of the cushion,see Fig. O,(
Seat back heater pad
Placethe cushionupsidedown on a table-
Cutandremovethefrontupholsteryretainingclamps.
Unhookthe plastichooksandpullout the heaterpad.
@(

R.moving st back h€t€r pad Fold back the upholsteryand installfive new clamps.

Gtoup85
38 lntetbr, Heating
 Frcnt seats

Re-installthe seatcushion.Connectwiresfor seat back use . screwdrlverto press our the hand wheel
and seat cushion heater pads: cover through one of the hand wheel holes:
,]tl
'l

CI Wneslor heaterpads

lnstall the seat in the vehicLeand conned rhe wires

at the junction box. handwheelcover
Removing

Replacing seat heater thermostat 5. T r r ' h e l o c k i nr h . h a n d w h F e o . n r q ( l o l w i s c

and remove the whee i
1. Bemovetheseat heaterpad (seeseparatenstruc

2. Disconnectthe thermostal wres. Remove the

3. Installthe new thermosratin the heater pad and

connect the wtres,
4. Installthe heater pad (seeseparateinstructions).

Beplace:
Seat reclining

Seat back upholstery

Latch or cable for seat

concern cars with seat back latch Removing

handwhal

1. Disconnectthe seat and pad electricalwires at Eemovethe mechanismcovercby bendingloose

rhe junction box. the lower edge and ihen pressingupwards:
2. Bemove the seat, complete with rails,from the

I Disconnectwiresfrom seatbackand seatcushion

Removethe screws and rcmovethe seat cushionl

Removingplastic @ver
1. Unhooktheuphosteryfrom the seatreclininsme-
chanism.cut and removethe clampsat the seal
b a c ku p h o l s t e r y j o i n t .

Gtwp 85
39
 Unhookthe plastichooks and pull our rhe heaier Replacinghead.estraint

Seat back upholstery

A. Unscre the lumbarsuppon hand wheel.
loosetheplasticbushing
in theseatback:

D(
Heater pad
Removingbushing

O, (
Replacing seat reclining mechanism (B). Pry loose the fr.me for the catch release lev€r
A Unfold the upholsteryto ga n accessro rhe me
chanism relaining screws.
{B). Pul off the cablelocksand disconnecrthe caDres
trom the mechanism.
C. Fold down the padding,remove the screws and
tlre mechansm:

Removing
frame Qr {
C. Fold away the upholsteryuntil three clamps are
accessble. Cut and remove rhe clamps:

Removing
seat.eclininsmechanism

NOTE: the seat rec Ining mechanlsmcannot be

repared and lhe whole assemblymust be replac

D l.lsea screwdriverto tlrn lhe new rec ining me-

chanismto the rear stop position.Put the me
chansms on top of each other and check that

E, Attach the mechanismto the seal back. Attach

the control shaft to the mechanism,
Positionthe other mechansm on the shaft and
tghten it to the seat back.Finalizetheinsla Lation
of the seat feclinng mechanisms.
(c).Attach the cablesto the mechanismsand fit the

Group 85
40

L
t-
 Front seats

D, Unfold the upholsterycompletety.Knocktoosethe (B). Pry loose ihe frame for the catch releaseLever.
headresrraint.Removeheadresvaintand uphot- C, Fold away the uphoisteryunri three clamps are
accessibe.Cul and remove the clamps.
D. Unfold rhe uphostery unti the releaseever is ac

&t E. Pulloff the cabe locksand disconfecl lhe cables

from the seat reclinng mechanisms.

.t Pry oosethe re easeleverfortheseat back catch:

Knockinglooseheadresrraint

E. Carefuly loosenrhe p.dding andfoid it toosefrom Removing

mehanismlever
lhe seai frame. Removethe head restraintlower
G . Bemove Iwo .elarn g sc.ews and tl-. , dtcl rol
Install new bushings(ocks)l
Disconnectcables from rhe mechanisnr.
L Atlach the new mechansnr and coverto the seal

Installing
machanism
andcowr
hstattingbushings
J,
G . Apply slue to the seat frame back sjde and fotd Attachcableswirh rerainers
io rhe reteaseme
Fold on the upholsreryslightty.Instal the head
restraint.Checkthat the headrestrainris securelv

attach the rod to rhe suspensionmat with three

Replacing control or control cables {or sear

$i
back latch
(Seeaiso"Beplacinsheadrestrainr
or seatbackuphol-
st€ry',prcvious
page)
A. Removethe lumbarsupporthand wheet.putl
loosethe oldsrkbushrngtr tt-e seal bact

Group85
lnteior. Heating 41
L. Hook the cablesto the seat recliningmechanisms 14. Benclouitheshe€tmetaltabsof theseatreclining
and lock the cable sheaths.
l/1. Anach the rod to the suspensionmat with three andthenre-
Fit andhookon the sideupholstery
shapethe tabs,
9. Fold on the upholsterycompletely.Checkfor

10. Poshionthe heaterpad.

barbsshouldpointto-
NOTE:the heaterelenJent
wardsthe padding.The wiresshouldbe routed
towardsthe inboardside of the cushionl

Press on the releaselever f€me.

Pressonthe bushingforthe lumbarsuppon hand
wheel. Install the hand wheel.
Installrhe plastrccoversfor the seat recliningme-

Installing €t back heater pad 1 7 . Tum lhe locl clockwiseand Inslallthehandwheel

I t . Attach the upholsteryplastic hooks to the sus
pension mat lower wire,
't2. Fit and attach rear upholsteryto the seat frame
for the reclining mechanisms.
Press on the hand wheel cover.
1 8 . Attach seatcushionrothe seatrecliningmechan
isms.Connectwires trom seal back and seai cu.

vvics Ior heator pads

Fittinq sido upholstery

1 9 . lnstalltheseat in thevehicleandconnectthewires
at the junction box.
1 3 . Fh and atlach front upholsteryto rear upholstery.

Gtoup 85
42
 Headlinins

Repfacing headlining 242 /244 ano . T L ' n r h e p a s r c o l u g sa t l l - e e a r p d g ed q a r t p

262 /264 turn to releasethe headining.
12. Li'l o-r the rpcdlir 1q .hro-91-rl-p redr w,ndow
Removing
1. Disconnectthe battery ground cabte, 13. Pry oose wirh a screwdrver to remove panes
2. Removerear seatcushionand backrest.Reft,ove on fiort door p lar. Pry loose upper cover strip
rear shelfw ih plastc coversand artachmentsfor on the windshied.

3. Remove side panels located berween rear sroe Installing

window and fear window orherwiseihey may
1. nsert the headlining throughrhe rear window
4. Disconnectlhe elecrricconnecrtonsfor the rear
openrngand positionit oi the roof.
2. h s r a l l r e a rv r e wm . r o r . r r a c l m e n rw r r l o u r t 9 . ,
5. Removerhe rear window accordingto separare
3 . r n s l a l l t hD
. l . " r ( p J g s . t t l e r e d rc n do , t - e h e a .

c
hning. Press in and rurn a quarier lurn.
6. Removethe nteror rear view m ffor by pressng
InsiaI curue handle and artachmenis over the
it forwards.Bemovethe rearvtew attachingptate
lront doors. Instal trirrl covers.
5. - g l _ r e ar 1 ea t l d . l - T e n t ql o r r l o p . i v r e w m . 4 o r
Install sun visors wirh suppod bearings.
6. Insta fronr cover srrp and panelson rhe front

1. Confect and rnsral the interior rghr.

8. InstsI the rear view m rror,
9. nstal crank housi.g, geaf and crank.
1 0 . Install rear window. Connect rhe wtres.
1 1 . l 1 s r .I r e d r s d e o d n e l sI n s r a lcl . p " a n c t. l r a , h -
mefts for rear seal beLts.
12. lnstal rear shelf. nstai re.r seat.
1 3 . Reconnectihe baltery groLrndcabe.

Replacingheadlining,245 / 265
No.851O4
I Femovethe interiorlight.sunv sors.andreafvew
1 . Remove atiachmenls,inc. s!ppon bearings,for
2. P u r d o w n r l ' e e o q eo ' t - l c l o d d l i na q r h l g F l
sun visors. Remove the sun visors.
a r d l h u m b o n o n e s i d es o r l - d t t 1 e o r d c t p o g -
8. P ) l o o . e 1 1 " i n p l o r g l - r .D s c o n r e c rr t - ew i r € .
can be releasedfrorn hs fastenng if the ra L
L F e m o ! - ( r i 1 l d n d 9 F . . F e a r o v er h eh o J s- g t o r
3. Then pu I down the headining al rolnd.
1 0 . Removecutue handleand ailachmentsover ih€
dooron the drlver'sside.Bendlooserhe trim cov€r
10 garn access to the screws.
0
i

L. -1,*',,
Gtoup 85
4. Take down the stretchersbeginningfrom the
backby bendinsthem down in the middleand
.eleasrng
rhemlro- the edge of lhe roo|
Femoving rool str*hers
NOTE| Be careful when removing and installing
the siretchers.Carelesshandlingcan cause the
ends to damage the roof plate.
5 . Installthe strctchelsin the new headlining.
NoTE:the stretche6aredifferentlengths.
Makesurethattheyare providedwith rubbercaps
6. Installtheheadliningby first insertingthe stretch
els beginning with the front one.
Streich the headliningforwards and tuck in the
plastic srrip at the front edge.
8 . Then stretch the headliningbackwardsby pulling
both ends of a stretcherat the same time. Begin
at the front and pull on each stretcherworking
backwards,after which the rear plasticstrip can
be tucked into its groove.
9. Now pull over the headliningtowards one side
andtuckin theplasticstrip.Thenstretchthe head-
hnrngover towa.ds the olher side and tuck in lhF
10. Insrallthe inreriorlighl. su^ visorsand rear view
11. Anyfoldsin thefabriccanbe removedby pulling
rhe headliningin the necess:rydrect|on.The
then movesin the attachingrails.
headlining
Instrument and control panel
Removing instrument panel
1. Disconnectthe battery ground cable.
2. Femove steering wheel (Section 6 Replacing
steering wheel") and steering column covers.
3. Releasethe screws holdingthe switchesfor t'rrn
srgnalandwiper and rhereafle'lhe plastrccasing
in front of the steering wheel.
4. Remove the holder for the hom slip ring.
Gtoup85
44
5. Removefie combined instrumentaccording to
instructionsin Section 3.
Removelhe sreeringwheel locl accordrngto in-
siructions in Section 6.
Take out the bulb holders in the combined In-
strument lights and the hub holder in the clock.
Disconnectthe electricwire frcm the clock and
the harnessfromthe lower part of the instrument
panel.A clamp is situatedimmediatelyunder the
clock and another undeneath the combined in
strument to the left.
9- Bemovethe heatersidepanels.Removethe hoses
for the four air outlets on the instrument panel.
10. Removeboth lower screws for the control panel
and then tip it back as far as the wires permit.
11. Disconnectthe electricwires to the glove locker (
light byopeningthe lockerlid and pullingthe entire
light inwsrds.The wires are disconnectedin this
cl (
12. Removeoutboardair outletsand the lightswitch.
Removethe screws securingthe instrumentpa
nel. There are three on each side of the firewall.
two underneathand one which is visible when
the outboard air outlets have been removed. A
further two attachingscrews are located above
the upper attachingscrews for rhe control panel.
14. Releasethe instrumentpanelfrom its attachment
in the dashboardby pulling it backwardsand at
the $me time lifting it overthe control paneland
thesupponr€gs,
15. Lift our the instrument panel.
Installinginstrumentpanel
L Check to make sure that the tubber bushingsin
the dashboardare nor damaged.Othelw|se re
2. Placein the instrumentpanel with rhe guide pin
@I
in the rubberbushingand screw tight to the cowl
sides and support legs.
Install light switch and outboard air outlets.
Install hoses between car heater and center ail
outlets in the instrument panel.
5. Insrallrhe bulb holder for the clock and hook up
the electric cable to the cloclc
6. Installthe bulb holdersto the combined anstru-
ment light and fix the cable harnessto the in
sirument panel by the clamp.
7. Instaltstee ng wheel lock accordingto instruc-
tions in Section 6.
L I n s t a l l c o m b h e d r n s t r u m e n t a c c o r dl oi ni ngs l r u c
tions in Section 3.
Insralltheholderfor rhe horn deviceslip ring onto
the steering column.
10. In$altthe controlfor turn signalswilchand wind-
shieldwrperc.also hook up the electriccables to
 Glovebox

11. Install €sings over the steeringcolumn. Controlpanel

12. Install steering wheel, see Section 6.
Removalof ihe control panelcan be slarted once rhe
13. Hook up the elec,triccablesto the glove locker
baftery sround cable has been disconnecred.There-
light.
after remove the panel attachingscrews and lift rhe
14. Install the hoses to the outboard air ourlets.
panelfoNards until the wie connectionsare acces
lnstall center panels,
sible. Note that the panel is attached by six screws.
15. Installlower anachingscrews for the control pa-
Two are underneaththe panel.Ma* the connecrions
nel.
and disconnectthem from their terminas. The panel
16. Connectbafterygroundcable.Checkthe function
can lhen be lifted out.
of the instrumentsand lamps in connectionwrth
When re installing,place the panel first in a suitabte
position,re-connectthe wires and then ptacethe panc
in position.Thereafterscrew right and re connectthe
Removing glove box
battery ground cable.

Replacing outboard air outlet

1. Pull off the knob of rhe main tight switch.
2. Pressthe impact absorbermouldingdownwards.
3. Remove two retainingscrews and the outtet.
4. Installationin opposite order.

Removingstow box

L Remove six retainingscrews and pull the gtove

box out of rhe dash board.

Repl€cing glove box lock

Romovingimpact absorborhoulding

Replacingcenterair outlet
1. Loosenthe controlpaneland pull it out slighny.
2. Pressthe impactabsorber mouldingdownwards.
3. Removethe retainingscrewsand the outlets-
4. Removethe clock.
5- Instalblionin oppositeorder.

R6pl*ing glow bor ldk

'L Tuln the

and putl
lock 1/4 turn counterclockwise
out the lock €arwards.
2. Posrriona new locl and rurn it clockwiseto stop.

Gtoup85
45
CU heater

Combinedunit

20

This is a combinedheaterand fresh_airunit, prepared

tube for heatercontro valve
2. CapiLlary
3. Heaierconro vaNe
4. Shuter,air venr Leftfloor
6. Shuner,leit defrosrernozzle
8. Rerurnspringfor vacuummotor
L Evaporatof (vehcleswirh
10.
IL
1 2 . Vacuum motor lor an in€ke cover
13,
15.
1 6 . Ar conditioningswnch
18.
1 9 . Shuiier, fghr air d!cr, rear tloor
20. Ar duct to rear rloor
2 1 . Knob, an nrake cover
22. Knob, defrosler shuiter
for installationof air conditioning.lt consistsof a cen-
tral unit 14, locatedunderthe dash,and air ducts and
nozzlesfor distributingthe ai. lo the various points
insidethe car.Allshuttersforaifdirectingare regulated
by vacuum,which istakenfrom the engineintakeman
ifold via a vacuum tank locatedon the firewall in the
engine compartment.
An elect c motor ( 13) locatedin the centlal unit takes
careof the air circulation.This motor is providedwith
a throughshaftand two turbinewheels 3. The cellular
assembly 12 of the heater system is placed in front
@
ol Ine elpclrromotor. Vehicleswrlh air conditoling
have the evaporator9 installedin front of the heater
system cellular assembly.
Thecombinedunit isoperatedby two knobsand three
push buttons placed on the conlrol panel.

Group85
46

Replacingturbinewheel,teft side
Central!nit, 16ftside
1 . Screwsror bortombfacker
2 , Screwsfor upperbracket
3. Upperscrewsfor supponlegs
Lowerscrewfor slppon eas
Disconnecrthe battery ground cabte.
Fold rhe tloor carperlo t1e one sde and ,emove
the sde panels fiom the cenrrat unir.
3. Bemovescrews 4 and 5 for lhe conrotptare sup-
pod legs on both sides,a.d nove the ptare as
lar bacl on the r.ansmrss,ontunnetasrheetectfic
4. Remove the alachi.g screw for lhe rear ool
arrduct so that the duct can bedisconnecredfrom
5. Removethe combinedinstrument(seeinstruc
tions,Section3).
6. Disconnectvacuum hosesfrom vacuum motors
for left defrosier oltler and teft ftoor outlet.
Removedefrosrernozzleand air duct to teft air
1 . Removethe ak hosebetweenthe centratunh and
the left, inner air outlet.
8. Removethe clampson the centratunit outer end
and remove the end:
Romoving clahps for outer red
I
CU heater
L Removethe rurbinewheellockingwith helpof
two screwdrivers.
Removefte turbine.
Removing
lo.kingfor turbin
t o Place the new tubine wheel on the shaft and
instal the locking.
1 1 . Installthe outer end and check at ihe same time
that the heater control vatve capi[ary tube wjrh
rubber grommet is propedy insta ed in the air
Placing clamps for outer end
12. Connectbatterygroundcabteand mak€a func_
13. Disconnecr the banerygroundcabte.
'14. Install
the air duct betweenthe centratunit and
15. Jnstall
the defrosternozzteandair ductandcor_
nect up the vacuumhose,
16. Installcombinedinstrument(see insrructions,
Section3).
17. Installrhe air duct to the rear ftoor.
18. Placetheconvolplateandsupporttegsin position
and screwtight the supporrtegs.
19. Putbacktheftoormatandinsra rhesidepanets.
20. Re-connect the batterygroundcabte.
Gtoup85
47
CU heatel

Replacingturbine wheel, right side 4. Remove the blower motor retalner:

1. Perform ponts 1 to 4 under"Repacing tuftine
wh€el,left side'.
2. Removeright slde paneL.insulationpafel, and

screwslor blowermotor ctainer

5. Disconnectthe coniact unit from the blower mo-

tor control and disconnectthe blower motor el-
panelsand qlovebox
Removing ectric wires from rhe contactunit and the control

3. Drsconnecrfte vdcLJm noseslroa vai uu- mo

t o r s l o ' n g h rd e f r o s r enr o z z l ed n d r i g h rr l o o ro u r
let. Removethe defrosrerno//e and lhe a dJLt
to ihe righi air outlet-
R e m o v ei h e d i r d u c rb e l w e e _l h e r e n l a l - n r t d n d
rhe right inside alr outlet.
5. Removethe clampson the centralunitouier end
and remove the end.
6. Remove rhe turbine wheel locking with help oi
two screwdriveG and remove the lurb ne.
L Place the new turbine wheel on the shaft and
install the Locking.
8. Install the outer end. Regardingthe location ol

g.
the clamps, see Fig. previous page.
Connectbattery ground cable and make a func
Removinq
defic €bles for @ntactunit
@(
10. Disconnectbattery ground cable.
11. Install the hose beiween central uft and nghl
6. Removethe rubber grommet and pull down the
lnner air outlet.
electricwiresthroughtherightopeningin the cen_
12. Installdefrosternozzleand air dLrct.Connectthe
7. L,h ouI rheb'owe' moror I h'ough Ihe bft opering.
13. Install glove box, nsulationpanel and right side
8. Placethe blower motor in posirionin the central
unit and sc.ew tight the retainer.
14. Performpoints 17 to 20 under"Replacingturblne
9. Pullthroughthe electricwires and installthe rub_
whee, left side .
'lO.
Connectthe elecvic wires to thecontact unit and
the control plate, also connect the contact unit
Replacing blower motor to the blower motor control.
11- Installthe inner left end and adjust in the heater
Op. No. 85400
control valve capillarytube.
1- Rernovethe right and left turbinesaccordingto
12. Insrallrhe turoi.e wheels according lo plevious
previous instuctions.
2. Move the heater control valve capillarytube to

3. RFmovethe lefl ,1ner eno lrom lhe cenral unil

Gnup 85
48
 CUheater

Removing cantral unit

Thepointsin brackstsapplyonlyto vehictes equipped
with air conditioning.
L Drainthe coolant.
2. Disconnect batterygroundcable.
3. R€movsthe heatersystems water hosesfrom
th€ joinl pipesin the firewall.andplugthe pipes:

Contrclp.nel rsveFsside
1. Connecrorfor vacuum ho*
2. Contactunit for blowermolor @ntrol

the hot wne (thickyellow)from the

16. Disconnect

i"",,*g 17. Separatethe connector1 for the vacuumhoses

Installingplugsin heatsrsystomconnocrion
pip€ and disconnectthe vacuumtank hosefrom rhe

{4). Bemove clampsfromthe hosesto the evaporator 18. Movethe controlplateas far backon the trans-
and removethe firewalldoor wilhouLloosening missiontunnelas the wires permit.
thehosestothe evaporator, 19. Removsthe screws,for the upper and lower
5. Removethe combin€dinstrument(seeinstruc- brackets,
from the firewallandthe transmissaon
tionq Section3),rheairhosebetwe€nthecenval
unit andthe lefr innerair vent alsothe vacuum 120)Disconnect the thermostatattachmenrFig.bel
hosesfrom vacuummotorsfor left defrosternoz- ow, from the centralunit.and both ctampsse-
zl€ and left floor outlet. cunngthe coverto the evaporaror.
6. Removethe left side panelfor the centralunk.
7. Foldthe floormatout of the way anddisconnecr
the rear floor air duct from the cenfialunit.
L Disconnectths joinr pipesfor the heatersystem's
war€r hoses from the firewall.
L Removethe upperand lower screwsfor the teft
support leg, and the screws for the upp€r and
lower bracke$, from firewall and transmission

NOTE:The screwsfor ths upperbrackstshouro

only be slackened a coupleof turns.
1O. Removethe right sidepanslfrom the centratunit.
11. Remov€right insulationpaneland gtovebox.
12. Rsmovethe rightsidedefroster j€! andthe hoss
from the central unit to right center jet.
13. Foldthe tloor caDetout of the way 6nddiscon-
nect the rear floor air duct,
I 4. B€movethe upperandlowerscrewsfor the .ight
supportleg,alsothe lower screwsfor th€ control

15. Disconnect the groundwires from the control

plateandthe conractunitfromtheblowermotor
control 2.

Group85
49
CU heatel

(21) Bemove the evEporatorfrorn rhe central unit 8. lnstall ihe turbine wheel and the ouler end.
whholt disconnecting any of the refrigerant Location of clamps is shown below:
hoses,and place lt at the right side of the cowl:

9. InstaI air hose betweencentralunir and right, in

Placingevapotatoron floor 10. Insralr ghr defrosternozzleand connectvacuum

22. Removethe centra unit right, outer end, tlrbine 11. I n s i aI g l o v e b o x .

wh€el and inner end. 12. Insialarr duct to rightair outet.
2 3 . C e n t r a l! n i t . 13. InstaI a; ducts for rear floor.
14. I n s t al a n h o s e r o t h el e f t i r n e r a l r o u n e t a nadc l j u s t
Installing central unit eftdefrosternozzleand connectits vacuumhose.
1 5 . l l s r a I t n e c o r b r e d I n s l r u r e r r( s F en s t r u c l i o n s ,
The points n brackeis.pply only to vehiclesequipped
w t h a l r c o n dt i o n i n g . Secrion 3).
1 . L i f t t h ec e n t r a l u n l t o n ttoh e r l g h tf l o o r ,a n di n s t a 16. Pur rhe connectionpiece of the vacuum hoses
lhe rubber seal for the a r intake. togetherand connectthe hosefrom the vacuum
Lift the centrE lnit into positlon and rnsertthe
left, upper bracketover lhe screws on the dash- 17. connect the hot wire (thickyellow)ro the blower
board. Installthe right bracketscrewsand t ghten moto. controlconract un t, and connectthe con-
lact unit to the control.
(3) Inslall the evaporatorin the cenlral unit. Put on 18. Connectgroundwies and screw tight instrument
lhe cover and secLrreit with the two clamps (1, plate and support legs.
Fig.),also the thermostaton the openings lower 1 9 . F o d b d c \ r l o o rm a r .I n s r a l l c o n r ' o l p a n e
nels and insulaton panels.
20. Connect the heater system water hoses to lhe
sde pa
D
4. Sealwithsea ingcompoundroundthe evaporator
connection pipes on the dashboard.
. pipes and the thermost;t cap lary if necessary. 1 2 r ) I n s r a l rl h e f i r p w a l ld o o r a n d c l a m p t h e r e t r q e r
5. Insiall the connectionppe for the heater hoses
1o the clashboard. ation hoses in the engine compartmeni.
6. InsraI the lower tlnnel bfackets and rhe drain 22. Fill coolant.
hose through the hole in the transmissiontunnel. 23. Re-connectbattery ground cable and function
7. Instal ihe rlghl. inner end .nd rhe vacuum hose
for the floor shltter.

Group85
50
Y

-l r^t
,L. '=- dI

I l'l:ll
Vacuuh moio. for air shutrerlo rearlloor

Replacing vacuum motor for central unit air in-

The insrru.tio_a s ppl ro r'emoved,e.ra u-,1

0 Lay-outdiasr.mfor vacuumcontrolsystem
1. Conrrolpane
1. Remove hose from vaculm moto..
2. Pry loose the vacuum motor outer plaslic lock,
see Fig. below. Removethe vacuum motor irom
the housing and remove the sprng.
3. Vacuummoior for reariool eft
4. VacLUmmororfor rear floor,righl
5. Vacuummotorfor tronr floor, eft
6. Vacuummotof tor front floor,.ighr
7. Vacuummotof ior defrosrer,leh
a. V:cuummotor lor defroster,righi
L Engne intakemanlold
10. CheckvaLve
11. Vacuum lank
12. Vacllm mororfor ar ntake cover

Replacing vacuum motor for rca r floor air shut-

0 1.
2.
Dlsconnectihe batiery ground cable.
Bemovethe side panelfor the centralunh, righi
or left dependingon the vacuummotor to be re-
I

3_ Bemovethe uppef and lower screwsforthe sup

0 port legsand lift the control plateto the one side.

Disconnectthe vacuum motor locking from the
shutter shaft and attachment(Fig.l and motor
3. Unhook the return spring from the a r shltter.
5 Transfer the hose to the new vacuum motor.
6 Place lhe vaculm motor in postion and install
7. Insiallthe controlplate,suppon legsand sidepa
8. Re connect battery ground cabe and flnction
Remove the shutter shaft locks (1, Fg. above).
Push ihe shutter towards one side to free one
end of the shaft.Then reieasethe other end. Pul
out air shutterwith vacuummotor from the hous
ins
Pry loose the vacuum motor inner plaslic ock.
n t h e a i r s h u t i e rR, e m o v e v a c u u m o t o ra n ds p r -
ing.

Group85
51
 6. Positionrhe sping and insialla new vacuummo- 3. Remove the air intake left shutter shaft lock.
tor in theaifshutter, see below. Usea new plastic 4. Removethe screws 3 for the inner end and lift

5. Bemovethe screws 4 for the blower motor re-

6. Drsconnecrthe ware' hoses tom rhe cell as

7. Removethe clamps fof the central unlts middle

joint, Liftofi the left half and rcmovethe cell as-

8. Placethe new cell assemblywith insulaiionin po-

shion in the right half of the central unit.

7. Posltion alr shutter with vacuum motor in the

ho-s:ag. l.serr rhe shutrF sl"dfi in the housing.
Install the shaft locks.
8. Hook on the air shutter return spring.
9, Positionthe spdng and installthe vacuum motor
in the housing. Use a new plastic lock.
10. Beconnectvacuum hose to the vacuum motor.

Heating system
Positioning
c€llas$mbly
Removing cell assembly
Op. No.
9 . Install the left half. For location of clamps, se€
HeaterCore,replace = 85404
HeaterCore,pressuretest and repair
(solder),heatercore removed = 45419
The instructionsapply to a removed cenval unit.
L Femovethe leh ouler end rurbinewheel{seepre-
viods instructions).
2. Unscrewthe tlvo left screwsfor the tunnelbrack

l@tion of clamps for middlo connetor

10. Instarrthe retainerfor the blowermoror.

11. Installtheinnerend, tubinewheeland outerend.
12. Installtheatt€chingscrewsfor thetunnelbracket.
13. lnstallthe shuttershaftlockingfor the air intake

Disassembling@nrral unit
t . Screws ior lowef brackel 3. Screws for innef end
2. Shutter shaft locking 4. Screws for bower motor

Group85
52
 CU heatel

Replacingh€atercontrolvalve 1. Remove central unit left side panel.

Op.No.85464 2. Unfold floor mat and put rags under the valve
to Protect against water spill.
3. Pull loosethe control valvefrcm the heaterhous-
ing. Use tongs to block the water hosesor dlain

4. Disconnectcable and sheath from the control

5. Disconnectthe capillarytube f.om th€ hearer

housing.Disconn€stthecoolanthosesatthe con-
trcl v6lve.Removeth€ valve.
6. Transferthe bmcketto the nsw valve.
7. Connectthe coolant hosesto the valve. Remove
rongs,
8. Connect cable and sheath to the valve. Adjusr

o 9. Install rhe control valve in the heater howihg.

Transferrubber seal. Installthe capillarytl]be in
2, Hearercontorvalv€
1 0 . Fill coolant,if d6ined, and check tightiess and

1l Fold bac\ the floor rnar. llsrall sde pane..

Group85
lnte or, Heating 53
Rumper

Group86

BumPers

The bumpercare mad6Inaluminumandprovid€dwitl

sttlps.
heavy,snergyalrsorblng-rubber
This bumpercanstanda baniertest ol 5 mph= I km/h,
fronl and rear.

Op. No,
85134= r.mM andiBtalllont bumper
86136= emowandi..n ll@rbump.r
86189 = replaceflDnt bump€rstrip,bunp€. r€mowd
86191 = €plae rcdrbumperstrip,bump€rFmovad
@06 = rcpla@frent bumpersh@k Eb3olb€r,bump€rr€-

@ = 6pl6c. Far bump€rshockab€o6€r.bumpd B-

Removing/ installingbumper
L Removethe retaining platss (4).
2. R€movethe nuts{2}for rh€ brackerand lift ofi

3. installationin opposite order.

Group86
54 Bumpers
 lmpact absorbers
The impact absorbeB contain gas and ftuid and arc
speedrelated. That means rhat the resisrancein-
creaseswiththespeed.
Thereby the whole impact abso.bing stroke can be
used also for low speed impacts.
The function is very much the same as for a com
bination of a spdng and a shock absorber.
When €ompressed,gas and fluid are forced throush
naiiow channels.The compressis dampedand at the Placethe impact absorberhorzonta y. To reteaserhe
same time the fluid comprcssesthe gas. When the gas. drill a hole 5/32 \4 td diam. approx. 1.06"
outside lorce is released,the sas expandsagain and {3O mm) from the end, as shown above.
p'essesrhp 'lLid ba.l .ro rrc bLrnperrelar s the on NOTE: Use safety glasseswhen dritttng.
ginal position.The fluid this way acts as a shock ab, A ' r q h o e s h a l e b e e r d r i l l e o c. l i t , n g . . 1 s a l e t ! b e
sorber and the gas as a spring.
Before scrapping,a damaged or otheNise replaced
The impact absorbers are partly gas filled and mpacl absorbershould be emptied by drittinghotes.
no welding on or close to them is permitted,
Heating mayexpand the gas to such an extent Replacing
that the impact absorbers are blown, L R e m o v et h e b u m p p .a s p t e v r o u s loy e s c r i b . d .
lJthorefore oxy-acetylene cutting must be per- 2. Removetwo retainingbolts 11)for rhe bracket.
formed to remove the impact absorbers, the
gas pressure should lirct be released.

There are two brands of impacr absorbersi

Fichtel & Sachs
Eoge

To release the gas pressurs,proceedas tottowsl

Fichtel & Sachs

io
.
3. Removerctainingbolt (3) in the side member. ti
. Placethe impactabsoberhorizontay. To retease
the is accessiblefrom inside the rrunk.

o gas,dill a hole1/32'{1 mm)diam.apwox.3/4,

(20 md from the end,as shown above.
Thendrillasecond hole,5/16"(8 mm)diam. approx.
7.5" (l9O mm) from the end.The hotesshoutoDe 4.
R e m o v e i m p a c t a b s o r bPeur .l l o f fr h e b r a c k e r a n o

NOTE:emptygas beforcscrapins.
Attach b€cket and spacerto the new impact ab
positioned 1800 opposite each other.
NOTE: Use safety glasseswhen dritting. 5. Positionthe impactabsorberandfit the boh from
the sademember.
6. Install bracket bohs.

NOTE:do not confusefront and rear impact ab-

sorbers.The r€ar ones have a shoner srroke.

Gtoup 86
Bumperc 55
Bumpermouldings

Removingand installing bumper Rear bumper

cover moulding Removesparetire and rear interiorpanel.
Pullloosethe mouldingends.They are retain€dby
Front bumper
Therubbercoveris rerained studs
by integralsnap-in Removeretaining nut both sides.
pull
When removing, out the moulding so thar the

Bs careful not to tsar off the studs.

l$ii.
Pullout rubbercover,completewilh retainingbars,
positionthe mouldingandpullin th€
Wheninstalling. Installationin oppositeorder.Ch€ckthat the retaaning
bar clips lock s€curely.
ifth€ studsarelubicatedwith
is facilitated
lnstallarion

Beplacingbumper {ace rubber mouldings

1. Removethe bolts retsiningthe bumperto rhe
bumpershockabsorber.
2. Lift oui the bumper.
3. Removethebarsretainingthe rubbermouldingq
from the bumperbar.
Disengage the rubbermouldings from the barc.
5. Installthenew rubbermouldings by foldingthem
over the retainingbars.
b6rsandrubbermould-
Installtheunitsketainjng
ings)to the bumper bar.
Use a small scr€wdriverto find the bolt holes.
7. Attachthe bumperbar to the bumpershockab-

Gtoup86
56 8umpe6
 l{atlonal
hstitlt€ for
tu0lt0l|vE
$mvlcE
CEU.EilGE

v0lv0 suPPonTs
vor.uilTARY
ITtECHAiltC
CEmtFtCATt0t{
BYTHEI{.I.A.S.E.