Body - Replacement Parts Modifications

MODEL
700

GROUP
80

NUMBER
906

TITLE
REPLACEMENT PARTS MODIFICATIONS
780 ALL

MARKET
US and Canada

DATE
May 1993

REFERENCE:
TP 31017/1 (ENGLISH); 12/86; INTERIOR FITTINGS, GLASS, 780

Replacement parts modifications, 780

Some parts are stocked only in the latest version and must be modified to fit earlier cars.

In addition, a number of parts common to the 700/900 and 780 require modification as described below for installation in the 780.

The components are:

- side doors
- front fender liner
- seat mounting cover (rear part)
- parcel shelf with child seat tether strap attachment
- antenna cover
- rear trim panel (between rear lights) on cars with ABS modulator in luggage compartment
- fuel filler cover plunger

Modification of side door

The clearance between the weatherstrip and window must be correct to ensure correct window travel speed. The window may stick if the clearance is too small. When replacing a side door, the weatherstrip flange should normally be bent slightly. However, if the flange is straight when the door is delivered, the correct alignment can be achieved by bending it outward as follows:





Between points A and C, the bend should increase from 0 to 3 mm.
Between points C and D, the bend should be 3 mm
Between points D and F, the bend should decrease from 3 to 0 mm.

Modification of fender liner

When replacing a fender liner, the front edge of the component should be modified to seat against the bumper.





The upper of the three front catches should be cut off and the two lower catches cut as indicated by the shaded areas in the illustration.

The bottom corner at the bumper should be cut as indicated by the shaded area in the illustration to seat against the fender and bumper.

Seat mounting cover (rear part)





The original two-part cover has now been replaced by a new, single-part cover mounted with two screws. The original mounting point remains and a new point has been added i the bottom rail. A hole for fitting a plastic clip is provided in the bottom rail between the seat belt attachment points.


The following components are required to install the new cover:

Plastic clip p/n 1318908-9
Screw p/n 969476-1
Plain washer p/n 940090-4

Cutting holes in parcel shelf for child seat tether strap attachment





Mark off the hole positions as illustrated. Cut 11 mm dia. (7/16") holes using a tapered hole cutter. The illustration shows the holes at the left and center of the shelf for the child seat tether strap. The dimensions for the right-hand side are identical.

Modification of antenna cover





Certain sections of the antenna cover must be cut away to modify the component to suit the 780. If the original cover is available, it may be placed on top of the new cover as a template for marking out the sections to be cut. Otherwise, the dimensions of the cut-outs are as shown in the illustration.

Modification of rear trim panel (between rear lights)





The panel must be modified on the right-hand side on cars with the ABS modulator installed in the luggage compartment. Mark off and cut the panel as indicated by dimensions and shaded section in the illustration. The illustration shows the panel as seen from the rear of the vehicle.

Modification of fuel filler cover opener





The earlier type of spring-loaded opener has been discontinued and replaced by rubber stops. If replacement becomes necessary, replace both openers and transfer hinge spring (A) to the hole behind the hinge mounting (B).

The rubber stops, p/n 3510865-3, and spring, p/n 3510767-1, are included in a repair kit, p/n 3407215-7.





WARRANTY STATEMENT: Claims may be submitted under the New Car Limited Warranty when a manufacturing defect is present using claim type: 01.