SECTION 1A5 - FRONT & REAR

DOOR ASSEMBLIES

CAUTION:

This vehicle will be equipped with a Supplemental Restraint System (SRS). A SRS will consist of either

seat belt pre-tensioners and a driver's air bag, seat belt pre-tensioners and a driver's and front

passenger's air bag s or seat belt pre- tensio ners, d riv er’s and fron t p asseng er’s air bag and lef t and rig ht

hand side air bags. Refer to SAFETY PRECAUTIONS, Section 12M Supplemental Restraint System of

this Service Information CD before performing any service operation on, or around any SRS

components, the steering mechanism or wiring. Failure to follow the SAFETY PRECAUTIONS could

result in SRS deployment, resulting in possible personal injury or unnecessary SRS system repairs.

CAUTION:

This vehicle may be equipped with LPG (Liquefied Petroleum Gas). In the interests of safety, the LPG

fuel system should be isolated by turning 'OFF' the manual service valve and then draining the LPG

service lines, before any service work is carried out on the vehicle. Refer to the LPG leaflet included with

the Owner's Handbook for details or the appropriate Section of this Service Information for more

specific servicing information.

1. GENERAL INFORMATION

Since the VT Series Service Information CD was

first published, there have been revisions made to

the following components / procedures for front

and rear door assemblies:

The removal of the exterior rear view mirror

assembly has been revised.

Service replacem ent com ponents for the f ront door

lock exterior handle and lock cylinder assem bly are

supplied as single components (in lieu of an

assembly). To complement this change, a

procedure has been developed to assemble and

disassemble the assembly.

The left and right hand rear door wiring harness

connectors have been changed to a new type of

connector. With the introduction of this new

connector, it is unnecessary to have to use Tool

No. AU455 to remove the connector from the B

pillar. Once the grommet on the B pillar has been

removed, the wiring harness and connector can

simply be extracted for access or disconnection.

The front door check link mounting was revised;

the hinge at the A pillar is now attac hed by to bolts

and the check link as s embly is attached to the door

by two nuts.

Whenever reinstalling a door check link, ensure the

attaching bolts and nuts are tightened to the correct

torque specification.

DOOR CHECK LINK ATTACHING

BOLT AND NUT 10 - 12 Nm

TORQUE SPECIFICATION

The Service Operations for revisions 1 and 2 are

detailed in this Section. All other front and rear door

assembly Service Operations for VT Series and VT

Series II Models carry over from those detailed in

Section 1A5 FRONT & REAR DOOR

ASSEMBLIES of this Service Information CD.

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2. SERVICE OPERATIONS

2.1 EXTERIOR REAR VISION MIRROR

REMOVE

1. Disconnect battery earth lead.

2. Remove the mirror inner cover cap (1) by

gently prying the cap away from the door.

NOTE: The inner cover cap retaining clip (3) can

only be used once.

3. Remove door inner trim panel (2), refer to

Section 1A5 FRONT & REAR DOOR

ASSEMBLIES of this Service Information CD.

Figure 1A5-1

4. Remove the three screws (2) securing the

exterior rear view mirror (1) to the door and,

while supporting the mirror, disconnect the

mirror wiring harness connector (3).

Figure 1A5-2

REINSTALL

Reinstallation of the ex ter ior r ear view mirror as s embly

is the reverse of the removal procedure, noting the

following:

1. Ensure the wiring harness connector for the

exterior rear view mirror is routed correctly.

2. Ensure the exterior rear view mirror to door

securing screws are tightened to the correct

torque specification.

EXTERIOR REAR VIEW MIRROR

TO DOOR SECURING SCREW 2.5 - 3.0 Nm

TORQUE SPECIFICATION

3. Install mir ro r inner c over c ap us ing a new retaining

clip.

NOTE: If the mirror inner cover cap is removed, its

retaining clip will have a reduced tension, therefore,

offering insufficient retention if it is reused.

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2.2FRONT DOOR EXTERIOR HANDLE AND LOCK CYLINDER ASSEMBLY

DISASSEMBLY

1. Remove the f ront door exterior handle and lock

assembly, refer 1A5 FRONT AND REAR

DOOR ASSEMBLIES of this Service

Information CD.

2. Using a small screwdriver, gently prise the

retaining clip (20) away from the door handle

bracket assembly (1) and remove the security

shield (19).

3. Using a small screwdriver, gently prise the

microswitch retaining clip (18) away from the

door handle bracket assembly (1).

T21A5001

19 20

Figure 1A5-3

4. Slide the microswitch wiring harness connector

(22) off the connector retaining bracket and

feed the wiring harness out from under the

bracket assembly retainer (23) .

T21A5002

Figure 1A5-4

5. Using a small flat bladed screwdriver, push the

two microswitch contacts in and remove the

microswitch assembly.

T21A5003

Figure 1A5-5

6. Remove the circlip (2) and slide the cam

control, clips and springs (3, 4, 5, 6, 7 & 8)

away from lock assembly.

T21A5004

Figure 1A5-6

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7. Using a suitable pier of pliers, pull the roll pin

(9) out of the door handle bracket assembly.

T21A5005

Figure 1A5-7

8. Rotate lock housing anti-clock wise and rem ove

decorative housing, lock housing, O-ring, lock

assem bly, lock assem b ly sleeve, retaining balls

(two places) and coupling (10, 11, 12, 13, 14,

15 & 16) from the door handle bracket

assembly (1).

T21A5006

16 14

13 12

Figure 1A5-8

REASSEMBLY

Reassembly of the front door exterior handle and

lock assembly is the reverse of the removal

procedure, noting the following:

1. The Holden Service Parts Operations

departm ent supplies service k its with un-coded

lock cylinders to facilitate re-coding of the lock

cylinder to match the original key.

Holden Ltd. recommends lock cylinder

overhaul and re-coding be performed by a

qualified locksmith, and should be sublet.

2. To assist assembly of the front door exterior

handle and lock assembly, the following figure

shows an exploded view of the assembly.

Figure 1A5-9

1. Exterior Door Handle Bracket 8. Roller 15. Coupling

2. Circlip 9. Roll Pin 16. Retaining Balls

3. Cam Control 10. Lock Housing 17. Microswitch Assembly

4. Spring 11. Decorative Housing 18. Retaining Clip

5. Clip 12. O-Ring 19. Security Shield

6. Push Spring 13. Cylinder Lock Assembly 20. Retaining Clip

7. Push Spring 14. Cylinder Lock Sleeve 21. Connector Retaining Bracket