Chapter 1 Routine maintenance and servicing

Bodywork and fittings 11•1327.3 Tailgate lock retention arrangementA Lock barrel retainer securing boltB Lock barrel retainerretainer to the tailgate, then withdraw theretainer (see illustration).4 Remove the lock assembly from the tailgateby partially withdrawing the lock, twisting it sothat the lock rod can be removed, then fullywithdrawing.Refitting5 To refit, first ensure that the lock gasket isin position, then partially insert the lock intothe tailgate and reconnect the lock rod. Fullyinsert the lock and refit its retainer andsecuring bolt.6 Using an electrician’s thin screwdriver,prise up the lever on the latch and fit the lockrod to it, ensuring that it fully engages.7 Align the latch with its location and refit itstwo securing screws.8 Check for correct lock operation beforerefitting the tailgate interior trim panel asdescribed in Section 26.28 Rear doors (Courier models)- removal and refitting1Removal1 Open the door and disconnect the wiringleading to it; all connectors are accessiblefrom the openings inside the door frame.28.2 Unscrewing the bottom hinge’s capsecuring bolt on Courier rear door2 Unclip the door check arm, and unscrewthe bottom hinge’s cap securing bolt (seeillustration).3 Lift the door off its hinges and withdraw it.Refitting4 Refitting is the reverse of the removalprocedure; apply grease to the hinge pins,and tighten the cap bolt securely.5 The door hinges can be unbolted from thedoor and frame; either remove the door first,or support it carefully and remove the hingewith it in place.29 Rear door inner trim panels(Courier models) -removal and refitting1Removal1 Remove the interior handle bezel bypushing it away from the door’s hinges until itcan be withdrawn.2 Using either a trim clip releasing tool or ascrewdriver with a broad flat blade, andprotecting the paintwork and trim with a layerof rag, extract the clips securing the panel andwithdraw it.Refitting3 Refitting is the reverse of the removalprocedure.30.2a Courier rear door latch assemblyretaining screws (arrowed)30 Rear door lock, catches andhandles (Courier models) -removal and refitting1Interior handleRemoval1 Remove the inner trim panel, as describedin Section 29.2 Remove its four retaining screws, andwithdraw the complete latch assembly (seeillustrations).3 Disconnect the link rod and remove thesingle retaining screw to withdraw the interiorhandle.Refitting4 Refitting is the reverse of the removalprocedure.Exterior handle and lockassemblyRemoval5 Remove the inner trim panel, as describedin Section 29.6 Remove its four retaining screws, andwithdraw the complete latch assembly.7 Using pliers, rotate the exterior handlelocking ring anti-clockwise to release it, thenwithdraw the handle with the inner and outergaskets (see illustrations).8 The lock assembly is secured by a circlip tothe handle.1130.2b Latch assembly released -disconnect cables to withdraw30.7a Release locking ring and withdrawgaskets . . .30.7b . . . to release Courier rear doorexterior handle1595Ford Fiesta Remake