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Next, we want to fit and test the inner handle but since that goes over (in a Pallas at least) the upper upholstery section, that needs fitting first.
My upper trim is leather and clearly has shrunk slightly. Plus, the foam padding had turned into powder. So, I refilled it with 5mm foam sheet. In retrospect, although nicely padded, 3mm would have made everything much easier!
The top of the trim section is secured to the very top of the inner door by a steel plate with 7 flat headed screws. There is very little material beyond the holes for the screws, so go carefully.
The plate will get covered by a stainless trim, so has to be put on the correct way, hopefully shown here.
Next, the upholstered section must be secured at its lower edge, by a stainless steel finisher, again held with flat headed screws. This also acts as the holder for the top of the door card
The rearmost screw can foul against the door catch mechanism (front door only) and so needs to be short.
You can see the distortion of the leather over the holes for the inner handle due to the XS thickness of the foam filling. In this case, less would have been better!
Next is the difficult job of fitting the inner handle. It must be inserted vertically, getting the flange beyond the inner door skin and then rotated to secure. In addition, the long rod from the catch need to go through the lever. Quite tricky. An alternative method is to get the handle fitted and then fit the loose long rod and finally refit the other end to the catch mechanism. I tried it both ways and either seems fine.
Now test the handle works. The back part of the handle is fixed by a kind of captive screw and require some jiggling back and forth with the handle plate to get it aligned and therefore to work
My front doors had the long rod fixed with a set screw and the rears with grub screws, so presumably, fouling can occur in certain circumstances.
If your doors are like mine, also check the rear inner handles are able to lock the catch from within and yet are disabled by the child lock lever. IN my car, the built in inner handle ‘lock buttons’ serve no purpose.So, the first step is to fit the door catch mechanism. These are sided and either front or back, not least because the front will have the key lock part. My rear catches also have the function to lock from within the car plus a built in child lock.
There is no adjustment in the position for these catches but is is quite easy to not get them seated properly.
Once the mechanism is in, it is possible to check the door shuts and can be opened by pulling either the short rod which goes to the outer handle or the longer rod for the inner handle. Final door alignment also checked at this point.
Next the outer handle is fitted. This has an inner plate fitted top down. Feed the handle arm over the short rod as the handle is fitted then tighten the securing nuts and washers over the inner plate (10mm socket)
To set the position, trigger the door closing cam (but dont close the door!) and then tighten the set screw (8mm socket)to fix the rod. Handle should now work.
In addition, the door can now be easily removed and refitted but loosening the bottom hinge screw (a v long screw driver is great for this, about 45cm) and, whilst holding the door, release by opening the handle. Adie Pease has a nice video showing this https://youtu.be/vnw1l-4fDX0?si=SMUxk7UBTuA4hehm
Fit the lock on the front doors – a sliding clip on the inside secures it.
Check everything works.Nope. The crank access was too much of an angle to confidently dock with the screw.
Zip access also no good because of angles.In the end, I went with the obvious and direct route – straight through the radiator cowl in line with the regulator.
Just need to remove spare wheel etc. Works well.
