GTM Libra - Main build manual

to enable the retaining clip to work satisfactorily. Mount the door lock in a vice
and carefully saw the door lock barrel to increase the width of the notches to
approximately 4/5 mm. The door lock can now be assembled to the door shell
using the standard Rover Metro spring retainer.
Using the indentations of the outer side door shell, pilot the two Ø5mm
clearance holes required for the door handle and open out to Ø5mm
clearance. Using the door handle T0514 as a template, mark and drill a hole
approximately Ø28 mm to enable the door button to come through the outer
shell. The door handle T0514 and the door handle mechanism T0511/2 can
now be mounted to the door shell using two Ø5mm Nyloc nuts and washers.
Make sure that the door handle mechanism fits flush against the internal glass
fibre face of the door and if necessary clean the face up using production
paper.
Assemble the door button T0515 through the door button carrier T0513 using
a Ø6mm socket cap head screw 10mm long and a washer. The carrier can
now be mounted to the door handle mechanism and mounted to the door
using a Ø2mm split pin 35mm long. Do not turn the ends of the split pin at this
stage, as it will have to be removed in the assembly of the door rods. Check
at this stage that the door button swings in and out of the door freely without
binding.
Hold the door striker T0520 and move it in and out of the latch assembled to
the door and familiarise yourself with the working of the latch.
Take a 260mm long piece of the door rod wire T0523 and form a joggle at one
end to fit in the pawl that operates the door lock mechanism in the door latch.
Remove the three securing bolts from the door latch and remove it from the
door. Fit this joggle into the door lock pawl with the wire coming up through
the pawl away from the outer shell of the door. Refit the latch to the door.
Place the rod over the top of the outside key mechanism and mark the
position of the hole in the plastic lever arm of the door key mechanism. Again
remove the door latch mechanism from the door, remove the door rod and
form a right angle at the end as previously marked approximately 15mm long.
Reassemble and make sure everything works satisfactorily using a key from
the outside of the door and manually inserting the door striker.
Take a 280mm long piece of the door rod wire T0523 and form a joggle in the
end to fit into the pawl that operates the door latch. Remove the door latch
and fit this joggle into the pawl in a similar manner to the lock rod with the wire
coming up away from the outside face of the door. Reassemble the latch into
the door and very carefully mark the position of the required joggle that the
door button holder T0513. Make sure that the door button is in its most
outside point when you mark this position. Remove the wire and form another
joggle at right angles to the previous joggle to fit through the door button
carrier T0513.
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