How to change door lock barrel on Alfa 145
1. First remove the door interior and then the clip holding the doorlock. You then have to prise the white plastic arm off the door lock. This is a ball and socket fitting so a little force is required. Now you can work on a bench. http://i45.photobucket.com/albums/f1...lock/Pict1.jpg
2. Now gently heat the plastic sleeve and using a precision screwdriver either side, lift the plastic over the metal stops and pull off. http://i45.photobucket.com/albums/f1...lock/Pict2.jpg
3. Using a very small precision screwdriver remove the circlip holding the barrel to the body and then pull the barrel out of the body. http://i45.photobucket.com/albums/f1...lock/Pict3.jpg
4. The 2 dogs on the end of my barrel had broken off and these turn the plastic body. http://i45.photobucket.com/albums/f1...lock/Pict5.jpg
Do the same procedure with the donor doorlock. These are handed so you have to change like for like ie. Driverís side for driverís side. http://i45.photobucket.com/albums/f1...lock/Pict6.jpg
5. Now using a precision screwdriver and a hammer, gently take the indents out of the cap that holds the lock together. There are about 4 of these around the cap, support the barrel on a piece of wood when you it. http://i45.photobucket.com/albums/f1...lock/Pict7.jpg
6. Take the cap off gently and look after the lock guard and spring mechanism. Do the same for the donor unit but keep everything separate. http://i45.photobucket.com/albums/f1...lock/Pict8.jpg
7. Now the tricky bit!!! On the donor unit, pull the rectangular brass pin out of the body and you can then remove all of the tumblers. Make sure that you do NOT lose any of the very small springs the work on the tumblers. There are 5 springs each side. http://i45.photobucket.com/albums/f1...lock/Pict9.jpg http://i45.photobucket.com/albums/f1...ock/Pict10.jpg
8. Now remove the brass pin from the damaged unit and take the tumblers out one at a time and put them in the corresponding position in the donor unit. Do this until all the tumblers have been changed over. Now hold all the tumblers down and slide the pin back in. Check that the key goes in and will turn when the barrel is in the body.
9. If all is fine, put the spring back in and then put the lock cover back on with the spring arm underneath. You will have to hold this down and then put the lock cover back on. I had someone hold the lock cover with a small precision screwdriver whilst I put the cap back on.
10. Now using a screwdriver or punch indent the cap onto the barrel. Check that fits and is smooth all the way around. Slide it back into the lock body and check that everything turns with the key.
11. Now put the circlip back in and then position the centre detent spring back on so that the lock keyslot is always vertical. http://i45.photobucket.com/albums/f1...lock/Pict4.jpg
12. Now push the plastic body back on, it can only go on one way. Check with the key that everything works and then refit to the car.