Replacing Lock Barrels - Fiat Scudo

Fiat Scudo JTD 2.0 2001

Tools & Parts:

-New barrel locks - https://bit.ly/3e7pKoJ

-T15 & T30 Torx screw bits

-1 Philips & 1 Crosshead screwdriver or something similar (To help push out old barrel from lock and pry off the door panels.)

-Stanley knife

-Universal super glue

-Telescope magnet (Not a must, but helpful).

Process:

Section 1 : Driver & passenger doors

Section 2 : Rear door

Section 3 : Side doors

Section 1 : Driver & Passenger's Doors

First we will start with the drivers and passengers doors.

Prise off the Stereo Cover. It is held in by plastic clips, so be careful not to break them (Or too many of them) or damage the speaker behind it.

Undo the three T15 screws 

Undo the four screws (mine were T15 screws) holding your speaker into the door and unclip any wiring which is attached to it, as the speaker needs to be completely taken out. The top right screw may be longer T30 screw. (Tip: stick some tape on the positive wire and terminal, so you know which cable goes where when you put the speaker back in.) 

Next undo the three T30 screws, slightly tucked away in the door pocket.

Pull off the window handle.

And take off the mirror adjustor rubber housing.

Loosen the screw for the mirror adjuster. The screw is at some weird angle. On my drivers side I didn't seem to have one and on the passengers side I didn't have a small enough Torx screwdriver to fit in the hole. So I just pulled out the adjuster once I got the panel off the door. And then later I was able to undo the screw slightly, to help get the adjuster back in for re-assembly.

Now with the help of a Philips/Flat head screw driver pop the plastic cover off the door (My doors just popped off, but if your door has never been taken off before there might be something else holding it in place, which might have snapped/broken off mine perviously).

There was about 5 places where the panel was popped into.

Maybe more plugs, which have broken off my door

With your Stanley knife separate the foam cover which is glued to the metal door frame. You don't need to take off too much, just enough so you can see/get your hands in.

Next with a screwdriver lift out the metal pin from it's housing. Once removed the pin should sit behind the housing (Closer to you.)

Then with your T30 undo the two screws inside the door holding the door handle on. You can use a telescope magnet to help get the screws out once you've unscrewed them.

With the screws out, it's now time to try and get the handle off. There are 3 clips underneath the handle helping to hold it in place. To get the handle out can take a bit of patience and wiggling.

Next you need to unclip and remove the metal pole from the back of the exterior handle. 

(remember how you did it, for reassembling purposes.) 

 

Once you have the handle out it's time to remove the barrel. First look at the rear of the barrel and take note how the rear of the barrel sits in the handle mechanism, as the new barrel needs to go in the same way.

For the next part, I found it useful to use the Philips/flat head & a Crosshead screwdriver. You need to push the barrel clip back into the barrel housing (Use Crosshead) and at the same time use the Philips screw driver to push the barrel down out out of the handle, It takes quite a bit of strength to get it out.

Once the barrel has disengaged from the housing, it should just pull out. 

Once the barrel is out, just pop off the front plastic cover and put it on your new barrel lock. (For me this applied to all the locks on the van, bar the rear door, where the plastic covered supplied on the new barrel matched the old one).

Also the plastic covers will only go on one way, so make sure to aline the indents on the cover to the barrel.

Now it's just time to push the new barrel into the handle housing, making sure the rear of the barrel alines with the handle housing mechanism. Make sure the barrel is completely in.

Next it's the fun task of trying to get the handle back into the door, unfortunately I didn't find a knack of doing it, but persistence seems to be the key. 

First replace the metal pole back into the door handle and then try and clip the handle back flush into the door. Good luck!!

Once it's in, screw back in the 2 T30 screws and put the metal pin back into the black housing of the door handle. 

Next superglue the foam cover back onto the door. 

Then it's a case of putting the plastic inside door panel on, making sure you insert the mirror adjuster and inside door lock first and then pop the panel back on and screw the screws back in and reattach your speaker and cover. 

Now it's time to test out your new lock!!!

Section 2 : Rear door

Next we will do the rear door and this is equally as tricky. As my van has been altered into a camper the panels on your van will probably be different, but taking out the mechanism should be the same.

First pop off the plastic inside handle cover.

Then remove what ever panel you have on your van.

(With this plastic cover off I was able to fully remove the dark painted wooden panel, not sure if this panel is original or aftermarket) 

Then slide left the inside door handle and take it out of it's housing, it will then need to be turned anti-clock wise into a vertical position so you can detach it from the metal rod.

Next take the three plastic screw covers out of the door. 

Then with your T30 screwdriver and the help of the telescope magnet, undo and remove the three screws into the van door holding the handle on. Be extremely careful not to let the screws fall down into the door!!! 

Before you can take out the handle from the housing, you need to also undo the three T30 screws holding the latching mechanism. 

Once they are all removed the handle and the lock mechanism should come out of the door. Just remember how everything comes out to help you when it comes to putting it back in.

From here it is the same procedure to remove the barrel lock as the driver & passenger ones, although I found the the plastic barrel cover on the new barrels fitted, so I didn't need to swap them over.

Once you have changed the lock, re-insert the latch mechanism and the handle and first screw in the latch mechanism, but making sure the metal rod for the inside handle is back in it correct location for re-attaching later. Screw the latch back in and the exterior handle, re-attach the interior handle, reattach metal pole to interior handle and put back all your panelling. Then pop the interior handle cover back on.

Section 3 : Side/Loading Doors

These doors are the easiest to do, so best to do them last so you end the job on a high!! (In theory!!)

Undo the six T15 screws holding the plastic cover onto the door and the T15 screw hold the plastic latch handle on. Once they are undone the panel should simply just come off.

Then you need to unclip the three black clips from the three metal rods and then slide the rod out of the holes. Remember where each one goes and which hole in the door they are threaded through. 

Once the rods/poles are removed, Unscrew the two T30 screws holding the handle into the door.

Remove the handle from the door, leaving the metal pole/rods attached.

Then it's just a case of replacing the barrel lock, changing over the plastic barrel covers and then fitting it all back together again!!!

I hope this is some help to people out there. Please leave any comments if you feel I've got something wrong, could improve the process or found it useful! 
Thanks a lot :)