Page 620 of 873

70BRAKES
18
REPAIR SENSORS - FRONT
Service repair no - 70.65.32
CAUTION: If a sensor is removed for any
reason, a NEW sensor bush and seal must
be fitted.
Remove
1.Disconnect battery negative lead.
2.Disconnect required sensor electrical
connection, located on inner wing [fender] panel.
3.Remove sensor lead from clips.
4.Clean area surrounding sensor to prevent
ingress of dirt. Using a suitable lever pry sensor
from mounting bush.
5.Release harness cable ties, remove sensor lead
from vehicle.
6.Remove top swivel retaining bolts complete with
brake jump hose and sensor seal. Remove
sensor bush.
Refit
7.Insert new sensor bush and seal.
8.Refit brake jump hose bracket, coat bolts with
Loctite 270.
9.Lightly coat new sensor using EP 90 oil. Push
sensor through bush until it contacts exciter ring.
Sensor will be 'knocked back' to correct position
when vehicle is driven.
10.Secure sensor lead in original position.
11.Reconnect sensor electrical connection.
12.Drive vehicle to ensure ABS warning light is
extinguished.
SENSOR RINGS
The rear sensor ring is assembled to the rear brake
disc to form part of the rear hub assembly.
See
REAR AXLE AND FINAL DRIVE, Repair, Rear Hub
Assembly
The front sensor ring is a toothed ring on the axle
shaft which forms part of the front stub axle assembly.
See FRONT AXLE AND FINAL DRIVE, Overhaul,
Front Stub Axle, Constant Velocity Joint and
Swivel Pin Housing ABS
Page 621 of 873

BRAKES
19
REPAIR SENSORS - REAR
Service repair no - 70.65.31
CAUTION: If a sensor is removed for any
reason, a NEW sensor bush must be fitted.
Remove
1.Disconnect battery negative lead.
2.Disconnect sensor electrical connections,
located above rear axle.
3.Remove sensor from its locating clip.
4.Remove bolts securing mudshield.
5.Using a suitable lever, pry sensor from mounting
bush.
6.Release harness cable ties, remove sensor lead
from vehicle.
7.Remove sensor bush.
Refit
8.Fit new sensor bush.
9.Lightly grease new sensor using silicone grease.
See LUBRICANTS, FLUIDS AND
CAPACITIES, Information, Recommended
Lubricants and Fluids
10.Push sensor through bush until it touches exciter
ring. Sensor will be 'knocked back' to correct
position when vehicle is driven.
11.Secure harness in position.
12.Reconnect sensor electrical connection.
13.Drive vehicle to ensure ABS warning light is
extinguished.STOP LIGHT SWITCH ABS
Service repair no - 86.65.51
Remove
1.Turn ignition off. Disconnect battery negative
lead.
2.Remove lower trim panel.
3.Disconnect multiplug to switch.
4.Depress brake pedal access front of switch.
5.Pull sleeve and plunger of switch FULLY
forward.
6.Remove switch rearwards
NOTE: If switch is difficult to release,
check sleeve is FULLY forward.
Refit
7.Pull sleeve and plunger of switch fully forward.
8.Depress brake pedal, fit switch. Ensure retaining
clips are FULLY located.
9.Hold switch firmly in place, pull brake pedal back
fully to set switch.
10.Reconnect battery and turn ignition on.
11.Check switch operation by slowly depressing
brake pedal and checking that the switch clicks
twice.
12.Check stop lamps go off when pedal is released.
13.Recheck switch is securely fitted.
14.Operation may be checked using Testbook.
Page 622 of 873
70BRAKES
20
REPAIR STOP LIGHT SWITCH - NON ABS
Service repair no - 86.65.51
Remove
1.Disconnect battery negative lead.
2.Remove lower dash panel.
3.Depress foot brake.
4.Remove rubber protector from switch, if fitted.
5.Remove hexagon nut.
6.Withdraw switch.
7.Disconnect electrical leads.
Adjust
8.With switch still in position and multiplug
disconnected, connect an ohmmeter across
switch terminals.
9.Screw switch in until open circuit exists across
terminals with pedal released and continuity
exists as soon as pedal is depressed.
10.Tighten locknut.
CAUTION: Ensure switch does not prevent
brake pedal returning fully.
Refit
11.Reverse removal procedure.
Page 635 of 873

74WHEELS AND TYRES
6
REPAIR WHEELS
Remove
WARNING: The parking brake acts on
transmission, not rear wheels, and may
not hold vehicle when jacking unless
following procedure is used. If one front wheel
and one rear wheel is raised no vehicle holding or
braking effect is possible. Wheels MUST be
chocked in all circumstances.
Apply parking brake, select 'P' or a gear in main
gearbox and engage low gear in transfer box.
1.Loosen five wheel nuts.
2.Using a suitable trolley jack raise vehicle and
place on axle stands.
See INTRODUCTION,
Information, Jacking
3.Remove wheel nuts and carefully withdraw
wheel over studs.Refit
4.Ensure that retaining studs and nuts are clean.
5.Alloy wheels: Lightly coat wheel mounting spigot
face with a suitable anti-seize compound to
minimise possibility of adhesion between wheel
and spigot face.
6.Refit wheel taking care not to damage stud
threads. (Do not apply oil)
7.Fit wheel nuts and turn by hand for at least three
full threads before using any form of wheel
wrench.
8.Tighten nuts as much as possible using a
suitable wrench.
9.Lower vehicle and finally tighten nuts to correct
torque sequence shown. Alloy wheels and steel
wheels:
130Nm.
Page 711 of 873
76CHASSIS AND BODY
44
REPAIR
7.Remove centre console switch pack cover.
8.Remove 4 screws securing switch pack to
console.
9.Release switch pack from console and
disconnect 7 multiplugs.
NOTE: If the 'Cold Pack' option is not fitted
there will only be 5 switches in pack.
10.Remove switch pack.
Models fitted with electric front seats
11.Release electric front seat switches from centre
console.
12.Disconnect 2 multiplugs from each switch.
13.Remove switches.All models
14.Release hand brake lever gaiter from centre
console.
15.Remove clip and clevis pin securing cable to
hand brake lever.
16.Remove 4 screws securing centre console to
body.
17.Raise hand brake lever, pull centre console
rearwards to gain access to cigar lighter
multiplug and illumination bulb Lucar.
18.Disconnect cigar lighter multiplug and
illumination bulb Lucar.
19.Remove centre console assembly.
Page 712 of 873

CHASSIS AND BODY
45
REPAIR Refit
20.Position centre console assembly, ensuring
harnesses and connectors are not trapped and
are routed to their correct locations.
21.Connect cigar lighter multiplug and illumination
bulb Lucar.
22.Align centre console to body fixings and fascia.
23.Fit and tighten screws securing centre console to
body.
24.Lubricate hand brake lever to cable clevis pin.
25.Align hand brake cable to lever, fit clevis pin and
secure with clip.
26.Secure hand brake lever gaiter to centre
console.
Models fitted with electric front seats
27.Position electric front seat switches,connect
multiplugs and secure to centre console.
All models
28.Position centre console switch pack and connect
multiplugs to switches.
29.Align switch pack to centre console and secure
with screws.
30.Fit centre console switch pack cover.
31.Fit centre console rubber mat.
32.Fit gear selector lever knob and secure gaiter.
33.Fit transfer gear lever knob and secure gaiter.
34.Reconnect battery earth lead.DRINKS TRAY
Service repair no - 76.46.41
Remove
1.Disconnect battery negative lead.
2.Remove ash tray.
See ash tray - dash panel
central louvre panel.
3.Remove switch pack.See switch pack - dash
panel central louvre panel.
4.Remove 6 screws securing drinks tray to dash
panel central louvre panel.
5.Remove drinks tray.
Refit
6.Position drinks tray to dash panel central louvre
panel and secure with screws.
7.Fit switch pack.
See switch pack - dash panel
central louvre panel.
8.Fit ash tray.See ash tray - dash panel central
louvre panel.
9.Connect battery negative lead.
Page 821 of 873

ELECTRICAL
1
REPAIR FUSE BOX - INTERIOR
Right Hand Drive shown
The interior fusebox is fitted below the steering column, behind the trim panel. It comprises of three integral units.
'A'Main fusebox,'B'Satellite 2,'C'Satellite 1.
A label in the fusebox cover shows the circuits protected, the fuse rating and their locations. Access is by
releasing the fixing screws and lowering the panel.
'A' Main fusebox
1. Stop lights, direction indicators
2. LH side light
3. Radio/cassette/CD player
4. RH headlight main beam
5. LH headlight main beam
6. Cigar lighter
7. Airbag SRS
8. RH side lights
9. Rear fog guard lights
10. RH headlight dipped beam
11. LH headlight dipped beam
12. Multi-function unit
13. Ignition feed for Multi-function unit
14. Instruments, reversing lights
15. Air conditioning, windows
16. Washers & wipers - front
17. Starter, glow plug
18. Wash/wipe - rear, mirrors, cruise control
'B' Satellite 2
1. Electric windows - front
2. Electric windows - rear
3. Anti-lock braking
4. Central door locking
5. Electric sun roof
6. Trailer lights
'C' Satellite 1
1. Anti-theft alarm
2. Headlight washers
3. Engine management
4. Anti-lock brakes
5. Anti-theft alarm
6. Rear air conditioning, heater
'D' Spare fuses (5 off)
Page 854 of 873
86ELECTRICAL
34
REPAIR PRINTED CIRCUIT AND WARNING LIGHTS
1. Panel illumination bulbs
2. Transmission oil temperature warning lamp bulb
3. Hazard warning lamp bulb
4. Check engine warning lamp bulb
5. Handbrake/brake fluid warning lamp bulb
6. ABS warning lamp bulb
7. Headlamp main beam warning lamp bulb
8. Trailer direction warning lamp bulb9. Direction indicator warning lamp bulb
10. Air suspension warning lamp bulb
11. Ignition/no charge warning lamp bulb
12. Seat belt warning lamp bulb
13. Not used
14. Traction control warning lamp bulb
15. Diesel heater plug warning lamp bulb (if fitted)
16. Main printed circuit
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