Page 426 of 455

ELECTRICAL
1
REPAIR ELECTRICAL PRECAUTIONS
The following guidelines are intended to ensure the
safety of the operator whilst preventing damage to
electrical and electronic components fitted to the
vehicle.
Polarity
Never reverse connect the vehicle battery and always
observe the correct polarity when connecting test
equipment.
High voltage circuits
WARNING: Before commencing work on
an ignition system, all high tension
terminals, adaptors and diagnostic
equipment for testing should be inspected to
ensure that they are adequately insulated and
shielded to prevent accidental personal contacts
and minimize the risk of shock. Wearers of
surgically implanted pacemaker devices should
not be in close proximity to ignition circuits or
diagnostic equipment.
Whenever disconnecting live high tension circuits
always use insulated pliers and never allow the open
end of a high tension lead to come into contact with
other components particularly electronic control units.
Exercise caution when measuring the voltage on the
coil terminals while the engine is running, since, high
voltage spikes can occur on these terminals.
Connectors and harness
Always ensure that these items are dry and oil free
before disconnecting and connecting test equipment.
Never force connectors apart either by using tools or
by pulling on the wiring harness. Always ensure
locking tabs are disengaged before removal and note
orientation to enable correct reconnection. Ensure that
any protective covers and substances are replaced if
disturbed. Having confirmed a component to be faulty
switch-off the ignition and disconnect the battery.
Remove the component and support the disconnected
harness. When replacing the component keep oily
hands away from electrical connection areas and
push connectors home until any locking tabs fully
engage.Battery disconnecting
Before disconnecting the battery, switch off all
electrical equipment.
Battery charging
Recharge the battery out of the vehicle and keep the
top well ventilated. While being charged or
discharged, and for approximately 15 minutes
afterwards, batteries emit hydrogen gas which is
flammable. Always ensure any battery charging area
is well ventilated and that every precaution is taken to
avoid naked flames and sparks.
GENERAL PRECAUTIONS
Switch-off ignition prior to making any connection or
disconnection in the system as electrical surge
caused by disconnecting 'live' connections can
damage electronic components.
Ensure hands and work surfaces are clean and free of
grease, swarf, etc. as grease collects dirt which can
cause tracking or high-resistance contacts.
When handling printed circuit boards, treat them as
you would a disc - hold by the edges only.
Prior to commencing a test, and periodically during a
test, touch a good earth, for instance, a cigar lighter
socket, to discharge body static as some electronic
components are vulnerable to static electricity.
Page 429 of 455

86ELECTRICAL
4
REPAIR HANDSET BATTERY
Service repair no - 86.77.13
Remove
1.Unlock vehicle and disarm alarm system.
2.Turn starter switch to position 'II'.
3.Turn starter switch back to position '0' and
remove key.
4.Carefully prise handset apart, starting from
keyring end, using a coin or small screwdriver.
5.Slide battery out from retaining clip.
6.Press and hold one of the handset buttons for at
least five seconds to drain any residual power
from handset.
NOTE: The engine will immobilise five
minutes after key is removed from starter
switch.Refit
7.Fit new battery into handset retaining clip with
positive side uppermost. Finger marks will
adversely affect battery life; if possible, avoid
touching flat surfaces of battery and wipe clean
before fitting.
8.Reassemble two halves of handset.
9.Press RH (Padlock) button at least four times
within range of vehicle to resynchronise handset.
10.Check operation of alarm system.
WARNING: The handset contains delicate
electronic circuits and must be protected
from impact and water damage, high
temperatures and humidity, direct sunlight and
effects of solvents, waxes and abrasive cleaners.
NOTE: New handsets must be be
initialised using TestBook.
Page 438 of 455

ELECTRICAL
13
REPAIR HEADLAMP
Service repair no - 86.40.02
Remove
1.Remove screws retaining side and direction
indicator lamps.
2.Withdraw lamp units and disconnect plugs.
3.Remove 2 screws and withdraw headlamp
finisher.
4.Remove 2 headlamp retaining screws.
5.Rotate headlamp clockwise, disengage from
body, and lift out headlamp.
6.Disconnect multi-plug to release headlamp. On
vehicles fitted with headlamp levelling unit, also
release unit harness plug
See Headlamp
levelling unit.
7.Remove rubber cover.
8.Release spring clip and withdraw headlamp
bulb.
NOTE: Do not touch bulb glass with
fingers. If necessary, clean bulb with
methylated spirits.Refit
9.Fit bulb to headlamp and retain with spring clip.
10.Fit rubber cover and reconnect multi-plug. If
applicable, fit headlamp levelling unit plug
See
Headlamp levelling unit.
11.Locate headlamp in body and rotate
anti-clockwise to engage.
12.Fit headlamp retaining screws.
13.Fit headlamp finisher, side and direction
indicator lamps.
14.Check main beam alignment
See Headlamp
beam alignment.
Page 444 of 455

ELECTRICAL
19
REPAIR INSTRUMENT ILLUMINATION - BULB RENEWAL
Service repair no - 86.45.49 - Speedometer
Service repair no - 86.45.51 - Temperature gauge
Service repair no - 86.45.52 - Fuel gauge
Remove
1.Disconnect battery.
2.Remove 4 screws retaining instrument panel.
3.Ease panel forward and disconnect
speedometer cable to improve access to
illumination bulbs.
4.Twist bulb holder and pull from socket.
5.Pull bulb from holder.
Refit
6.Fit new bulb and refit holder.
7.Reconnect speedometer cable and fit instrument
panel.
8.Reconnect battery.STARTER SWITCH
Service repair no - 86.65.03
Remove
1.Remove instrument panel
See INSTRUMENTS,
Repair, Instrument panel.
2.Remove steering column nacelleSee
STEERING, Repair, Steering column nacelle.
3.Note position of harness leads on back of starter
switch and disconnect lukars. If fitted, remove
alarm system passive coil from switch
See
Passive coil.
4.Remove single screw and withdraw starter
switch from steering column lock.
Refit
5.Fit new switch in steering column lock.
6.Connect harness leads to starter switch.
7.If applicable, fit alarm system passive coil
See
Passive coil.
8.Fit steering column nacelleSee STEERING,
Repair, Steering column nacelle.
9.Fit instrument panelSee INSTRUMENTS,
Repair, Instrument panel.
Page 446 of 455

ELECTRICAL
21
REPAIR MAIN LIGHT SWITCH
Service repair no - 86.65.10
Remove
1.Remove steering column nacelle
See
STEERING, Repair, Steering column nacelle.
2.Disconnect main light switch multi-plug from
main harness.
3.Slacken locknut and release light switch from
slot in mounting bracket.
Refit
4.Fit light switch in mounting bracket.
5.Reconnect switch multi-plug.
6.Fit steering column nacelle
See STEERING,
Repair, Steering column nacelle.
HEATED REAR SCREEN, REAR FOG LAMP AND
HAZARD WARNING SWITCHES
Service repair no - 86.65.36 - Heated rear screen
Service repair no - 86.65.65 - Rear fog lamp
Service repair no - 86.65.50 - Hazard warning
Remove
1.Remove 2 screws and withdraw switch panel
from lower fascia.
2.Disconnect multi-plug from rear of switch.
3.On hazard warning switch only, remove 2
separate leads.
4.Press in spring retainers and withdraw switch
from switch panel.
Refit
5.Fit new switch into switch panel.
6.Reconnect switch multi-plug, and leads if
applicable.
7.Fit switch panel to lower fascia.
Page 447 of 455

86ELECTRICAL
22
REPAIR CIGAR LIGHTER
Service repair no - 86.65.60
Remove
1.Remove 2 screws and withdraw switch panel
from lower fascia.
2.Disconnect electrical leads from switch housing,
including illumination bulb.
3.Release 2 retaining tags and remove bulb holder
from switch housing.
4.Remove cigar lighter from switch housing.
5.Press in retaining tags and withdraw housing
from switch panel.
Refit
6.Fit housing to switch panel.
7.Fit bulb holder to switch housing.
8.Connect electrical leads and illumination bulb.
9.Insert cigar lighter into switch housing.
10.Fit switch panel to lower fascia.REAR SCREEN WIPER/WASHER SWITCH
Service repair no - 84.35.34
Remove1.Remove 2 screws and withdraw switch panel
from lower fascia.
2.Disconnect electrical leads from rear screen
wiper/washer switch.
3.Insert a small screwdriver in base of switch
knob, press in retaining lug, and remove knob
from switch spindle.
4.Unscrew locking ring, with wavy washer, and
withdraw wiper/washer switch from panel.
Refit
5.Fit switch to switch panel.
6.Press in retaining lug and fit knob onto switch
spindle.
7.Connect electrical leads to switch.
8.Fit switch panel.
Page 448 of 455

ELECTRICAL
23
REPAIR HEADLAMP LEVELLING SWITCH
Service repair no - 86.65.16
Remove
1.Remove 2 screws and withdraw switch panel
from lower fascia.
2.Disconnect multi-plug from rear of headlamp
levelling switch.
3.Remove knob from switch spindle.
4.Unscrew retaining nut and withdraw switch from
switch panel.
Refit
5.Fit switch into switch panel and secure with
retaining nut.
6.Fit switch knob.
7.Connect switch multi-plug.
8.Fit switch panel.HEADLAMP LEVELLING UNIT
Service repair no - 86.41.16
Remove
1.Remove headlamp
See Headlamp.
2.Disconnect headlamp levelling unit harness
plug.
3.Rotate levelling unit anti-clockwise to release
retaining lugs from mounting bracket on
headlamp body.
4.Release levelling unit spindle from retaining slot
on headlamp bezel and withdraw unit from
mounting bracket.
Refit
5.Fit levelling unit into mounting bracket and locate
unit spindle into slot in headlamp bezel.
6.Press in unit and rotate clockwise to engage
retaining lugs behind mounting bracket.
7.Connect levelling unit harness plug.
8.Fit headlamp
See Headlamp.
Page 452 of 455

88INSTRUMENTS
2
REPAIR FUEL AND TEMPERATURE GAUGE
Service repair no - 88.25.26 - Fuel gauge
Service repair no - 88.25.14 - Temperature gauge
Remove
1.Remove instrument panel
See Instrument
panel
.
2.Release illumination bulb holder and disconnect
electrical leads from gauge.
3.Unscrew knurled nut and remove clamp
securing gauge.
4.Remove earth lead eylet from gauge stud.
5.Withdraw gauge from instrument panel
Refit
6.Fit gauge into instrument panel, locate earth
lead, and secure with clamp.
7.Fit bulb holder and electrical leads.
8.Fit instrument panel
See Instrument panel.CLOCK - FASCIA PANEL
Service repair no - 88.15.07
Remove
1.Remove 4 screws securing instrument panel to
fascia cowl.
2.Pull panel away fom fascia sufficient to
disconnect speedometer cable.
3.Disconnect electrical leads and bulb holder from
clock.
4.Unscrew knurled nut and remove clamp
securing clock.
5.Remove clock from instrument panel.
Refit
6.Fit clock into instrument panel and secure with
clamp.
7.Fit bulb holder and electrical leads.
8.Connect speedometer cable.
9.Secure instrument panel to fascia cowl.