76CHASSIS AND BODY
36
REPAIRREV: 05/99 26.Release demist hose and lift parcel shelf from
lower fascia panel (heater duct). Feed main
harness leads and plugs through aperture in
parcel shelf.
27.Remove parcel shelf.
28.Remove 7 screws securing bottom edge of lower
fascia panel to fascia bulkhead, noting position
of both footwell cover retaining plates.
29.Remove both retaining plates and lower footwell
covers.
30.Unscrew 2 retaining bolts securing top edge of
lower fascia panel to bulkhead.
31.With assistance, lower fascia panel and, if
applicable, disconnect RH radio speaker leads.
32.Remove fascia panel from vehicle.Refit
33.Position lower fascia panel to bulkhead,
reconnect RH speaker leads, if applicable, and
secure top edge with 2 bolts.
34.Locate RH footwell cover retaining plate under
bottom edge of fascia panel and secure with 3
screws.
35.Repeat operation for LH footwell cover retaining
plate.
36.Fit remaining lower fascia panel fixing screws.
37.Locate parcel shelf. Ensure all radio and
auxiliary switch panel harness leads and plugs
are fed through aperture in parcel shelf.
38.Fit demist hoses into heater duct of lower fascia
panel. Ensure flanges of hose grommets are
correctly seated.
39.Fit trim panel and secure with cap fasteners.
40.Reconnect LH speaker leads, if applicable,
locate wiper motor cover pins in lower fascia
panel and secure wth 3 screws. Ensure wiper
rack cover is correctly seated. On LH drive
vehicles, reconnect multi-plugs to rear of switch
panel.
41.Secure finisher to wiper motor cover.
42.Fit door check strap covers on both sides.
43.Fit footwell vents to lower fascia panel.
44. Models fitted with hand throttle:
Fit hand throttle cover.
Secure LH side of fuse box.
45.Fit fuse box cover.
46.Fit auxiliary switch cover to parcel tray, if
applicable.
82AIR CONDITIONING
6
REPAIR 9.Remove plug connector from resistor.
10.Remove relay from connecting block to gain
access to fixing screw.
11.Remove screw and release relay connector
block. Retain relay in connector block.
12.Remove screw and detach air conditioning 30
amp fuse bracket from resistor. Refit both
resistor retaining screws.
13.Using suitable pipe clamps, clamp heater matrix
feed and return hoses at base of heater/cooler
unit. Release retaining clips and remove hoses.
14.From inside vehicle remove front passenger
carpet, if fitted.
15.Remove retaining screws and fold back footwell
insulation.
16.Remove 2 bolts securing heater/cooler unit lower
mounting bracket to bulkhead.
17.From inside engine compartment remove 2 bolts
securing top heater/cooler unit mounting bracket
to engine bulkhead. This also releases earthing
leads.
18.Remove bolt securing support bracket to front of
heater/cooler casing.19.Lift heater/cooler unit clear of air duct seal and
remove from vehicle.
20.Discard all pipe connection 'O' rings.
Refit
21.Coat unions, threads and new 'O' rings with
refrigerant oil prior to reassembly.
22.Position heater/cooler unit in engine
compartment and locate with air duct seal.
23.Secure unit top and bottom mounting brackets to
bulkhead and support bracket to front of unit
casing. Fully tighten fixing bolts when unit is
correctly positioned.
24.Fit footwell insulation.
25.Reconnect heater matrix hoses.
26.Fit air conditioning fuse bracket, relay connector
block, relay and resistor plug connector.
27.Fit control cable to evaporator air flap operating
rod, using a new clip.
28.Fit pipe connector to vacuum switch.
29.Connect compressor clutch switch multi-plug.
30.Connect high and low pressure pipes to
evaporator.
31.Fit expansion tank
See COOLING SYSTEM,
Repair, Expansion tank.
32.Evacuate and recharge air conditioning system
See Adjustment, Refrigerant recovery,
recycling, recharging.
33.Reconnect battery.
82AIR CONDITIONING
18
REPAIR RESISTOR, BLOWER MOTOR - LH DRIVE
Service repair no - 82.20.26
Remove
1.Remove multi-plug from resistor.
2.Remove blower motor relay from connecting
block to gain access to fixing screw.
3.Remove screw and release relay connector
block. Retain relay in connector block.
4.Remove screw and detach air conditioning 30
amp fuse bracket from resistor.
5.Lift resistor unit from top cover.
Refit
6.Locate resistor unit in top cover.
7.Fit fuse bracket.
8.Fit blower motor relay connector block and relay.
9.Fit resistor multi-plug.RESISTOR, BLOWER MOTOR - RH DRIVE
Service repair no - 82.20.26
Remove
1.Remove multi-plugs from resistor.
2.Remove 2 screws securing resistor to wing
mounted block.
3.Withdraw resistor unit.
Refit
4.Secure resistor to mounting block.
5.Fit resistor multi-plugs.
ELECTRICAL
7
DESCRIPTION AND OPERATION ALARM SYSTEM FUSES
When the vehicle immobilisation and alarm system is
fitted, three fuses are used to protect the circuit:
·Alarm system 15 amp fuse, main harness, located
behind instrument binnacle.
·Alarm sounder 20 amp fuse No.10, located in main
fuse box.
·Alarm system 5 amp fuse No.20, located in main
fuse box.
The main fuse box is positioned in the centre of the
fascia, in front of the main gear lever. A label in the
fuse box cover shows the circuits protected, the fuse
rating and their locations. They are also listed below.
MAIN FUSE BOX
Fuse No. Value (amps) Electrical circuit
1 15 Hazard warning lights
2 20 Interior lamp, horn
3 15 Wipers & washers - rear
4 10 Wipers & washers - front
5 15 Heater
6 7.5 Rear fog guard lamps
7 5 Radio/cassette player
8 15 Heated rear window
9 10 Cigar lighter
10 20 Alarm sounder
11 7.5 Headlamp - RH, dipped beam
12 7.5 Headlamp - LH, dipped beam
13 7.5 Headlamp - RH, main beam
14 7.5 Headlamp - LH, main beam
15 5 Side lamps - LH
16 5 Side lamps - RH
17 15 Stop & reverse lamps
18 20 Air conditioning
19 5 Air conditioning
20 5 Alarm system
ELECTRICAL
9
DESCRIPTION AND OPERATION IMMOBILISATION AND ALARM SYSTEM CIRCUIT
DIAGRAM
1.Anti-theft alarm indicator light (LED)
2.Engine immobilisation warning light
3.Alarm system fuse - 15 amp
4.Alarm sounder relay
5.Under bonnet lighting fuse
6.Alarm sounder (without battery back-up)
7.Alarm system fuse - 5 amp (position 20)
8.Electronic control unit (ECU)
9.Bonnet switch
10.Alarm sounder protection fuse - 20 amp
(position 10)
11.Starter switch
12.Under bonnet ignition fuse
13.Driver's door switch
14.Vehicle horn switch
15.Vehicle horn
16.Passive coil
17.Starter switch relay
18.Front passenger door switch
19.Hazard warning light fuse - 15 amp (position 1)
20.Ultrasonic sensor
21.Interior lamp and horn fuse - 20 amp (position 3)
22.Alarm sounder (with battery back-up)
23.LH direction indicator lamps
24.RH direction indicator lamps
25.Interior lamp
26.Immobilisation spider
27.Rear side doors and rear door switches
28.Diagnostic connector
29.Diagnostic fuse - 7.5 amp
30.Starter solenoid
31.Fuel switch-off solenoid (injection pump)
32.Generator
33.AerialKey to cable colours
B-Black
G-Green
K-Pink
LG-Light Green
N-Brown
O-Orange
P-Purple
R-Red
S-Slate
U-Blue
W-White
Y-Yellow
The last letter of a colour code denotes the tracer
colour
ELECTRICAL
11
DESCRIPTION AND OPERATION IMMOBILISATION AND ALARM SYSTEM CIRCUIT
DIAGRAM - WITH DDS
1.Anti-theft alarm indicator light (LED)
2.Engine immobilisation warning light
3.Alarm system fuse - 15 amp
4.Alarm sounder relay
5.Under bonnet lighting fuse
6.Alarm sounder (without battery back-up)
7.Alarm system fuse - 5 amp (position 20)
8.Electronic control unit (ECU)
9.Bonnet switch
10.Alarm sounder protection fuse - 20 amp
(position 10)
11.Starter switch
12.Under bonnet ignition fuse
13.Driver's door switch
14.Vehicle horn switch
15.Vehicle horn
16.Passive coil
17.Starter switch relay
18.Front passenger door switch
19.Hazard warning light fuse - 15 amp (position 1)
20.Ultrasonic sensor
21.Interior lamp and horn fuse - 20 amp (position 3)
22.Alarm sounder (with battery back-up)
23.LH direction indicator lamps
24.RH direction indicator lamps
25.Interior lamp
26.Digital diesel shut-off valve (DDS)
27.Rear side doors and rear door switches
28.Diagnostic connector
29.Diagnostic fuse - 7.5 amp
30.Starter solenoid
31.Fuel shut-off solenoid (injection pump)
32.Generator
33.AerialKey to cable colours
B-Black
G-Green
K-Pink
LG-Light Green
N-Brown
O-Orange
P-Purple
R-Red
S-Slate
U-Blue
W-White
Y-Yellow
The last letter of a colour code denotes the tracer
colour
86ELECTRICAL
12
DESCRIPTION AND OPERATION VEHICLE ALARM SYSTEM BUILT-IN TEST
NOTE: The handset should be detached
from the key to allow perimetric testing of
the alarm system. The system will
automatically switch to volumetric testing if the
handset is in close proximity to the starter switch.
The built-in test procedure can be accessed providing
the following conditions exist:
Alarm disarmed.
Ignition 'off'.
Doors unlocked.
Bonnet closed.
With assistance, the test mode can be entered by
completing the following instructions within 5 seconds:
1.Open bonnet.
2.Turn starter switch 'on'.
3.Open driver's door (far enough to activate door
switch).
4.Turn starter switch 'off'.
5.Turn starter switch 'on'.
If the test mode has been correctly accessed, the
alarm sounder/horn will operate briefly and the
anti-theft alarm indicator and direction indicator lamps
will flash.
Perimetric tests
The anti-theft alarm indicator light and direction
indicator lamps will flash when:
1.Door switches are activated.
2.The bonnet is opened.
3.Key switches are activated.Volumetric tests
Press the LH (unlock) button or move the handset
close to the starter switch to disable perimetric testing
and enable volumetric testing. If movement is
detected within the vehicle by the ultrasonic sensor
the anti-theft alarm indicator and direction indicator
lamps will illuminate.
NOTE: Exit the anti-theft alarm built-in test
by turning the starter switch to the 'off'
position.
If the previously described conditions are not achieved
during the built-in test procedure, this would indicate a
fault in the alarm system. Before undertaking detailed
fault diagnosis procedures, first make visual checks of
components such as a faulty door switch or blown
alarm system fuse.
86ELECTRICAL
10
REPAIR Refit
12.Fit alarm indicator light into fascia panel and
reconnect plug lead.
13.Reconnect speedometer cable and fit instrument
panel to fascia cowl.
14.Fit steering wheel
See STEERING, Repair,
Steering wheel.
15.Reconnect battery negative lead.
16.Fit battery access cover.
17.Fit LH seat cushion.ALARM SYSTEM FUSE
Service repair no - 86.77.04
Remove
1.Remove LH front seat cushion.
2.Release retaining clip and remove battery
access cover.
3.Slacken battery negative lead clamp bolt.
4.Turn starter switch 'on'.
5.Turn starter switch 'off' and remove key.
6.Disconnect battery negative lead.
NOTE: Operation 6 needs to be carried out
within 15 seconds to avoid activating
battery backed-up alarm sounder, if fitted.
NOTE: If an alarm sounder without battery
back-up is fitted, it is not necessary to
disconnect battery.
7.Remove steering wheel
See STEERING,
Repair, Steering wheel.
8.Remove 4 screws securing instrument panel to
fascia cowl
See INSTRUMENTS, Repair,
Instrument panel.
9.Pull instrument panel away from fascia and
disconnect speedometer cable, main harness
multi-plugs, alarm LED plug lead, heated rear
screen leads, gearbox oil temperature lead and
immobiliser warning light lead.
10.Remove instrument panel.
11.Remove alarm system 15 amp (blue) fuse from
holder located behind starter switch.