Exterior Lighting - Fog Lamp Switch
Removal and Installation
Removal
Installation
1. Remove battery cover and disc onnect ground cable from
battery terminal. Refer to 86.15.19.
2. Remove instrument pa nel veneer panel. Refer to 76.47.24.
3. Remove combined front and rear fog lamp switch pack.
Use a small screwdriver to re lease upper retaining tag.
Position switch for access to connector.
Disconnect connector and remove switch.
1. Position switch pack at instrument panel.
2. Connect harness connector to switch pack
3. Install switch pack in panel, ensuring that retaining tangs are
fully seated.
4. Install instrument panel veneer panel. Refer to 76.47.24.
5. Connect ground cable to batter y terminal and install battery
cover. Refer to 86.15.15.
Body closures
Each front and rear door consists of a welded, mild steel inner frame and an outer panel. The outer panel is welded to the
waist rail and cheater of the inner frame, then bonded and clinched to fo rm the door assembly. Cosmetic PVC bead is
applied to all clinch joints. Sp onge rubber seals are mounted on the doors. Inte rnal insulation is provided by a foam water
shedder attached to the door by double-sided adhesive tape.
The door aperture B/C posts are reinforced over their full height to fully satisfy all forthcoming European and Federal side
impact legislation. The hood consists of one piece inner and outer panels clinched and bonded together, with cosmetic bead
PVC sealant applied to all clinch joints. Th e hood pivots at the front on two hinges each secured by bolts to the hood front
underside and the BIW front upper crossmem ber. Two gas struts secured to the hood by pivot pins and snap-on couplings,
support the hood in the open position. A full width insulating pad is secured by screws to the underside of the hood. A
sponge rubber tubular seal is mounted tran sversely towards the front of the hood underside. The trunk lid is of similar
construction to the hood, consisting of inner and outer pa nels clinched and bonded together and PVC bead sealed.
Incorporating a removable moulded liner and two trunk illuminati on lights, the trunk lid is supported when open, by two gas
struts, each secured to the inner wheel arch and trunk hinge by snap fittin gs. For some markets, a warning triangle is
attached to a bracket on the trunk lid underside and is retained in the open position by a rubber block.
Fascia
One-piece slush-moulded fascia on inject ion moulded armature and steel cross-rail reinforcement. Fascia support brackets
set with BIW to achieve close tolerance fit of fascia to bo dy eliminate necessity for adjustment following removal and
installation..
Fuel Filler Flap
The fuel filler comprising a hinged flap attached to the body decking panel by tw o nuts, incorporates a rubber buffer, snap-
in striker, hinge spring and fuel cap stowage magnet. The rubber fuel bowl moulding is attached via a steel armature to the
body reinforcement panel by five M5 nuts and is retained at the filler neck by a clip. The mating drain tube is fitted with an
internal filter. The fuel filler flap latch mechanism attached to the fuel bowl armatu re by two M5 nuts, includes a locking pin
and actuator which are both se rviceable items. The latch actuator operates independently from the central locking system;
it is driven directly by the se curity and locking control module. Locking of the fuel filler flap is achi eved only by operation of
the key or by the remote rf transmitter.
Seating
All front seats are equipped with electric height adjustment. In addition, both seats are available with manual or power
forward and rearward adjustment, manual or power operated headrest adjustment, 12 way electric adjustment, memory
controlled 12 way seat adjustment and integral seat heating. A side air bag module is installe d in the outboard squab wing
of each front seat. Each front seat has a non-handed, one-piece frame incorporatin g cushion and squab frames, side air bag
support bracket and seat adjuster mechanis ms. Seat switchpacks are installed on the outboard side of driver and passenger
seats and control modules are installed in the base of each seat . The standard rear seat is of fixed, bench type with full
width removable cushion. For certain mark ets, two individual rear seats are available as an option on long wheelbase
models. Both type s of rear seat are available with th ermostatically controlled heating of the cushion and sq uab. Individual
rear seats are electrically adjustable fo r squab re cline (via cushion fore and af t movement), head restraint height and
lumbar support. Separate motors provide ad justment of each seat cushion and head restraint and an electrically driven air
compressor provides variation of lumbar support. Seat adjustment is controlled via switches installed on a panel in an
extension to the centre console.Both the driver and front pass enger seat are secured to the vehicle floor at four points.
Interior Trim
The one-piece door casings are trimmed in UEV to match the seating, with wood veneer at the waistline and a carpet insert
at the front lower corner. Each casing is secured to the door inner panel by fir tree fastener s along the lower section, two
armrest fixings at the centre and veneer panel dowels and fixings at the top. The armrests which are common to front and
rear doors, are trimmed in matc hing leather or UEV according to specification. Switchpacks dedicated to driver and front or
rear passenger, are incorporated in the ar mrests. A speaker is installed in the lower section of each door and a tweeter is
incorporated behind each interior door handle escutcheon. where premium ICE is fitted, the front tweeters are installed in
the upper A posts. On each side, a graine d UEV finisher trimmed to match the head lining is secured to the 'A' post and
cantrail by fir tree fasteners locating in BIW apertures. Th e upper 'D' post finisher is trimmed and secured in the same
manner. The single piece'B' post finishers, also finished in grained matching UEV, each have a front seat belt exit aperture
and are secured to the BIW by four spring clips and two fir tree fasteners. The one-piece headlining consists of a 6mm thick
polyurethane foam membrane covered with suede effect knitted polyester. The headlining is secured to the BIW roof by
body tangs, the roof console, sun visors, combined grab handles and coat hooks, th e cantrail finishers and where fitted, the
Interior Trim and Ornamentation - Interior Trim
Description and Operation
Carpets
The passenger compartment carpet is a one piece moulded constr uction with integral sound deadening material, heel mats
and driver's footrest. The carpet is attach ed to the vehicle floor by plastic clips fitted below the door treadplates. Removal of the carpet necessitates re moval of the front seats, lifting of the centre console rear extens ion and removal of the heelboard
carpet.
Fascia
The full width, slush moulded, soft feel PVC fascia is mounted on an injection moulded armature and is faced with wood
veneer. In addition to the air conditioning and central, outer and demisting vents, it accepts instrument packs dedicated to
market requirements and a centrally mounted analogue clock.
Doors
The one-piece door casings are trimmed in UEV to match the seating, with wood veneer at the waistline and a carpet insert
at the front lower corner. Each casing is secured to the door inner panel by fir tree press fast eners along the lower section,
two armrest fixings at the centre and vene er panel dowels and fixings at the top. The armrests which are common to front
and rear doors, are trimmed in matching leather or UEV according to specification. The door switchpacks, dedicated to
driver and front or rear passenger, are in corporated in the armrests. A speaker is in stalled in the lower section of each door
and a tweeter is incorporated behind each interior door handle escutcheon. Where premium ICE is fitted, the front tweeters
are installed in the upper A posts.
A, B, C and D Posts
On each side,a grained UEV finisher trimmed to match the headlining is secured to the 'A' post and cantrail by fir tree
fasteners locating in BIW apertures. The upper 'D' post finisher is trimmed and secured in the same manner. The single
piece'B/C' post finishers, also finished in grained matching UEV, each have a front se at belt exit aperture and are secured to
the BIW by four spring clips and two fir tree fasteners.
Headlining
The one-piece headlining consists of a 6mm thick polyurethane foam membrane covered with suede effect knitted polyester. The headlining is secured to the BIW roof by body tangs, the roof console, sun visors, combined grab handles and coat
hooks, the cantrail finishers and where fitt ed, the sliding roof finisher and clips.
Trunk
Carpet covered trims line the trunk and are secured by fir tr ee fasteners to the sides and front inner panel. The carpet
covered, two-section, removable trunk fl oor provides access to the spare wheel and wheel changing equipment, the battery
and electrical carrier. The floor board rests on the spare wheel, with the front and rear edges locating in blocks on the fuel
tank backboard and the rear of the body. The support blocks provide for two floor he ight settings to accommodate either a
space saver or full size spare wheel.A moulded finisher covering the rear of the trunk below the sill is secured to the rear
panel by tabs and fir tree fasteners. Finish er panels fitted to the rear lamp units provide trunk interior access to the lamps.
The trunk lid underside is fitted with a removabl e moulded liner and two trunk illumination lights.
Interior Trim and Ornamentation - Door Window Control Switch Finish
Panel
Removal and Installation
Removal
Installation
1.
Remove door casing veneer panel. Refer to 76.47.11.
2. Remove door casing. Refer to 76.34.01.
3. Remove door armrest and remo ve switchpack assembly from
armrest. Refer to 76.34.22.
4. Slacken and remove th ree screws securing door glass lift
switch veneer panel to switchpack.
5. Remove veneer panel from switch assembly.
1. Position veneer panel over swit ch assembly and fit and tighten
securing screws.
2. Position switchpack assembly on armrest and fit and tighten
securing screws.
3. Fit armrest to door casing. Refer to 76.34.22.
Interior Trim and Ornamentation - Floor Covering
Removal and Installation
Removal
1. Remove battery cover and disc onnect ground cable from
battery terminal. Refer to 86.15.19.
2. Remove rear seat cushion. Refer to 76.70.37.
3. Remove front seats. Refer to 76.70.01
4. Remove 'J' gate surroun d. Refer to 76.25.24.
5. Remove centre console finish er veneer panel. Refer to
76.47.26.
6. Remove fascia centre veneer panel. Refer to 76.47.06.
7. Remove centre console assembly. Refer to 76.25.01.
8. Remove 'A' post lower trim pads. Refer to 76.13.30.
9. Remove 'B' post trim pads. Refer to operations in this section.
10. Slacken and remove centre console heater ducting securing
screw and remove ducting from vehicle..
11. Rotate heelboard fasteners 1/4 turn and remove both
heelboards from vehicle.
12. Remove front sill treadplates. Refer to operations in this
section.
13. Remove rear sill treadplates. Refer to operations in this
section.
14. Release the carpet retainers fro m BIW flanges at each side.
15. Release the two carpet rear retainers from BIW brackets.
2. Ensure that
gear selector is in position 'R'.
3. Inst
all gear selector cable in 'J' gate.
1. Position gear selector cable in support bracket.
2. Connect inner cable to 'J' gate stud and fit and
tighten securing nut.
4. Adjust
gear selector cable.
1. Adjust selector cable nuts so that selector lever freely
moves to 'R' position in gate.
2. Tighten gear selector ca ble locknut, ensuring that
tabwasher tangs engage in bracket slots.
5. Ensure that
gear selector cable
to tunnel grommet is correctly
seated.
6. Fit and secure handbrake trim finisher. Refer to 76.13.63.
7. Fully seat carpet side and rear retaining clips.
8. Fit front sill treadplates. Refer to operations in this section.
9. Fit rear sill treadplates. Refer to operations in this section.
10. Position and fully seat rear heel boards and rotate 1/4 turn
fasteners to secure.
11. Install console heater ducting and fit and tighten securing
screw.
12. Fit 'B' post trim pads. Refer to operations in this section.
13. Fit lower 'A' post trim pads. Refer to 76.13.30.
14. Fit centre console asse mbly. Refer to 76.25.01.
15. Fit fascia centre ve nt veneer panel. Refer to 76.47.06.
16. Fit centre console finisher vene er panel. Refer to 76.47.26.
17. Fit 'J' gate surround. Refer to 76.25.24.
18. Fit rear seat cushion. Refer to 76.70.37.
19. Fit front seats. Refer to 76.70.01.
20
.
Connect ground cable to batt ery terminal and fit battery
cover. Refer to 86.15.15.
Interior Trim and Ornamentation - Folding Tray
Removal and Installation
Removal
Installation
1. Remove screws securing picnic tray hinges to seat back
finisher and remove tray from seat.
2. Remove screws securing hinges to picnic tray. and remove
hinges from tray
3. Remove clips from hinge centre securing screw positions.
4. Remove trim securing screws and remove trim from veneer
panel.
1. Position trim on veneer panel an d install trim securing screws.
2.
Install clips at hinge centre securing screw positions.
3. Position hinges on veneer panel and install securing screws.
4. Position hinges on seat back finisher and install securing
screws.