Page 1979 of 2490
Engine Management Fuse Box Relay
Engine Compartment - Front Relays
Engine and Transmission Control Module Compartment Relays
Relay NoColorCircuit
1BrownEMS control relay
Relay NoColorCircuit
1BlackWindshield wiper fast/slow
2BlackWindshield wiper on/off
Relay NoColorCircuit
1BlueSC coolant water pump
2BrownFuel injection main
3BrownIgnition coils
4BrownThrottle motor
5BrownStarter solenoid
6BrownAir conditioning compressor clutch
Page 2008 of 2490

Driver Door Module (DDM)
Interior lights circuit
BPM inputs from: BPM outputs to:
Header console courtesy light switch
SCPInstrument and switch illumination. Fade 1 (Header console courtesy lamps) Fade 2 (E-post courtesy lamps) Map lights Sun visor lamps Glovebox lamp Trunk lamps
Washer / wiper circuit
Wiper park switch Low screen wash switch Wiper slow speed switch Wiper fast speed switch Wiper intermittent switch Wash/wipe switch
Power wash relay Wiper motor run Screen wash pump Wiper fast/slow speed
Ignition circuit
Ignition position Auxiliary position Transit relay Mirror fold out Mirror fold flat
Central door locking circuit
Central locking button Valet switch SCP (door modules)
Central door locking relay SCP (door modules, security and locking control
module)
Sun roof ECU
Security system circuit
Hood security switch Horn switches Central locking button SCP (door modules, security and locking control
module)
ISO link (key transponder module)
Horn relay Active security sounder Passive security sounder Security status LED Central door locking relay SCP (door modules, security and locking control
module)
ISO link (key transponder module)
Steering column adjustment circuit
Column adjustment switchesColumn tilt motor Column reach motor
Gear shift interlock circuit
Neutral switch J-gate not in park Keylock solenoid Gearshift interlock solenoid
Seat heaters circuit
Seat heater switchesSeat heater relay Status LED
Seat buckle circuit
Seat buckleAudible warning SCP
Page 2021 of 2490

Body System - General Information - Body
Description and Operation
This section covers the following areas of the vehicle body:
Front end body panels
Body closures
Aperture seals
Door seals
Instrument panel, console and radio
Centre console
Handles, locks, latches and mechanisms
Wipers and washers
Glass, frames and mechanisms
Fascia
Fuel filler flap assembly
Sun visors
Seating
Interior trim and ornamentation
Exterior trim and ornamentation
Rear view mirrors
Rear parcel tray
Roof console
Bumpers
Occupant restraints
Sliding roof
Steering column cowl
Underscuttle pad
Front End Body Panels
A false bulkhead together with two insulation covers, are installed between the engine compartment and the BIW front
bulkhead to provide optimum insulation ag ainst noise and heat intrusion. Two plenum braces bolted between the BIW upper toeboards and the plenum further increase bodyshell structural integrity. The plastic ra diator grill and vane block achieve
weight reductions over steel parts and provid e high resistance to front end corrosion.
Page 2028 of 2490
Front End Body Panels - Cowl Panel Grille
Removal and Installation
Installation
1.
Open the hood and fit fender covers.
2. Remove the wiper arm and blade assembly. Refer to
84.15.44.90.
3. Slacken and remove the five pl enum cover securing screws.
4. Position the plenum cover for access and disconnect windshield
washer pump tube from pl enum cover connector.
5. Remove plenum cover from vehicle.
6. Remove screenwasher conne ctor from plenum cover.
7. Remove plenum cover spacers,
1. Fit washer hose connector to plenum cover.
2. Fit and fully seat plenum cover spacers.
3. Position plenum cover for access and fit windshield washer
pump to plenum connector hose.
4. Fit plenum cover ensuring that it seats correctly in upper seal.
5. Fit and tighten securing screws.
6. Fit washer hose to plenum connector.
7. Fit wiper arm and blade. Refer to 84.15.44.90.
8. Close hood and remove fender covers.
Page 2039 of 2490
2.
Ensure that multiplugs are clea r of door front edge, and check
arm is fully retracted, then with assistance, lift door into
position and locate hinge pins.
3. Fit and fully tighten new hinge locking screws.
4. Position check arm bracket on 'A' post and fit and tighten
securing screws.
5. Fully open door and apply a thin co at of grease to both sides of
check arm.
6. Connect door harness multiplugs and fit and fully seat harness
gaiter in 'A' post.
7. Remove masking tape from front edge of door.
8. Check that door shuts correctly.
9. Wipe any excess grease from check arm.
10. Connect ground cable to batt ery terminal and fit battery
cover. Refer to 86.15.15.
Page 2185 of 2490
Glass, Frames and Mechanisms - Front Door Window Glass Weatherstrip
Removal and Installation
Removal
Installation
1.
Pull seal out of door frame channelling and discard seal.
2. Clean channelling ensuring that any residual adhesive is
removed.
1. Avoiding adhesive at ends, apply a suitable dry lubricant to
seal.
2. Commencing at front of frame, feed seal into channelling
ensuring it is uniformly tensioned and free from kinks.
3. Wipe residual lubricant fro m adhesive contact areas.
4. Remove protective tape from en ds and press adhesive firmly
onto frame.
5. Clean any excess lubricant from external surfaces and check
that door shuts correctly.
Page 2194 of 2490
Glass, Frames and Mechanisms - Rear Door Window Glass Weatherstrip
Removal and Installation
Removal
Installation
1.
Pull seal out of door frame channelling and discard seal.
2. Clean channelling ensuring that any residual adhesive is
removed.
1. Avoiding adhesive at ends, apply a suitable dry lubricant to
seal.
2. Commencing at front of frame, feed seal into channelling
ensuring it is uniformly tensioned and free from kinks.
3. Wipe residual lubricant fro m adhesive contact areas.
4. Remove protective tape from en ds and press adhesive firmly
onto frame.
5. Clean any excess lubricant from external surfaces and check
that door shuts correctly.
Page 2201 of 2490

Installation
the spray bottle with water and mix.
5. Apply cutting lubricant to the rear quarter window glass
adhesive.
6. Install the cutting tool blade BTB-WK4ZS to the cutting tool
BTB-WK10HD.
7. WARNING: When removing the rear quarter window
glass, personal protec tion must be worn. Failure to follow this
instruction may result in personal injury.
• NOTE: Apply cutting lubricant to the cutting tool frequently
through out the cutting process.
Using the special tool cut throug h the rear quarter window glass
adhesive.
8. Remove the rear quarter window glass.
1. WARNINGS:
If the rear quarter window glass is being installed at a
temperature of 23°C (73°F) or abov e make sure the vehicle is not
driven for at least 1 hour after installation.
If the rear quarter window glass is being installed at a
temperature of 11°C (52°F) make sure the vehicle is not driven
for at least 1.5 hours after installation.
If the rear quarter window glass is being installed at a
temperature of 5°C (41°F) make su re the vehicle is not driven for
at least 2 hours after installation.
If the rear quarter window glass is being installed at a
temperature below 5°C (41°F) use heat and make sure the
windshield glass adhesive has set before the vehicle is driven.
Using the special tool, remove any residual adhe sive from the
body aperture.
2. NOTE: If the original rear qu arter window glass is to be
installed remove the residual ad hesive from rear quarter window
glass mating surface using the special tool.
Thoroughly clean rear quarte r window glass surface using
Betawipe spirit.
3. Thoroughly clean the mating face of the body using Betawipe