Page 1094 of 1529

PANEL REPAIRS
REPAIRS 77-2-27
Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.Refit
1.Fit centre brace.
2.Fit 2 bolts securing bulkhead to chassis and
tighten bolts to 45 Nm (33 lbf.ft).
3.Fit bonnet release cable.
4.Fit crush can.
5. Models with A/C: Fit A/C pipes.
6.Fit 2 earth leads to LH of front bulkhead.
7.Fit air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
Td5, REPAIRS, Air filter assembly.
+ ENGINE MANAGEMENT SYSTEM -
V8, REPAIRS, Air cleaner assembly.
8.Fit battery tray.
9.Fit headlamp wiring and headlamp levelling
motors.
10.Fit repeater lamp.
+ LIGHTING, REPAIRS, Lamp - front
repeater - up to 03MY.
11.Fit headlamp.
+ LIGHTING, REPAIRS, Headlamp - up
to 03MY.
12. Diesel models: Fit gearbox fluid cooler.
13. Models with A/C: Fit condensor.
+ AIR CONDITIONING, REPAIRS,
Condenser.
14.Fit washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer - up to 03MY.
15.Connect leads/multiplug to alternator.
16.Connect battery leads, negative lead last.
Page 1236 of 1529
WIPERS AND WASHERS
DESCRIPTION AND OPERATION 84-1
WIPERS AND WASHERS DESCRIPTION AND OPERAT ION
Wipers and washers component layout
RHD shown, LHD similar
1Headlamp power wash relay
2Passenger compartment fuse box
(rear wiper relay, front wiper relay and IDM)
3Variable Delay Switch
4Front wash/ wipe switch
5Rear wiper motor
6Rear washer switch7Rear wiper switch
8Body Control Unit (BCU)
9Front washer pump
10Rear washer pump
11Front wiper motor assembly
12Headlamp power wash pump
Page 1237 of 1529
WIPERS AND WASHERS
84-2 DESCRIPTION AND OPERATION
Front wiper components
1Linkage assembly
2Wiper motor
3Stud plate
4Gasket
5Wheel box 2 off
6Bolt 2 off
7Earth strap
8Cover plate9Bolt 3 off
10Lock washer
11Nut
12Flanged nut 5 off
13Wiper blade 2 off
14Cover
15Nut
16Wiper arm 2 off
Page 1238 of 1529
WIPERS AND WASHERS
DESCRIPTION AND OPERATION 84-3
Rear wiper components
1Wiper blade
2Washer jet
3Washer
4Seal
5Washer 2 off
6Lock washer 2 off
7Bolt 2 off8Wiper motor
9Nut
10Nut
11Cover
12Wiper arm
13Washer tube
Page 1239 of 1529
WIPERS AND WASHERS
84-4 DESCRIPTION AND OPERATION
Washer components
Reservoir with headlamp power wash shown
Page 1240 of 1529
WIPERS AND WASHERS
DESCRIPTION AND OPERATION 84-5
1Windscreen washer jet 2 off
2Elbow 3 off
3In-line non-return valve
4Tube
5'T' connector
6Tube
7Connector
8Filler neck tube
9Filter
10Cap
11Bracket
12Level float
13Filler neck seal
14Bolt
15Reservoir
16Pump sealing grommet (if fitted)
17Powerwash pump (if fitted)18Clip
19Tube
20Screw 2 off
21Powerwash jet 2 off
22Clip 4 off
23Tube
24'T' connector
25Tube
26Nut 2 off
27Pump sealing grommet 2 off
28Rear washer pump
29Front windscreen washer pump
30Elbow 2 off
31Tube - front windscreen
32Tube - rear tail door window
33Non-return valve
Page 1241 of 1529
WIPERS AND WASHERS
84-6 DESCRIPTION AND OPERATION
Wipers and washers block diagram
Page 1242 of 1529
WIPERS AND WASHERS
DESCRIPTION AND OPERATION 84-7
1BCU
2IDM
3Front wiper relay
4Front wash / wipe switch
5Front wiper motor assembly
6Front washer pump motor
7Variable delay switch
8Rear wiper relay
9Rear wiper switch
10Rear washer switch
11Rear wiper motor
12Rear washer pump motor
13Headlamp power wash relay
14Headlamp power wash pump motor