Page 510 of 1007

STEERING
REPAIRS 57-17
Column lock & ignition/starter switch
assembly
$% 57.40.31
Remove
1.Disconnect battery earth lead.
2.Remove starter key from ignition lock.
3.Remove steering column nacelle.
+ STEERING, REPAIRS, Nacelle -
column.
4.Disconnect multiplugs from ignition switch and
passive coil.
5.Remove passive coil.
6.Remove 2 screws and remove ignition switch.
7.Move rubber column cover aside to access
column lock bolts.
8.Mark both column lock bolts using a centre
punch.
9.Drill out both column lock bolts.10.Remove column lock saddle and remove
column lock.
11. Models with automatic transmission:
Loosen union and release key interlock cable
from column lock.
Refit
1. Models with automatic transmission: Align
key interlock cable to column lock and tighten
union to 4 Nm (3 lbf.ft).
2.Position lock to steering column assembly and
fit shear bolts. Do not tighten shear bolts at this
stage.
3.Insert starter key, check operation of steering
lock and that key turns freely.
4.Ensure correct operation of key interlock cable.
5.Remove starter key from column lock.
6.Tighten shear bolts fully and shear heads off.
7.Position ignition switch to column, fit and
tighten screws.
8.Fit passive coil.
9.Connect multiplugs to ignition switch and
passive coil.
10. Models with automatic transmission:
Ensure correct operation of microswitch.
11.Align column cover.
12.Fit steering column nacelle.
+ STEERING, REPAIRS, Nacelle -
column.
13.Connect battery earth lead.
Page 512 of 1007

STEERING
REPAIRS 57-19
Refit
1.Position cable, align to heater and steering
column bracket and secure in retaining clips.
2.Align key interlock cable to column lock and
tighten union to 4 Nm (3 lbf.ft).
3.Fit height adjuster clamp bolt and tighten nut to
10 Nm (7.5 lbf.ft). Ensure bolt and plastic stop
are correctly located in slot in column bracket.
4.Fit height adjuster lever and tighten bolt 12 Nm
(9 lbf.ft). Ensure lever is in the fully up position
before tightening bolt. Hold clamp bolt nut to
prevent nut rotation.
5.Connect cable to interlock mechanism.
6.Check key interlock cable adjustment.
+ STEERING, ADJUSTMENTS, Cable
- key interlock - adjust.
7.Fit steering column nacelle.
+ STEERING, REPAIRS, Nacelle -
column.
8.Fit front console.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
9.Connect battery earth lead.
Column assembly - inner & outer
$% 57.41.01
Remove
1.Disconnect battery earth lead.
2.Remove steering column multi purpose switch.
+ LIGHTING, REPAIRS, Switch -
combined direction indicator/headlight/
horn.
3.Disconnect multiplugs from ignition switch and
passive coil.
4.Remove 2 screws securing steering column
aperture trim and remove trim.
Page 515 of 1007

STEERING
57-22 REPAIRS
Refit
1.Remove column from vice.
2.Fit new cable ties to steering column.
3. Models with automatic transmission: Fit key
interlock cable clip.
4.Position steering column to vehicle, locate
steering column on PAS rack, aligning column
coupling with PAS rack input flag.
5.Locate steering column on studs fit nuts but do
not tighten at this stage.
6.Fit bolts and snubber to pivot mountings and
tighten bolts to 14 Nm (10 lbf.ft).
7.Tighten nuts to 14 Nm (10 lbf.ft).
8.Fit and tighten PAS rack pinion clamp bolt to 32
Nm (24 lbf.ft).
CAUTION: Nuts and bolts must be tightened
with weight of vehicle on suspension.
9. Models with automatic transmission:
Remove clamp bolt from height adjuster and
position key interlock cable.
10. Models with automatic transmission: Fit
height adjuster clamp bolt and tighten nut to 10
Nm (7.5 lbf.ft). Ensure bolt and plastic stop are
correctly located in slot in column bracket.
11. Models with automatic transmission: Fit
height adjuster lever and tighten bolt 12 Nm (9
lbf.ft). Ensure lever is in the fully up position
before tightening bolt. Hold clamp bolt nut to
prevent nut rotation.
12. Models with automatic transmission:
Remove starter key from column lock.
13. Models with automatic transmission: Align
key interlock cable to column lock and tighten
union to 4 Nm (3 lbf.ft).
14. Models with automatic
transmission:Position lock to steering column
assembly and fit shear bolts. Do not tighten
shear bolts at this stage.
15. Models with automatic transmission: Insert
starter key, check operation of steering lock
and that key turns freely.
16. Models with automatic transmission:
Ensure correct operation of key interlock cable.
17. Models with automatic transmission:
Remove starter key from column lock.
18. Models with automatic transmission:
Tighten shear bolts fully and shear heads off.
19. Models with automatic transmission: Fit
passive coil.
20. Models with automatic transmission:
Position ignition switch to column, fit and
tighten screws.
21. Models with automatic transmission:
Secure key interlock cable in clip.
22. Models with automatic transmission:
Ensure key interlock cable is correctly fitted.23.Fit side support bolt and tighten to 10 Nm (7.5
lbf.ft).
24.Position harness and secure cable ties.
25.Fit fusebox cover and close glove box lid.
26.Connect multiplugs to column switch and
passive coil.
27.Fit aperture trim and secure with screws.
28. Fit steering column multi purpose switch.
+ LIGHTING, REPAIRS, Switch -
combined direction indicator/headlight/
horn.
29.Connect battery earth lead.
Page 914 of 1007

CHARGING AND STARTING
ADJUSTMENTS 86-1-1
CHARGING AND STARTING ADJUST ME NTS
Ancillary drive belt - K1.8
$% 86.10.05
Check
1.Disconnect battery earth lead.
2.Turn steering on RH lock.
3.Remove 3 bolts and remove splash shield.
4.Rotate crankshaft a sufficient number of turns
to check condition of drive belt. Renew a drive
belt that shows signs of wear, splitting or oil
contamination.
5.Apply a force of 10 kg to drive belt at position 'X'
and measure deflection between crankshaft
pulley and alternator pulley. Deflection must be
6 - 8 mm.Adjust
1.Loosen alternator pivot nut and bolt.
2.Loosen bolt securing alternator adjustment
bracket to engine.
3.Loosen bolt securing alternator to adjustment
bracket.
4.Increase drive belt tension by rotating
alternator adjustment bolt clockwise.
5.Tighten alternator pivot and adjustment bracket
bolts to 25 Nm (18 lbf.ft).
6.Recheck drive belt tension.
7.Fit splash shield and secure with bolts.
8.Straighten steering.
9.Connect battery earth lead.
Page 915 of 1007
CHARGING AND STARTING
86-1-2 ADJUSTMENTS
Ancillary drive belt - K1.8 with A/C
$% 86.10.05
Check
1.Disconnect battery earth lead.
2.Turn steering on RH lock.
3.Remove 3 bolts and remove splash shield.
4.Rotate crankshaft a sufficient number of turns
to check condition of drive belt. Renew a drive
belt that shows signs of wear, splitting or oil
contamination.
5.Check belt length, belt must be renewed before
indicator reaches RH end of slot.
6.Fit splash shield and secure with bolts.
7.Straighten steering.
8.Connect battery earth lead.