Page 941 of 1007

LIGHTING
86-2-10 REPAIRS
Switch - hazard warning
$% 86.65.50
Remove
1.Remove radio.
+ IN CAR ENTERTAINMENT,
REPAIRS, Radio - up to 04MY.
2.Remove selector knobs from heater controls.
3.Remove 2 screws securing heater control
finisher to heater controls and remove finisher.
4.Release hazard warning switch from heater
controls.
5.Disconnect multiplug and remove hazard
warning switch.
Refit
1.Position hazard warning switch and connect
multiplug.
2.Fit hazard warning switch to heater controls.
3.Fit heater control finisher to heater controls and
secure with screws.
4.Fit heater control knobs.
5.Fit radio.
+ IN CAR ENTERTAINMENT,
REPAIRS, Radio - up to 04MY.
Switch - combined direction indicator/
headlight/horn
$% 86.65.55
Remove
1.Remove steering column nacelle.
+ STEERING, REPAIRS, Nacelle -
column.
2.Disconnect 2 multiplugs from indicator and light
switch.
3.Rotate steering wheel to access switch screws.
4.Remove 2 screws securing switch.
5.Depress retaining tag and remove switch.
Refit
1.Fit indicator and light switch and secure with
screws.
2.Connect multiplugs to switch.
3.Fit steering column nacelle.
+ STEERING, REPAIRS, Nacelle -
column.
Page 975 of 1007
IN CAR ENTERTAINMENT
86-6-12 REPAIRS
Coaxial lead - extension
$% 86.50.65
Remove
1.Remove radio.
+ IN CAR ENTERTAINMENT,
REPAIRS, Radio - up to 04MY.
2.Disconnect coaxial link lead from aerial lead.
3.Release coaxial link lead from harness.
4.Remove coaxial link lead.
Refit
1.Fit coaxial link lead and secure to harness.
WARNING: Ensure link lead does not foul
control pedals or steering column.
2.Connect link lead to aerial lead.
3.Fit radio.
+ IN CAR ENTERTAINMENT,
REPAIRS, Radio - up to 04MY.
Page 994 of 1007

DRIVER CONTROLS
REPAIRS 86-8-3
Sounder - parking aid - rear - from 04MY
$% 86.54.19
Remove
1. 3 door models: Remove RH rear lower quarter
trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 3 door.
2. 5 door models: Remove RH rear lower quarter
trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
3.Disconnect multiplug from parking aid sounder.
4.Remove 2 nuts securing parking aid sounder to
mounting bracket and remove sounder.
Refit
1.Position parking aid sounder to mounting
bracket and secure with nuts.
2.Connect multiplug to parking aid sounder.
3. 5 door models: Fit RH rear lower quarter trim
casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
4. 5 door models: Fit RH rear lower quarter trim
casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 3 door.
Switch - handbrake warning
$% 86.65.45
Remove
1.Remove rear console.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - rear.
2.Disconnect Lucar from handbrake warning
switch.
3.Release switch from handbrake.
Refit
1.Fit switch to handbrake and connect Lucar.
2.Fit rear console.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - rear.
M86 6117
Page 995 of 1007
DRIVER CONTROLS
86-8-4 REPAIRS
Switch - hazard warning - from 04MY
$% 86.65.50
Remove
1.Remove fascia cup holder.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Cup holder - fascia - from 04MY.
2.Release hazard switch from fascia carrier.
3.Disconnect multiplug and remove hazard
warning switch.
Refit
1.Position hazard warning switch and connect
multiplug.
2.Fit switch to fascia carrier.
3.Fit fascia cup holder.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Cup holder - fascia - from 04MY.
Cigar lighter - front
$% 86.65.60
Remove
1.Remove front console.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
2.Remove cigar lighter element.
3.Remove bulb holder from lighter.
4.Release cigar lighter body from console and
remove.
Refit
1.Fit and secure cigar lighter body to console.
2.Fit bulb holder to lighter.
3.Fit lighter element.
4.Fit front console.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
Page 1005 of 1007

INSTRUMENTS
88-6 REPAIRS
Sender unit - fuel tank gauge
$% 88.25.32
Remove
1.Disconnect battery earth lead.
2.Remove fuel pump assembly.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Pump - fuel.
+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Pump - integral - fuel tank - rear -
up to 03MY.
WARNING: Fuel vapour is highly flammable
and in confined spaces is also explosive
and toxic. Always have a fire extinguisher
containing foam, CO
2, gas or powder close
at hand when handling or draining fuel.
3.Disconnect 2 Lucars from top of pump unit
assembly.
4.Release sprag clip securing sender to pump
unit assembly.
5.Remove sender unit.
Refit
1.Position sender to location slots and engage
sprag clip.
CAUTION: Ensure that each of the 4
location lugs on the sender are engaged
with corresponding slots in the tank unit.
2.Connect Lucars to top of pump unit assembly.
3.Fit fuel pump assembly.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Pump - fuel.
+ FUEL DELIVERY SYSTEM - DIESEL,
REPAIRS, Pump - integral - fuel tank - rear -
up to 03MY.
4.Connect battery earth lead.
Sender unit assembly - fuel tank - Td4
models - from 03MY
$% 88.25.37
Remove
1.Disconnect battery earth lead.
WARNING: Fuel vapour is highly flammable
and in confined spaces is also explosive
and toxic. Always have a fire extinguisher
containing foam, CO
2, gas or powder close
at hand when handling or draining fuel.
2.If fuel tank is full, using a fuel recovery
appliance, drain excess fuel from fuel filler neck
until a level below height of fuel pump is
obtained.
3.Open RH rear and tail doors.
4.Fold RH rear seat forward.
5.Remove 3 fasteners securing front and rear
carpets.
6.Pull back carpet from fuel tank sender
assembly access panel.
M88 0356
Page 1006 of 1007

INSTRUMENTS
REPAIRS 88-7
7.Remove 6 screws securing fuel tank sender
assembly access panel to floor.
8.Remove fuel tank sender assembly access
panel.
9.Disconnect multiplug from fuel tank sender
assembly.
10.Place a container beneath fuel tank to collect
possible fuel spillage.
11.Release and remove fuel pressure relief, fuel
feed and return hoses from fuel tank sender
assembly.
WARNING: The spilling of fuel is
unavoidable during this operation. Ensure
that all necessary precautions are taken to
prevent fire and explosion.
12. Models with fuel burning heater (FBH):
Release clip and disconnect FBH fuel feed
hose from fuel tank sender assembly.
CAUTION: Always fit plugs to open
connections to prevent contamination.13.Use LRT-19-009 and remove locking ring from
fuel tank sender assembly.
14.Remove fuel tank sender assembly from fuel
tank and discard seal.
NOTE: The fuel pump and fuel gauge tank unit
are integral parts of the fuel pump housing and
cannot be renewed separately
M88 0359