Page 681 of 1007
INTERIOR TRIM COMPONENTS
76-3-20 REPAIRS
10.Disconnect 2 multiplugs from fuse box.
11.Close glove box.
12.Remove clock.
+ INSTRUMENTS, REPAIRS, Clock.
13.Remove hazard warning switch.
+ DRIVER CONTROLS, REPAIRS,
Switch - hazard warning - from 04MY.
14.Remove both 'A' post upper trim finishers.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim finisher - 'A' post - upper -
renew.
15.Remove passenger airbag.
+ RESTRAINT SYSTEMS, REPAIRS,
Air bag - fascia - passenger - from 04MY.
16.Disconnect 2 multiplugs from fascia harness.17.Remove 14 bolts securing fascia.
18.With assistance remove fascia.
NOTE: Do not carry out further dismantling if
component is removed for access only.
19.Disconnect 4 multiplugs from fascia switch
assembly.
20.Remove 4 switches from fascia switch carrier.
M76 4722
M76 4714
Page 682 of 1007
INTERIOR TRIM COMPONENTS
REPAIRS 76-3-21
21.Release mirror switch from fascia and
disconnect multiplug, remove switch assembly.
22.Remove passenger glove box internal finisher
and remove 4 screws securing liner.
23.Release glove box liner and release lamp
assembly.
24.Remove passenger side glove box liner
assembly.25.Remove glove box hinge pins and remove
glove box lids.
26.Remove cruise control switch carrier assembly
from fascia.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Switch - engagement
(on/off) - from 04MY.
27.Carefully release and remove 4 face level
fascia air vents.
28.Remove 2 screws securing drivers side glove
box striker plate assembly and collect striker.
Page 683 of 1007

INTERIOR TRIM COMPONENTS
76-3-22 REPAIRS
29.Noting fitted position remove fascia harness
assembly.Refit
1.Fit and secure fascia harness.
2.Fit striker plate, secure with screws and adjust
if necessary.
3.Fit passenger side glove box assembly.
4.Fit face level air vents.
5.Fit and secure cruise switch carrier assembly to
fascia.
+ FUEL DELIVERY SYSTEM -
PETROL, REPAIRS, Switch - engagement
(on/off) - from 04MY.
6.Fit glove box lids and secure hinge pins.
7.Connect mirror switch multiplug and fit switch
assembly to fascia.
8.Fit switches to fascia carrier and connect
multiplugs.
9.With assistance fit fascia to vehicle and secure
bolts to 10 Nm (7 lbf.ft).
10.Connect fascia harness multiplugs to main
harness.
11.Fit passenger airbag.
+ RESTRAINT SYSTEMS, REPAIRS,
Air bag - fascia - passenger - from 04MY.
12.Fit 'A' post upper trim finishers.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim finisher - 'A' post - upper -
renew.
13.Fit hazard warning switch.
+ DRIVER CONTROLS, REPAIRS,
Switch - hazard warning - from 04MY.
14.Fit clock.
+ INSTRUMENTS, REPAIRS, Clock.
15.Open drivers side glove box.
16.Fit Radio/CD module.
+ IN CAR ENTERTAINMENT,
REPAIRS, Radio/CD - from 04MY.
17.Fit fuse box cover and close glove box lid.
18.Fit steering column lower cover and secure with
screws.
19.Fit wiper/indicator switch and tighten clamping
screw.
20.Connect multiplugs to wiper/indicator switch.
21.Fit rotary coupler.
+ RESTRAINT SYSTEMS, REPAIRS,
Rotary coupler - (SRS) air bag system.
22.Fit heater control to fascia and secure with
screws.
23.Fit instrument pack.
+ INSTRUMENTS, REPAIRS,
Instrument panel - from 04MY.
M76 4721
Page 686 of 1007
INTERIOR TRIM COMPONENTS
REPAIRS 76-3-25
Glove box
$% 76.52.03
Remove
1.Open glove box and remove glove box mat.
2.Release illumination lamp from glove box.
3.Remove 4 screws from glove box and remove
glove box.
Refit
1.Fit glove box and secure with screws.
2.Fit illumination lamp.
3.Fit glove box mat.
4.Close glove box.
Headlining - 3 door
$% 76.64.15
Remove
1.Fold front seat squabs forward.
2.Remove both sun visors.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Sun visor.
3.Remove both 'A' post upper trim finishers.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim finisher - 'A' post - upper -
renew.
4.Remove 2 screws securing headlining to front
end of roof panel.
Page 770 of 1007
PANEL REPAIRS
WELDING PROCEDURES 77-2-15
WE LDING PROCEDURE S
ECU locations (3 door model shown, 5
door model similar)
1Central control unit (on forward side of
passenger compartment fusebox, behind
driver's glove box)
2RF Receiver (on top of instrument pack)
3Immobiliser ECU (rear of fascia)
4DCU (SRS on transmission tunnel below
heater)
5EAT ECU (inside Environmental 'E' box)
6ECM (inside 'E' box)
7Fuel Burning Heater (behind wheelarch liner)
'Diesel only'8Cooling Fan Ecu (rear of radiator housing) all
models except 1.8
9ABS ECU (RH side front of engine
compartment)
10Folding door mirror ECU (on transmission
tunnel under centre console)
11Window lift ECU (on driver `A` post)
12Cruise Control Interface ECU (under R/H seat)
13Cruise control ECU (under R/H seat)
Page 868 of 1007
HEATING AND VENTILATION
REPAIRS 80-3
Servo - air recirculation
$% 80.10.18
Remove
1.Remove glove box.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Glove box.
2.Disconnect multiplug from servo.
3.Remove screw securing servo to evaporator
and remove servo.
Refit
1.Fit servo to evaporator and secure with screw.
2.Connect multiplug to servo.
3.Fit glove box.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Glove box.
Switch - recirculation control
$% 80.10.21
Remove
1.Remove 3 heater control knobs.
2.Remove 2 screws securing heater control
finisher to heater controls and remove finisher.
3.Release switch and disconnect multiplug.
4.Remove switch.
Refit
1.Fit recirculation switch to heater control panel
and connect multiplug.
2.Fit heater control finisher to heater controls and
secure with screws.
3.Fit heater control knobs.
Page 939 of 1007
LIGHTING
86-2-8 REPAIRS
Lamp assembly - glove compartment
$% 86.45.08
Remove
1.Open glove box.
2.Release illumination lamp from glove box.
3.Disconnect 2 Lucars and remove glove box
lamp.
Refit
1.Position lamp and connect Lucars.
2.Fit lamp and close glove box.
Lamp assembly - load space
$% 86.45.16
Remove
1.Release load space lamp from trim casing.
2.Disconnect 2 Lucars and remove load space
lamp.
Refit
1.Position lamp and connect Lucars.
2.Fit load space lamp to trim casing.
Page 940 of 1007
LIGHTING
REPAIRS 86-2-9
Switch - headlamp levelling
$% 86.65.16
Remove
1.Release headlamp levelling switch from fascia
and disconnect multiplug.
Refit
1.Position switch, connect multiplug and secure
switch to fascia.
Switch - glove compartment
$% 86.65.24
Remove
1.Remove glove box.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Glove box.
2.Disconnect 2 Lucars from glove box lamp
switch.
3.Release clips and remove switch from glove
box latch.
Refit
1.Fit switch to glove box latch and connect
Lucars.
2.Fit glove box.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Glove box.