Page 910 of 1007

WIPERS AND WASHERS
REPAIRS 84-5
Pump - washer
$% 84.30.21
Remove
1.Remove front bumper.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
2.Position container to catch windscreen washer
fluid.
3.Disconnect multiplug from washer pump.
4.Release hose from pump.
5.Remove washer pump from reservoir and
remove and discard pump seal.
Refit
1.Fit new pump sealing grommet to reservoir.
2.Fit pump to reservoir.
3.Connect hose and multiplug to pump.
4.Fit front bumper.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper - assembly - front - up to 04MY.
Arm - wiper
$% 84.35.01
Remove
1.Remove wiper blade.
+ WIPERS AND WASHERS, REPAIRS,
Blade - wiper.
2.Remove spare wheel mounting bracket.
+ EXTERIOR FITTINGS, REPAIRS,
Bracket - spare wheel mounting.
3.Raise nut cover on wiper arm and remove nut.
4.Release washer jet tube and remove wiper
arm.
NOTE: Do not carry out further dismantling if
component is removed for access only.
5.Release washer jet and washer jet tube from
wiper arm.
Refit
1.Position and secure washer tube and jet to
wiper arm.
2.Position wiper arm to tail door and connect
washer tube.
3.Set wiper arm with tip contacting joint line
between waist seal and rear door. Fit and
tighten wiper arm nut to 13 Nm (10 lbf.ft).
4.Fit wiper blade.
+ WIPERS AND WASHERS, REPAIRS,
Blade - wiper.
5.Fit spare wheel mounting bracket.
+ EXTERIOR FITTINGS, REPAIRS,
Bracket - spare wheel mounting.
Page 938 of 1007
LIGHTING
REPAIRS 86-2-7
Lamp assembly - rear
$% 86.41.15
Remove
1.Remove 3 Torx screws securing lamp to body.
2.Release lamp, disconnect 2 bulb holders and
remove lamp.
3.Remove lamp sealing rubber.
Refit
1.Fit sealing rubber and bulb holders to lamp.
2.Position lamp, fit and tighten Torx screws.
Lamp assembly - centre high mounted
stop (CHMSL)
$% 86.41.32
Remove
1.Remove 3 screws securing CHMSL bracket to
spare wheel carrier.
2.Release lamp bracket and disconnect
multiplug.
3.Remove lamp and bracket.
4.Remove 2 nuts and remove lamp from bracket.
Refit
1.Position lamp to bracket and tighten nuts.
2.Position lamp bracket and connect multiplug to
lamp.
3.Position lamp bracket to spare wheel carrier
and secure with screws.
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 949 of 1007

SECURITY
86-4-2 REPAIRS
Switch/push - horn
$% 86.30.01
Remove
1.Remove airbag module from steering wheel.
+ RESTRAINT SYSTEMS, REPAIRS,
Air bag - steering wheel.
2.Release horn switch multiplugs and leads from
steering wheel base.
3.Disconnect multiplug from rotary coupler.
4.Using a broad round edged tool, carefully prise
horn switch from steering wheel.
5.Noting fitted position disconnect 2 Lucars and
remove horn switch.
Refit
1.Position horn switch and connect Lucars.
2.Carefully fit horn switch to steering wheel.
3.Connect multiplug to rotary coupler.
4.Secure leads and multiplug to base of steering
wheel.
5.Fit airbag to steering wheel.
+ RESTRAINT SYSTEMS, REPAIRS,
Air bag - steering wheel.
Horn
$% 86.30.10
Remove
1.Remove bolt securing horn to body.
2.Disconnect multiplug from horn and remove
horn.
NOTE: Do not carry out further dismantling if
component is removed for access only.
3.Remove nut securing bracket to horn and
remove bracket.
Refit
1.Fit bracket to horn and secure with nut.
2.Connect multiplug to horn.
3.Fit horn to body and secure with bolt.
Page 980 of 1007
HARNESSES
REPAIRS 86-7-5
44.Disconnect multiplug from wiper motor and pull
into engine bay.
45.With assistance pull main harness into vehicle
interior.
46.Remove 6 screws securing front mud flaps and
remove mud flaps.
47.Release rear edges of front wheel arch liners.48.Release side repeater lamps, disconnect
multiplugs and remove lamps.
49.Remove 3 bolts from passenger compartment
fuse box and pull fuse box forward.
50.Release and disconnect multiplug from RH 'A'
post.
51.Disconnect coaxial cable.
52.Release relays from fuse box bracket.
Page 986 of 1007

HARNESSES
REPAIRS 86-7-11
41.Position fuse box to body and connect
multiplugs.
42.Fit relays to fuse box bracket.
43.Connect coaxial cable.
44.Fit and connect multiplug to RH 'A' post.
45.Fit passenger compartment fuse box and
secure with bolts.
46.Position side repeater lamps, connect
multiplugs and fit to wings.
47.Secure rear edge of front wheel arch liners.
48.Fit front mud flaps and secure with screws.
49.With assistance feed harness through bulk
head into engine bay.
50.Position harness to wiper motor and connect
multiplug.
51.Fit air intake plenum.
+ HEATING AND VENTILATION,
REPAIRS, Plenum - air intake.
52.Secure harness to LH side of engine bay and
secure fixings.
53.Connect multiplug to inertia switch.
54.Connect multiplugs to underside of fuse box.
55.Fit nuts securing fuse box to brackets.
56.Fit battery connections and multiplug to fuse
box.
57.Fit fuse box cover.
58.Connect 'E' box cooling fan multiplug.
59.Connect 'E' box temperature sensor multiplug.
60.Connect engine harness multiplugs to main
harness.
61. Automatic gearbox only:Connect multiplug to
gearbox ECU.
62.Fit 'E' box cover and secure with Allen screws.
63.Connect engine harness multiplugs to main
harness.
64.Fit harness retaining clips.
65. Models with cruise control: Connect
multiplug to vacuum pump.
66.Connect Lucar connector to starter motor.
67.Connect multiplug to LH ABS speed sensor.
68.Fit LH earth header and secure with nut.
69.Connect multiplug to harness.
70.Connect multiplugs to LH headlamp and
headlamp levelling motor.
71.Secure harness to cooling fan clips.
72.Connect multiplugs to cooling fan pack and
cooling fans.
73.Position bonnet release cable to harness and
secure with cable ties.
74.Fit battery carrier.
+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
75.With assistance feed harness through bulk
head into engine bay.
76.Fit earth header to bulk head and secure with
nut.
77.Fit front screen washer tube to harness.
78.Fit harness retaining clips.79.Fit PAS and coolant reservoir support bracket
and secure with bolt and nuts.
80.Connect multiplug to bonnet switch.
81.Connect multiplug to brake fluid low level
indicator switch.
82.Fit jack to holder in engine bay.
83.Connect multiplugs to horn, refrigerant
pressure sensor and compressor.
84.Connect multiplugs to RH headlamp and
headlamp levelling motor.
85.Connect multiplug to RH ABS speed sensor
and secure to clips.
86.Connect multiplug to ABS modulator.
87.Fit earth header to RH inner wing and secure
with nut.
88.Position harness to windscreen washer
reservoir.
89.Fit windscreen washer reservoir.
+ WIPERS AND WASHERS, REPAIRS,
Reservoir - washer.
90.Fit engine acoustic cover.
+ ENGINE - Td4, REPAIRS, Cover -
engine acoustic - Up to 02.5 Model Year.
91.Fit carpet.
Page 987 of 1007
HARNESSES
86-7-12 REPAIRS
Harness - tailgate
$% 86.70.19
Remove
1.Remove RH rear quarter lower trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.
2.Remove tail door plastic sheet.
+ DOORS, REPAIRS, Plastic sheet -
tail door.
3.Remove 3 nuts and remove spare wheel.
4.Remove 3 screws securing CHMSL,
disconnect multiplug and remove CHMSL.
5.Release 2 harness clips.6.Disconnect rear washer tube from behind the
spare wheel carrier.
7.Remove 3 nuts from number plate lamp
housing and release housing.
8.Disconnect 2 Lucars and multiplug from
housing.
9.Collect 2 spacers and housing seal.
10.Remove housing.
Page 989 of 1007

HARNESSES
86-7-14 REPAIRS
17.Release tail door harness from 13 retaining
clips.
18.Release harness sheath from tail door and 'E'
post.
19.Remove harness from vehicle.Refit
1.Position harness to vehicle and secure in
retaining clips.
2.Secure harness sheath to tail door and 'E' post.
3.Connect multiplugs and washer tube to main
harness, secure multiplugs to body.
4.Connect multiplugs to window motor, wiper
motor and door lock.
5.Position door latch, fit and tighten screws.
6.Connect Lucars to heated rear screen.
7.Position number plate lamp housing, locate
seal and fit spacers.
8.Connect multiplug and Lucars to housing.
9.Fit housing and secure with nuts.
10.Connect washer tube behind spare wheel
carrier.
11.Secure harness clips to spare wheel carrier,
connect multiplug to CHMSL, fit CHMSL and
secure with screws.
12.Fit spare wheel and secure with nuts.
13.Fit tail door plastic sheet.
+ DOORS, REPAIRS, Plastic sheet -
tail door.
14.Fit rear lower trim casing .
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - rear quarter - lower
- 5 door.