Page 504 of 1007
STEERING
REPAIRS 57-11
Drive belt - K1.8
$% 57.20.02
Remove
1.Disconnect battery earth lead.
2.Turn steering on RH lock.
3.Remove 3 bolts securing RH splash shield to
body and remove shield.
4.Fit a 13 mm spanner to hexagon on belt
tensioner and rotate fully clockwise to release
tension on drive belt.
5.To hold tensioner in this position, fit a suitable
pin, not exceeding 3 mm diameter, through
centre of hexagon into tensioner backplate.
6.Remove and discard drive belt.Refit
1.Clean drive belt pulley grooves and ensure
grooves are not damaged.
2.Fit drive belt. Ensure belt is located correctly in
pulley grooves.
3.Release tension, remove retaining pin and
lower tensioner pulley onto drive belt.
4.Fit splash shield and secure with bolts.
5.Straighten steering.
6.Connect battery earth lead.
Page 600 of 1007

RESTRAINT SYSTEMS
REPAIRS 75-19
Rotary coupler - (SRS) air bag system
$% 76.74.20
Remove
WARNING: It is imperative that before any
work is undertaken on the SRS system the
appropriate information is read thoroughly.
1.Make the SRS system safe.
+ GENERAL INFORMATION,
Supplementary restraint system
precautions.
CAUTION: Before disconnecting any part of
the steering linkage, ensure the road wheels
are positioned straight ahead and the
steering wheel is prevented from turning.
Unrestricted turning of the steering wheel
will damage the SRS rotary coupler.
2.Remove steering wheel.
+ STEERING, REPAIRS, Steering
wheel.
CAUTION: Use adhesive tape to prevent
rotation of the rotary coupler once the
steering wheel is removed.
3.Remove steering column nacelle.
+ STEERING, REPAIRS, Nacelle -
column.
4.Disconnect 2 multiplugs from rotary coupler.
5.Remove 4 screws and remove rotary coupler.
CAUTION: Do not dismantle the rotary
coupler, it has no serviceable parts and
must be replaced as a complete assembly.Refit
1.Ensure the rotary coupler is installed in its
centred position. To obtain centre position,
rotate coupler gently clockwise and
anticlockwise until the white segment appears
on the indicator wheel.
CAUTION: Ensure front road wheels are in
the straight ahead position.
2.Fit rotary coupler and secure with screws.
3.Connect multiplugs to rotary coupler.
4.Fit steering column nacelle.
+ STEERING, REPAIRS, Nacelle -
column.
5.Fit steering wheel.
+ STEERING, REPAIRS, Steering
wheel.
6.Connect battery leads, earth lead last.
Page 617 of 1007
DOORS
76-1-12 REPAIRS
Glass regulator - tail door
$% 76.31.65
Remove
1.Remove rear screen.
+ DOORS, REPAIRS, Glass - tail door.
2.Disconnect multiplug from regulator motor.
3.Loosen 3 nuts securing regulator motor and
rotate motor to release from door.
4.Loosen 4 nuts securing top of cable guides and
release guides from door.
5.Remove 2 nuts securing pre-load adjusters and
rotate adjusters fully clockwise to improve
access.
6.Release regulator from door and detach
electrical harness from LH glass clamp.
7.Remove regulator from door.Refit
1.Position regulator to door and unclip motor
transit package from rail.
2.Connect multiplug to regulator motor.
3.Connect harness clip and align regulator to
door.
4.Fit nuts to pre-load adjusters, but do not tighten
at this stage.
5.Position tops of cable guides to door, leaving
fixings finger tight.
6.Tighten regulator motor fixings.
7.Fit rear screen.
+ DOORS, REPAIRS, Glass - tail door.
Page 675 of 1007

INTERIOR TRIM COMPONENTS
76-3-14 REPAIRS
Fascia - up to 04MY
$% 76.46.23
Remove
1.Remove front console.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
2.Remove rotary coupler.
+ RESTRAINT SYSTEMS, REPAIRS,
Rotary coupler - (SRS) air bag system.
3.Disconnect 4 multiplugs from wiper/indicator
switch.
4.Loosen clamping screw and remove wiper/
indicator switch.
5.Remove 2 screws from steering column lower
finisher and remove finisher.6.Open drivers glove box lid and remove fuse box
cover.
7.Disconnect 2 multiplugs from fusebox.
8.Close glove box.
9.Remove clock.
+ INSTRUMENTS, REPAIRS, Clock.
10.Remove both 'A' post upper trim finishers.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim finisher - 'A' post - upper -
renew.
11. Models without passenger airbag: Remove
fascia stowage box.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Stowage box - fascia.
12. Models with passenger airbag: Remove
passenger airbag.
+ RESTRAINT SYSTEMS, REPAIRS,
Air bag - fascia - passenger - up to 04MY.
Page 679 of 1007

INTERIOR TRIM COMPONENTS
76-3-18 REPAIRS
Refit
1.Fit fascia and coin tray mats.
2.Fit immobilisation ECU to fascia and secure
with nuts.
3.Connect multiplug to immobilisation ECU.
4.Fit switch blank.
5.Fit glove box locks to fascia and secure with
screws.
6.Fit glove box and secure with screws.
7.Fit glove box lamp and mat.
8.Fit glove box lids and secure hinge pins.
9.Fit face level vents and seals to fascia.
10.Fit centre bracket and secure with screws.
11. Models without passenger airbag: Fit grab
handle and secure with nuts.
12.Fit instrument pack lower cover and secure with
screws.
13.Fit instrument pack to fascia and secure with
screws.
14.Fit fascia harness to fascia and secure with
clips.
15.Connect Lucars to glove box lamp and switch.
16.Connect multiplugs to mirror switch and
headlamp levelling switch.
17.Fit mirror switch and headlamp levelling switch.
18.Connect multiplugs to instrument pack.
19.Fit instrument pack upper cover and secure
with screws.
20.Connect multiplugs to switches on instrument
bezel finisher, fit bezel and secure with screws.
21.With assistance fit fascia to vehicle and secure
with bolts.22.Connect fascia harness multiplugs to main
harness.
23. Models with passenger airbag: Fit passenger
airbag.
+ RESTRAINT SYSTEMS, REPAIRS,
Air bag - fascia - passenger - up to 04MY.
24. Models without passenger airbag: Fit fascia
stowage box.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Stowage box - fascia.
25.Fit 'A' post upper trim finishers.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim finisher - 'A' post - upper -
renew.
26.Fit clock.
+ INSTRUMENTS, REPAIRS, Clock.
27.Open drivers glove box lid and remove fuse box
cover.
28.Connect multiplugs to fusebox.
29.Fit fusebox cover and close glove box lid.
30.Fit steering column lower cover and secure with
screws.
31.Fit wiper/indicator switch and tighten clamping
screw.
32.Connect multiplugs to wiper/indicator switch.
33.Fit rotary coupler.
+ RESTRAINT SYSTEMS, REPAIRS,
Rotary coupler - (SRS) air bag system.
34.Fit front console.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Console - front - up to 04MY.
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 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 890 of 1007
AIR CONDITIONING
ADJUSTMENTS 82-3
ADJUST ME NTS
Drive belt - compressor - Td4
$% 82.10.01
Check
1.Disconnect battery earth lead.
2.Remove underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
3.Turn steering on RH lock.
4.Remove 3 bolts and RH splash shield.
5.Check condition of drive belt. Renew a drive
belt that shows signs of wear and splitting.Adjust
1.Loosen clamp and pivot bolts of compressor
drive belt tensioner.
2.Apply an anti-clockwise torque of 38 Nm (28
lbf.ft) for an existing belt and 47 Nm (35 lbf.ft)
for a new belt to tensioner plate hexagon.
3.Tighten tensioner clamp bolt to 24 Nm (18
lbf.ft).
4.Tighten tensioner pivot bolt to 24 Nm (18 lbf.ft).
5.Fit splash shield and tighten bolts to 10 Nm (7.5
lbf.ft).
6.Fit underbelly panel.
+ EXTERIOR FITTINGS, REPAIRS,
Panel - underbelly.
7.Connect battery earth lead.
M82 0721