Page 519 of 1007

STEERING
57-26 REPAIRS
10.Using a broad round edged tool, carefully prise
horn switches from steering wheel.
11.Noting fitted position, disconnect 2 Lucars and
remove horn switch.
12.Repeat for other horn switch.
13. Disconnect multiplugs from cruise control (if
fitted) and radio control switches.
14.Release harness from clips and remove
harness.
15. Models with cruise control: Remove 2
screws securing cruise control switches to
steering wheel.
16. Models with cruise control: Remove cruise
control switches from steering wheel.
17.Remove 2 screws securing radio switches to
steering wheel.
18.Remove radio switches from steering wheel.Refit
1.Fit radio switches to steering wheel and secure
with screws.
2. Models with cruise control: Fit cruise control
switches to steering wheel and secure with
screws.
3.Position harness to horn, cruise control (if
fitted) and radio switches and secure in clips.
4.Position horn switch and connect Lucars.
5.Repeat for other horn switch.
6.Connect multiplugs to cruise control and radio
control switches.
7. Td4 models: Position damper, fit and tighten
screws.
8.Remove tape from rotary coupler.
9.Ensure road wheels are in straight ahead
position and indicator cancelling cam is aligned
horizontally.
10.Fit steering wheel to column and ensure
spokes are horizontal.
11.Fit new self locking nut and tighten to 45 Nm
(33 lbf.ft).
12.Connect multiplug to rotary coupler.
13.Fit drivers airbag.
+ RESTRAINT SYSTEMS, REPAIRS,
Air bag - steering wheel.
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 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 926 of 1007
CHARGING AND STARTING
REPAIRS 86-1-13
Carrier - battery
$% 86.15.11
Remove
1.Remove battery.
+ CHARGING AND STARTING,
REPAIRS, Battery.
2. Models with cruise control: Disconnect
multiplug and hose from cruise control vacuum
pump if fitted.
3.Release harness clips from battery carrier.
4.Remove 4 bolts and remove battery carrier.5. Models with cruise control: Remove cruise
control vacuum pump and mountings from
battery carrier if fitted.
Refit
1. Models with cruise control: Fit mountings
and cruise control vacuum pump to battery
carrier if fitted.
2.Fit battery carrier and tighten bolts to 10 Nm
(7.5 lbf.ft).
3.Secure harness clips to battery carrier.
4. Models with cruise control: Connect
multiplug and hose to cruise control vacuum
pump if fitted.
5.Fit battery.
+ CHARGING AND STARTING,
REPAIRS, Battery.
Page 978 of 1007
HARNESSES
REPAIRS 86-7-3
18.With assistance feed harness through bulk
head into vehicle.
19.Remove battery carrier.
+ CHARGING AND STARTING,
REPAIRS, Carrier - battery.
20.Remove 3 cable ties and release bonnet
release cable from harness.
21.Disconnect multiplug from cooling fan pack and
2 multiplugs from cooling fans.
22.Release 4 clips securing harness to cooling
fans and release harness from cooling fans.
23.Disconnect 2 multiplugs from LH headlamp and
headlamp levelling motor.
24.Disconnect multiplug from harness.25.Remove nut securing LH earth header and
release header.
26.Disconnect multiplug from front LH ABS speed
sensor.
27.Disconnect Lucar connector from starter motor.
28. Models with cruise control:Disconnect
multiplug from cruise control vacuum pump.
29.Release 5 harness retaining clips.
30.Disconnect 2 engine harness to main harness
multiplugs.
31.Release 5 Allen screws securing 'E' box cover
to 'E' box.
32.Remove 'E' box cover
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.
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