Page 25 of 1007

CONTENTS
22 CONTENTS
NAVIGATION SYSTEM ............................................................................ 87-1
REPAIRS
Interface unit - remote control ........................................................................................................ 87-1
Display unit - navigation system .................................................................................................... 87-1
INSTRUMENTS ......................................................................................... 88-1
REPAIRS
Clock .............................................................................................................................................. 88-1
Instrument panel - up to 04MY ....................................................................................................... 88-2
Instrument panel - from 04MY ........................................................................................................ 88-3
Cowl - instrument - up to 04MY ...................................................................................................... 88-4
Cowl - instrument - from 04MY ....................................................................................................... 88-5
Sender unit - fuel tank gauge.......................................................................................................... 88-6
Sender unit assembly - fuel tank - Td4 models - from 03MY.......................................................... 88-6
Page 680 of 1007
INTERIOR TRIM COMPONENTS
REPAIRS 76-3-19
Fascia - from 04MY
$% 76.46.23
Remove
1.Remove instrument pack.
+ INSTRUMENTS, REPAIRS,
Instrument panel - from 04MY.
2.Remove the Radio/CD module.
+ IN CAR ENTERTAINMENT,
REPAIRS, Radio/CD - from 04MY.
3.Remove 4 screws securing heater controls to
centre console.
4.Remove rotary coupler.
+ RESTRAINT SYSTEMS, REPAIRS,
Rotary coupler - (SRS) air bag system.
5.Disconnect 4 multiplugs from wiper/indicator
switch.6.Loosen clamping screw and remove wiper/
indicator switch.
7.Remove 2 screws from steering column lower
finisher and remove finisher.
8.Open drivers glove box lid and remove fuse box
cover.
9.
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 957 of 1007
SECURITY
86-4-10 REPAIRS
Receiver - alarm system
$% 86.77.31
Remove
1.Remove instrument cowl.
+ INSTRUMENTS, REPAIRS, Cowl -
instrument - up to 04MY.
Up to 04MY illustrated.
2.Remove 4 screws and remove instrument
panel upper cover.
3.Disconnect multiplug and remove alarm
receiver from instrument pack.
Refit
1.Fit alarm receiver and connect multiplug.
2.Fit instrument panel upper cover and secure
with screws.
3.Fit instrument cowl.
+ INSTRUMENTS, REPAIRS, Cowl -
instrument - up to 04MY.
Coil - passive immobilisation - alarm
system
$% 86.77.35
Remove
1.Remove steering column nacelle.
+ STEERING, REPAIRS, Nacelle -
column.
2.Release passive coil from steering lock.
3.Collect illumination ring.
4.Disconnect multiplug and remove passive coil.
Refit
1.Fit illumination ring.
2.Fit passive coil and connect multiplug.
3.Fit steering column nacelle.
+ STEERING, REPAIRS, Nacelle -
column.
Page 1001 of 1007
INSTRUMENTS
88-2 REPAIRS
Instrument panel - up to 04MY
$% 88.20.01
Remove
1.Make the SRS system safe.
+ GENERAL INFORMATION,
Supplementary restraint system
precautions.
2.Remove instrument cowl.
+ INSTRUMENTS, REPAIRS, Cowl -
instrument - up to 04MY.
3.Remove 4 screws and remove instrument
panel upper cover.
4.Remove 4 screws securing instrument panel to
fascia.5.Disconnect 4 multiplugs and remove
instrument panel.
Refit
1.Position instrument panel and connect
multiplugs.
2.Fit instrument panel to fascia and secure with
screws.
3.Fit instrument panel upper cover and secure
with screws.
4.Fit instrument cowl.
+ INSTRUMENTS, REPAIRS, Cowl -
instrument - up to 04MY.
5.Connect battery leads, earth lead last.
Page 1002 of 1007
INSTRUMENTS
REPAIRS 88-3
Instrument panel - from 04MY
$% 88.20.01
Remove
1.Remove instrument cowl.
+ INSTRUMENTS, REPAIRS, Cowl -
instrument - from 04MY.
2.Remove 2 screws securing instrument pack to
fascia, release pack from lower mounting lugs
and move aside.
3.Disconnect 3 multiplugs from instrument pack.
4.Release clip, securing aerial receiver wire from
underside of instrument pack retaining bracket.
5.Remove instrument pack.Refit
1.Position instrument pack and connect
multiplugs.
2.Position and secure aerial wire to retaining
bracket.
3.Fit instrument pack to fascia and secure with
screws.
4.Fit instrument cowl.
+ INSTRUMENTS, REPAIRS, Cowl -
instrument - from 04MY.
M88 0365
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