PANEL REPAIRS
REPAIRS 77-2-37
Sill outer assembly
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove RH or LH front wing.
+ EXTERIOR FITTINGS, REPAIRS,
Wing - front - up to 03MY.
4.Remove RH or LH front door.
+ DOORS, REPAIRS, Door - front.
5.Remove RH or LH rear door.
+ DOORS, REPAIRS, Door - rear.
6.Remove RH or LH sill finisher.
7.Remove RH or LH 'A' post inner lower
finishers.
8.Remove RH or LH front seat.
+ SEATS, REPAIRS, Seat - front.
9. LH side: Remove power amplifier and EAT
ECU.
+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
10. RH side: Remove CD autochanger.
+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
11.Remove rear seats.
+ SEATS, REPAIRS, Seat - rear.
12.Remove RH or LH front seat belt.
+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - front.
13.Remove tread plates from front and rear door
apertures.
14.Release carpet and position aside.
15.Remove front and rear door aperture seals.
16.Release relevant wiring from 'A' post, 'B/C' post
and sill areas, and position aside.
17.Remove loadspace lower trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
18. RH side: Remove lower ACE accelerometer.
+ FRONT SUSPENSION, REPAIRS,
Accelerometer - ACE - lower.
19. LH side: Remove SLS air compressor unit.
+ REAR SUSPENSION, REPAIRS,
Compressor unit - air - SLS.
20. Models with rear A/C: Recover refrigerant
from A/C system and remove A/C pipes from
LH sill.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
21.Remove 2 bolts securing body to chassis.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit 2 bolts securing body to chassis and tighten
to 45 Nm (33 lbf.ft).
2. Models with rear A/C: Fit A/C pipes to sill and
recharge A/C system.
+ AIR CONDITIONING, REFRIGERANT
RECOVERY, RECYCLING AND
RECHARGING, Refrigerant recovery,
recycling and recharging.
3. LH side: Fit SLS air compressor unit.
+ REAR SUSPENSION, REPAIRS,
Compressor unit - air - SLS.
4. RH side: Fit lower ACE accelerometer.
+ FRONT SUSPENSION, REPAIRS,
Accelerometer - ACE - lower.
5.Fit loadspace lower trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - side - loadspace.
6.Fit relevant wiring to 'A' post, 'B/C' post and sill
areas.
7.Fit front and rear door door aperture seals.
8.Fit carpet and secure into position.
9.Fit tread plates to front and rear door apertures.
10.Fit front seat belt.
+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - front.
11.Fit rear seats.
+ SEATS, REPAIRS, Seat - rear.
12. LH side: Fit CD autochanger.
+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
13. RH side: Fit power amplifier and EAT ECU.
+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
14.Fit front seat.
+ SEATS, REPAIRS, Seat - front.
15.Fit 'A' post inner lower finishers.
M77 1716A
PANEL REPAIRS
REPAIRS 77-2-39
'B/C' post assembly
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove RH or LH rear door.
+ DOORS, REPAIRS, Door - rear.
4.Remove front door striker from 'B/C' post.
5.Remove RH or LH sill finisher.
6.Remove RH or LH front seat.
+ SEATS, REPAIRS, Seat - front.
7. RH side: Remove power amplifier.
+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
8. LH side: Remove CD autochanger.
+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
9.Remove RH or LH front seat belt.
+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - front.
10.Remove RH or LH rear seat.
+ SEATS, REPAIRS, Seat - rear.
11.Remove head lining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.
12.Remove tread plate from front and rear door
apertures.
13.Release carpet from fixings and position aside.
14.Remove front and rear door door aperture
seals.
15.Release relevant wiring from 'B/C' post and sill
areas and position aside.
16.Remove side drip rail finisher.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
2. Before welding 'B/C' post to roof, apply
'Heat shrink paste' to roof area to avoid heat
damage to paintwork.
Refit
1.Fit side drip rail finisher.
2.Fit wiring to 'B/C' post and sill areas.
3.Fit front and rear door door aperture seal.
4.Position carpet and secure with fixings.
5.Fit tread plates to front and rear door apertures.
6.Fit head lining.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Headlining.
7.Fit rear seat.
+ SEATS, REPAIRS, Seat - rear.
8.Fit front seat belt.
+ RESTRAINT SYSTEMS, REPAIRS,
Seat belt - front.
9. LH side: Fit CD autochanger.
+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
10. RH side: Fit power amplifier.
+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
11.Fit RH or LH front seat.
+ SEATS, REPAIRS, Seat - front.
12.Fit sill finisher.
PANEL REPAIRS
REPAIRS 77-2-43
'D' post outer assembly
In this procedure, the panel body side assembly is
also replaced in conjunction with the 'D' post
assembly. The 'D' post inner closing panel can also
be replaced in this procedure, if required.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove panel body side assembly.
+ PANEL REPAIRS, REPAIRS, Panel
body side assembly.
4.Remove RH or LH sill finisher.
5.Remove front seat.
+ SEATS, REPAIRS, Seat - front.
6. RH side: Remove power amplifier.
+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
7. LH side: Remove CD autochanger.
+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
8.Remove 'B/C' post lower trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - lower - 'B' post.
9.Remove rear seat.
+ SEATS, REPAIRS, Seat - rear.
10.Remove loadspace carpet.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - loadspace.
11.Release carpet for access to 'D' post assembly
and position aside.
12.Remove relevant wiring.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit and secure wiring.
2.Position and secure carpet into position.
3.Fit loadspace carpet.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - loadspace.
4.Fit rear seat.
+ SEATS, REPAIRS, Seat - rear.
5.Fit 'B/C' post lower trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - lower - 'B' post.
6. LH side: Fit CD autochanger.
+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
7. RH side: Fit power amplifier.
+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
8.Fit front seat.
+ SEATS, REPAIRS, Seat - front.
9.Fit RH or LH sill finisher.
10.Fit panel body side assembly.
+ PANEL REPAIRS, REPAIRS, Panel
body side assembly.
11.Connect leads/multiplug to alternator.
12.Connect battery leads, negative lead last.
M77 1699B
PANEL REPAIRS
77-2-44 REPAIRS
Wheelarch rear outer assembly
In this procedure, the panel body side assembly is
replaced in conjunction with the wheelarch rear outer
assembly.
Remove
1.Disconnect both battery leads, negative lead
first.
2.Disconnect leads/multiplug from alternator.
3.Remove panel body side assembly.
+ PANEL REPAIRS, REPAIRS, Panel
body side assembly.
4.Remove front seat.
+ SEATS, REPAIRS, Seat - front.
5. RH side: Remove power amplifier.
+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
6. LH side: Remove CD autochanger.
+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
7.Remove 'B/C' post lower trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - lower - 'B' post.
8.Remove rear seat.
+ SEATS, REPAIRS, Seat - rear.
9.Remove loadspace carpet.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - loadspace.
10.Release carpet for access to 'D' post assembly
and position aside.
11.Remove relevant wiring.Repair
1.Remove existing panel(s), prepare panel joint
faces and install new panel(s) in accordance
with Panel Replacement Procedure. Punch or
drill holes in new panel for plug welding as
shown.
Refit
1.Fit and secure wiring.
2.Position and secure carpet into position.
3.Fit loadspace carpet.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Carpet - loadspace.
4.Fit rear seat.
+ SEATS, REPAIRS, Seat - rear.
5.Fit 'B/C' post lower trim casing.
+ INTERIOR TRIM COMPONENTS,
REPAIRS, Trim casing - lower - 'B' post.
6. LH side: Fit CD autochanger.
+ IN CAR ENTERTAINMENT,
REPAIRS, CD autochanger.
7. RH side: Fit power amplifier.
+ IN CAR ENTERTAINMENT,
REPAIRS, Amplifier - power.
8.Fit front seat.
+ SEATS, REPAIRS, Seat - front.
9.Fit panel body side assembly.
+ PANEL REPAIRS, REPAIRS, Panel
body side assembly.
10.Connect leads/multiplug to alternator.
11.Connect battery leads, negative lead last.
M77 1700A
IN CAR ENTERTAINMENT
DESCRIPTION AND OPERATION 86-6-1
IN CAR ENTERTA INMENT DESCRIPTION AND OPERAT ION
ICE System Component layout
High line RHD system shown (LHD system similar)
1FM aerial and amplifier (high line only)
2AM/FM aerial and amplifier
3Power amplifier (high line only)
4Radio cassette player
5Remote radio control switches (mid line and
high line only)
6Upper front door speaker LH/RH (high line
only)
7A post speaker LH/RH (mid line and high line
only)8Upper rear door speaker, LH/RH (high line
only)
9Lower front door speaker LH/RH
10CD-autochanger (if fitted)
11Lower rear door speaker LH/RH
12Radio headphone amplifier LH/RH (high line
only)
13Tail door speakers (high line only)
IN CAR ENTERTAINMENT
DESCRIPTION AND OPERATION 86-6-3
High line ICE system control diagram
1Fusible link
2Battery power supply fuse
3Remote radio control switches
4Radio cassette
5CD-autochanger
6Telephone system interface
7Speed signal from SLABS ECU
8Speakers
9Power amplifier10Auxiliary power supply fuse
11Auxiliary relay
12Radio headphone amplifier RH rear
13Radio headphone amplifier LH rear
14Amplifier FM aerial
15FM aerial
16Amplifier AM/FM aerial
17AM/FM aerial
IN CAR ENTERTAINMENT
86-6-4 DESCRIPTION AND OPERATION
Description
General
The in car entertainment (ICE) system allows the driver and passengers to listen to audio output from the speakers
or optional headphones inside the vehicle. Buttons or knobs on the radio cassette allow changes of levels or
selections during the various modes of operation. The system can be controlled from the fascia mounted radio
cassette, or optional remote control switches on the left hand side of the steering wheel. High line systems may also
have rear headphone amplifiers that have some control of the system via the radio cassette player.
One or two amplified aerials located in the rear side windows send radio signals to the radio cassette player. On high
line systems a power amplifier and a CD-autochanger may be located under the front seats. Speakers are located in
the lower door panels, additional speakers may be located in upper door trim, the A-post and the tail door. A display
screen shows the user the current system status.
The ICE supplied varies with trim level and market. Vehicles may not have all of the speakers, amplified aerials, CD-
autochanger, rear headphone amplifiers or power amplifier.
Base system radio cassette
The base radio cassette has buttons for LD (loudness) AM, FM, EJECT (tape), Reverse, Base/Balance, treble, MAN
forward and reverse. The base radio cassette is located in the center of the fascia and contains the radio and tape
player, four clips (accessible through holes in the front of the unit) secure the unit in the fascia. To remove the unit
the four clips must be released with a special tool. The base system can be controlled from the fascia mounted radio
cassette. A logic control circuit in the radio cassette player controls the operation in the various control modes.
The radio cassette has a display screen, the information shown can be the current radio frequency, tape operating,
bass or loudness settings. Power for the illumination on the radio cassette is supplied from the passenger
compartment fuse box. A main fuse is also located in the connector socket area on the back of the radio cassette.
Security code function
A combination of buttons on the radio cassette are used to input and change security codes. Security codes make the
unit unusable if the unit is disconnected from the vehicle without deactivating the security code. The radio cassette
has an internal memory chip that stores the code information, if the power is removed from the unit the chip will
activate the security code feature. For this reason the security code feature must be deactivated before the unit is
removed or the vehicles battery is disconnected.
Audio functions
The radio cassette has buttons for the following audio functions: LD (loudness), bass/balance, fader, treble and
volume.
Cassette functions
The radio cassette has buttons for the following cassette functions: eject, forward, reverse and tape reversal.
Multi function buttons
The function of presets 1-6 and the MAN button depends on current mode of operation and allows selection of radio
band, radio on, tape track and search/seek functions. The MAN button is mode dependent, when pressed the button
allows manual operation or alternate mode selections such as manual tuning.
Internal memory
An internal memory chip stores the station presets and security code, power is supplied internally to the chip via a
permanent power feed, supplied from the passenger compartment fuse box.
IN CAR ENTERTAINMENT
DESCRIPTION AND OPERATION 86-6-5
Radio cassette player connector pin details.
Connector/Pin No. Description Input/Output
C0092
1 Rear RH speaker line Output +
2 Rear RH speaker line Output -
3 Front RH speaker line Output +
4 Front RH speaker line Output -
5 Front LH speaker line Output +
6 Front LH speaker line Output -
7 Rear LH speaker line Output +
8 Rear LH speaker line Output -
C0098
1 Telephone mute Input
2 Steering wheel remote radio controls Input
3 Steering wheel remote radio controls Output
4 Permanent battery feed Input
5 System enable Output
6 Illumination Input
7 Auxilary feed Input
8EarthInput
C0921 (high line systems)
1 Radio headphone left channel Output +
2 Radio headphone right channel Output +
3 Telephone audio Input +
4 Radio headphone left channel Output -
5 Radio headphone right channel Output -
6 Telephone audio Input -
C0922 (high line systems)
7 Radio headphone active Input