CONTENTS
CONTENTS 23
Headlamps beam alignment - from 03MY ...................................................................................... 86-2-2
REPAIRS
Lamp - front repeater .................................................................................................................... 86-2-3
Headlamp - up to 03MY .................................................................................................................. 86-2-4
Headlamp - from 03MY .................................................................................................................. 86-2-5
Lamp - tail ..................................................................................................................................... 86-2-6
Lamp - front fog up to 03MY ........................................................................................................... 86-2-6
Lamp - front fog from 03MY ............................................................................................................ 86-2-7
Housing - number plate lamp ......................................................................................................... 86-2-8
Motor - headlamp levelling ............................................................................................................ 86-2-9
Lamp - stop - centre high mounted (CHMSL) .............................................................................. 86-2-10
Lamp - tail/flasher - bumper ............................................................................................................ 86-2-10
Lamp - interior - front .................................................................................................................... 86-2-11
Lamp - interior - rear ..................................................................................................................... 86-2-11
Rheostat - panel lights dimmer ...................................................................................................... 86-2-12
Switch - hazard warning ................................................................................................................. 86-2-13
Switch - indicator and exterior lighting - combined.......................................................................... 86-2-13
Socket - accessory ......................................................................................................................... 86-2-14
Switch - front/rear fog lamps ......................................................................................................... 86-2-14
BODY CONTROL UNIT ............................................................................ 86-3-1
DESCRIPTION AND OPERATION
Description ...................................................................................................................................... 86-3-1
Operation ........................................................................................................................................ 86-3-19
REPAIRS
Body control unit (BCU) .................................................................................................................. 86-3-39
ALARM SYSTEM AND HORN ................................................................. 86-4-1
DESCRIPTION AND OPERATION
Alarm system component layout ..................................................................................................... 86-4-2
Alarm system block diagram ........................................................................................................... 86-4-4
Description ...................................................................................................................................... 86-4-5
Operation ........................................................................................................................................ 86-4-16
REPAIR
Switch - central door locking ......................................................................................................... 86-4-25
Switches - horn ............................................................................................................................. 86-4-25
Vehicle horn .................................................................................................................................. 86-4-26
Sounder - alarm ............................................................................................................................ 86-4-26
Sounder - battery backed-up (BBUS) ............................................................................................. 86-4-27
Switch - bonnet ............................................................................................................................. 86-4-27
Receiver - alarm system - models with sunroof ............................................................................. 86-4-28
Receiver - alarm system - models without sunroof ......................................................................... 86-4-28
Coil - passive immobilisation ......................................................................................................... 86-4-29
WINDOWS ................................................................................................ 86-5-1
DESCRIPTION AND OPERATION
EXTERIOR FITTINGS
76-2-12 REPAIRS
3.Remove 2 nuts securing bumper valance side
mountings to body.
4.Remove 4 nuts securing bumper to crush cans
and remove bumper from body.
5.Remove 3 screws securing bumper to front
cross bar.
6. Models with headlamp wash: Position
container to collect screen washer fluid and
disconnect hose from headlamp washer pump.
Refit
1. Models with headlamp wash: Connect hose
to headlamp washer pump. Refill washer
reservoir with fluid.
2.With assistance position bumper to body.
3.Fit and tighten 3 screws securing bumper to
front cross bar.
4.Tighten nuts securing bumper to crush cans to
13 Nm (10 lbf.ft).
5.Tighten nuts securing bumper to side
mountings to 13 Nm (10 lbf.ft).
6.Connect multiplugs to fog lamps.
7.Fit wheel arch liner extensions and secure with
screws.
Bumper assembly - rear - from 03MY
$% 76.22.15
Remove
1.Remove both rear tail lamps.
+ LIGHTING, REPAIRS, Lamp - tail/
flasher - bumper.
2.Disconnect park distance control harness
multiplug.
3.Release rear lamp harness clips.
M76 4566
LIGHTING
86-2-6 REPAIRS
Lamp - tail
$% 86.40.70
Remove
1.Remove 4 screws securing tail lamp to body.
2.Disconnect multiplug from tail lamp.
3.Remove tail lamp.
Refit
1.Position tail lamp to body and connect
multiplug.
2.Secure tail lamp to body with screws.
Lamp - front fog up to 03MY
$% 86.40.95
Remove
1.Raise front of vehicle, one side.
2. For RH lamp: Remove 7 screws securing
wheel arch liner extension to liner and bumper
valance and remove liner extension.
Disconnect lamp multiplug from harness.
3. For LH lamp:Remove front bumper assembly.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - front.
LIGHTING
REPAIRS 86-2-7
4.Remove 4 screws and remove lamp.
Refit
1.Fit new lamp and secure with screws.
2. For LH lamp:Fit front bumper assembly.
+ EXTERIOR FITTINGS, REPAIRS,
Bumper assembly - front.
3. For RH lamp: Connect multiplug to harness.
Fit wheel arch liner extension, secure to
bumper valance and liner with screws.
4.Lower vehicle.
Lamp - front fog from 03MY
$% 86.40.96
Remove
1.Remove the front bumper finisher.
+ EXTERIOR FITTINGS, REPAIRS,
Trim finisher - bumper - front - from 03MY.
2.Remove 3 screws securing the fog lamp to the
bumper.
3.Disconnect the fog lamp multiplug and remove
the fog lamp.
Refit
1.Position the fog lamp to the bumper, connect
the multiplug and secure with screws.
2.Fit the front bumper finisher.
+ EXTERIOR FITTINGS, REPAIRS,
Trim finisher - bumper - front - from 03MY.
LIGHTING
86-2-14 REPAIRS
Socket - accessory
$% 86.65.62
Remove
1.Remove screw securing accessory socket
escutcheon to loadspace side trim casing.
2.Release accessory socket assembly from trim
casing.
3.Disconnect multiplug and bulb from accessory
socket.
4.Remove accessory socket.
5.Release bulb holder from accessory socket.
Release accessory socket from escutcheon.
Refit
1.Fit accessory socket to escutcheon.
2.Fit bulb holder to accessory socket.
3.Position accessory socket to trim casing and
connect multiplug and bulb.
4.Fit accessory socket to trim casing and secure
with screw.
Switch - front/rear fog lamps
$% 86.65.65
Remove
1.Carefully remove switch from instrument cowl.
2.Disconnect multiplug and remove switch.
Refit
1.Position switch and connect multiplug.
2.Carefully push switch into instrument cowl.
BODY CONTROL UNIT
DESCRIPTION AND OPERATION 86-3-9
IDM outputs
The IDM receives the following signals from the BCU using the serial datalink to provide power outputs:
Description Signal type System
Unlock all doors enable Digital Locking/ Unlocking/ Alarm
Lock passenger and rear doors enable Digital Locking/ Unlocking/ Alarm
Superlock all doors enable Digital Locking/ Unlocking/ Alarm
Lock driver's door Digital Locking/ Unlocking/ Alarm
Rear fog lamps enable Digital Exterior lighting
Daylight running lamps enable Digital Exterior lighting
LH direction indicators enable Digital Direction indicators/ Hazard warning/ Alarm
RH direction indicators enable Digital Direction indicators/ Hazard warning/ Alarm
Gear position indicator illumination Digital Illumination
Headlamp main beam indicator disable Digital Illumination
Front wiper enable Digital Wipers and washers
Rear wiper enable Digital Wipers and washers
Rear window enable Digital Power windows
Shift lever solenoid enable Digital Automatic gearbox
Transfer box solenoid enable/ Alarm sounder
relayDigital Gearbox
Heated rear window enable Digital Heated screens
BODY CONTROL UNIT
DESCRIPTION AND OPERATION 86-3-11
Programmable options
The BCU can be programmed with a number of options to satisfy specific market requirements and customer
preferences. The options can be set using TestBook.
Function Option Details
Transmission Manual The vehicle is fitted with manual transmission.
Automatic The vehicle is fitted with automatic transmission.
Front fog lamps None The vehicle is not fitted with front fog lamps.
Main The front fog lamps will operate if the headlamps are on main
beam.
No main The front fog lamps will not operate if the headlamps are on main
beam.
Interlocks None The vehicle is not fitted with key, shift or transfer box interlocks.
Shift The vehicle is fitted with key, shift and transfer box interlocks.
No transfer The vehicle is fitted with key and shift interlocks, but not a transfer
box interlock.
Daylight running lamps None The vehicle is not fitted with daylight running lamps.
No main The daylight running lamps are on if the headlamp main beams
are off.
No heads The daylight running lights are on with headlamp main and dipped
beams off and the gearbox not in Park.
Programmed wash/ wipe Normal The front wipers operate if the front wash is operated.
No wipe The front wipers do not operate if the front wash is operated.
Key-in warning Disabled The ignition key in audible warning is disabled.
Enabled The ignition key in audible warning is generated if the ignition key
is in and the driver's door is open.
Electric front seats None The vehicle is not fitted with electric front seats.
Normal Electric seat adjustment is available for 45 seconds after the
driver's door opens or if the ignition is on.
Ignition II Electric seat adjustment is available if the ignition is on.
Electric front windows Driver cancel The front windows will be disabled 44 seconds after the driver's
door is opened.
All cancel The front windows will be disabled 44 seconds after any door is
opened.
No cancel The front windows will be disabled when the ignition is turned off.
Heated front screen Fitted The vehicle is fitted with heated front screens.
None The vehicle is not fitted with heated front screens.
Rear windows and
sunroofDriver cancel The rear windows and sunroof will be disabled 44 seconds after
the driver's door is opened.
All cancel The rear windows and sunroof will be disabled 44 seconds after
any door is opened.
No cancel The rear windows and sunroof will be disabled when the ignition
switch is turned off.
Gear position indicator
illuminationAlways The automatic gearbox selector illumination is on when the
ignition is on.
Sidelights The automatic gearbox selector illumination is on when the
ignition is on and the sidelights are off.
Hill descent control None The vehicle is not fitted with hill descent control.
Fitted The vehicle is fitted with hill descent control.
Courtesy headlamps Disabled The vehicle is not fitted with courtesy headlamps.
Enabled The vehicle is fitted with courtesy headlamps.
Odometer error warning Disabled The odometer will not flash if there is an odometer error.
Enabled The odometer will flash if there is an odometer error.
BODY CONTROL UNIT
86-3-16 DESCRIPTION AND OPERATION
Headlamps
The BCU contains a feature which allow the vehicle headlamps to be turned on when the remote transmitter is
pressed (courtesy headlamps).
For markets with daylight running lamps, the BCU controls the logical operation of the daylight running lamps. Options
are daylight running lamps are on if the main beam headlamps are off, or the daylight running lamps are on with main
and dipped beam off and the gearbox not in Park.
Front fog lamps
For markets with front fog lamps fitted, the BCU controls the operation of the front fog lamps. Options can be selected
so that the fog lamps will operate with or without the headlamps on main beam.
Instrument pack
The BCU communicates with the instrument pack via a serial data bus.
+ INSTRUMENTS, DESCRIPTION AND OPERATION, Description.
lThe instrument pack provides the BCU and IDM with details of vehicle speed.
lSignals are provided from the IDM to the instrument pack and BCU when the direction indicator lamps are active.
lFor certain markets, the BCU provides a signal to the instrument pack for indicating when the transfer box is in
neutral.
lThe IDM can signal the instrument pack to illuminate a trailer warning lamp. This operates when the IDM senses
that the current drawn by the indicator circuit exceeds a preset threshold.
lThe odometer reading displayed on the instrument pack LCD screen is also stored in non volatile memory in the
BCU. Whenever the ignition is turned from position I to position II, the instrument pack and the BCU compare
their stored values.
lThe gear selector position is displayed on the instrument pack LCD screen under the direction of the BCU.
Starting
The starting system comprises a starter motor and solenoid located at the rear right hand side of the engine. A starter
relay controlled by the BCU is used to supply battery power for starter solenoid operation. The starter motor receives
its feed directly from the battery.
Cruise control
The BCU processes several signals used for cruise control:
lWhen the brake pedal is pressed, a low voltage brake lamp signal is sent via the BCU to the cruise control ECU.
lThe gear position switch sends an input via the BCU to the cruise control ECU if the selector lever is in Park,
Neutral or Reverse.
lA voltage supply is fed from the BCU to the cruise control SET+ switch.
lA voltage supply is fed from the BCU to the cruise control RES switch.
On vehicles with automatic transmission, if the BCU receives an input from the gear position switch or the brake pedal
switch, the BCU sends a signal to the cruise control ECU to cancel or inhibit cruise control operation.
+ ENGINE MANAGEMENT SYSTEM - Td5, DESCRIPTION AND OPERATION, Description.
+ ENGINE MANAGEMENT SYSTEM - V8, DESCRIPTION AND OPERATION, Description - cruise control.
Shift interlock (where fitted)
On automatic gearbox models, the BCU and IDM combine with an interlock relay located in the passenger
compartment fuse box to operate a shift interlock solenoid, so that the gear selector lever cannot be moved out of
Park until certain logical conditions have been satisfied. Operation of the interlock may be affected, if the battery
becomes discharged.
+ AUTOMATIC GEARBOX - ZF4HP22 - 24, DESCRIPTION AND OPERATION, Description.