Antenna (15.02)
Vehicle Entertainment (15.00)
May 2007 Workshop Manual 15-2-1
Vehicle Entertainment (15.00)
Antenna (15.02)
Maintenance
ICE System Antenna-Renew
Removal
1. Battery isolation switch ‘OFF’.
2. Remove RH rear wheel arch liner (see Workshop Manual procedure 01.02.HB Wheel Arch Liner - Rear -
RH - Renew). 3. Remove bolts (x2) securing AM antenna to body (see Fig.
1).
4. Remove nut securing AM antenna earth connection to body.
5. Release AM antenna cable from clips (x4).
6. Remove bolts (x4) securing tuner base plate to wheel arch (note position of earth lead) (see Fig. 2).
Repair Operation Time (ROT)
Repair Operation Time (ROT)
Fig. 1
Fig. 2
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Antenna (15.02)
Vehicle Entertainment (15.00)
May 2007 Workshop Manual 15-2-3
7. Position AM antenna to body , install and torque tighten
bolts (x2).
8. Position AM antenna earth connector, install and torque tighten nut.
9. Route AM antenna cable through grommet into luggage compartment.
10. Correctly route AM antenna cable, connect to marked position in multiplug, secure with clip.
11. Feed multiplugs into wheel arch and connect to tuner assemblies.
12. Secure antenna cables in clips (x3), luggage compartment.
13. Install power amplifier assembly (see Workshop Manual procedure 15.01.AB Power Amplifier - Renew).
14. Raise vehicle on ramp.
15. Position tuner base plate, position earth lead, install and torque tighten bolts (x4).
16. Install RH rear wheel arch liner (see Workshop Manual procedure 01.02.HB Wheel Arch Liner - Rear - RH -
Renew).
17. Lower vehicle on ramp.
18. Battery isolation switch ‘ON’.
Front Lights (17.01)
Lighting (17.00)17-1-2 Workshop Manual May 2007
Lighting (17.00)
Front Lights (17.01)
Specifications
Maintenance
RH/LH Headlamp Assembly-Renew
Removal
1. Disconnect vehicle battery.
2. Raise vehicle on ramp.
3. Remove LH/RH road wheel.
4. Remove intake air filter box (see Workshop Manual procedure 03.12.AB/03.12.BB Air Filter Box LH/RH
Renew).
5. Disconnect headlamp mu ltiplug (see Fig. 1). 6. Remove bolts (x3) from headlamp to bracket.
7. Disconnect headlamp washer supply hose (see Fig. 2).
8. Remove headlamp unit (see Fig. 4).
Installation
1. Connect multiplug and washer hose.
Bulbs
Rating
Type
(European) Type
(Federal)
Headlight dipped
beam-HID 35W D1S D1S
Headlight dipped
beam-Halogen 55W H11LL H11LL
Headlight main beam 65W H9 H9
Side Repeater 5W WY5W WY5W
Side marker (front and
rear) 3W N/A W3W
Headlamp AlignmentEuropeanFederal
Main Beam Alignment 1% Down 0.7% Down Vol.
Dipped Beam Alignment 1% Down 0.7% Down Vol.
Main beam is fixed to the Dipped beam.
Repair Operation Time (ROT)
Fig. 3
Fig. 2
Fig. 4
Front Lights (17.01)
Lighting (17.00)
May 2007 Workshop Manual 17-1-3
2. Position headlamp unit.
3. Install 3 Bolts from headlamp to bracket.
4. Install intake air filter box (see Workshop Manual procedure 03.12.AB/03.12.BB Air Filter Box LH/RH
Renew).
5. Install road wheel.
6. Lower vehicle on ramp.
7. Connect vehicle battery
8. Check headlamp alignment (see Workshop Manual procedure 17.01.BC Headlamp Alignment - Adjust).
Headlamp Alignment-Adjust
1. Top up all fluids to correct level.
2. Ensure fuel tank is ‘FULL’.
3. Position 37.5 kg in each seat.
4. Remove the access panel from wheel arch liner.
5. Position beam setting equipment to vehicle.
6. Switch ignition to position 2 and back to 0 (to set headlights).
7. Check headlamp alignment.
8. Switch ignition to position 2 and back to 0 (to set headlights).
9. Check headlamp alignment.
10. Adjust headlights
11. Check headlamp alignment.
12. Remove beam setting equipment from vehicle.
13. Install the access panel to wheel arch liner.
14. Remove the 37.5 kg weights.
Front Side Repeater Lamp Assembly -
Remove and Install
Remove
1. Raise the vehicle and make it safe.
2. Remove the two M6 Torx head screws that attach the wheelarch liner at the middle of the wheelarch.
3. Move the wheelarch liner to get access to the repeater lamp assembly.
4. Disconnect the electrical connector for the side repeater lamp.
5. Turn the side repeater lamp assembly clockwise (When
you look from outside the wing) and pull the assembly
out of the wing.
Install
1. Install the side repeater lamp assembly into the wing . Turn the assembly counterclockwise to attach it. 2. Install the electrical connector to the side repeater lamp.
3. Put the wheelarch liner back into position.
4. Install the two M6 Torx head screws that attach the
wheelarch liner.
5. Lower the vehicle.
Front Side Repeater Bulb - Remove and
Install
Remove
1. Raise the vehicle and make it safe.
2. Remove the two M6 Torx head screws that attach the
wheelarch liner at the middle of the wheelarch.
3. Move the wheelarch liner to get access to the repeater lamp assembly.
4. Hold the side repeater body and turn the bulb holder assembly counterclockwise an d pull it out of the body.
5. Pull the bulb to release it from the bulb holder.
Install
1. Push the bulb into the bulb holder.
2. Align the bulb holder assembly with the side repeater body.
3. Push the bulb holder assemby into the side repeater body and turn it clockwise to lock it.
4. Put the wheelarch liner back into position.
5. Install the two M6 Torx head screws that attach the wheelarch liner.
6. Lower the vehicle.
Repair Operation Time (ROT)
Repair Operation Time (ROT)
Repair Operation Time (ROT)
WARNING
BE CAREFUL WHEN YOU IN STALL AND REMOVE THE
BULB. THE GLASS OF THE BULB CAN BREAK AND CAUSE INJURY.
WARNING
BE CAREFUL WHEN YOU IN STALL AND REMOVE THE
BULB. THE GLASS OF THE BULB CAN BREAK AND
CAUSE INJURY.
Wiring and Circuit Protection (18.01)
Electric Distribution/E lectronic Control (18.00)
18-1-34 Workshop Manual May 2007
74. Remove bolts (x4) and earth strap for satellite navigation
mounting plate access (tie aside) (see Fig. 33).
75. Disconnect GPS (x2) and AM/FM tuner multiplugs.
76. Disconnect Lucar connectors (x2) from AM/FM tuner and unclip service loop and push harness into vehicle.
77. Push rear light harness and grommet into vehicle.
78. Remove harness clips (x4).
79. Remove wires from earth headers (x3).
80. Disconnect Interior light, accessory sockets (x2), battery disconnect switch, power pl ug and barometric sensor
(clipped to body x4).
81. Release harness from body (x3).
82. Release grommet and pull harness from wheel arch area (see Fig. 34). 83. Disconnect multiplugs forward harness to main harness
(x3) (clipped to body x1) (see Fig. 35).
84. Disconnect (bolted) multiplug forward harness to main harness (clipped to body).
85. Release grommet and feed harness from under bonnet through bulkhead into cabin.
86. Remove harness from vehicle.
Installation
1. Connect throttle pedal mult iplugs (x2) (see Fig. 1).
2. Install earth headers (x3).
3. Connect Stop light switch, Clutch UP switch and Clutch DOWN switch multiplugs (x2) Clip to body (x1).
4. Install harness clips (x3).
5. Secure multiplugs to sill (x2).
6. Secure roof harness clips (x4) and velcro (x2) to body
7. Connect engine harness to main harness multiplugs (x4) (clip to body).
8. Install earth headers (x4).
9. Connect battery header (x1).
10. Secure harness from clips (x3).
Fig. 33
Fig. 34
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Fig. 35
Fig. 1
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Wiring and Circuit Protection (18.01)
Electric Distribution/Electronic Control (18.00)
May 2007 Workshop Manual 18-1-35
11. Connect door harness to main harness multiplug and
secure boot.
12. Connect Crash sensor an d parking brake multiplugs.
13. Connect Fuel pump module, parking aid module (x2) and pre-tensioner multiplugs (clip to body).
14. Install earth header.
15. Install clips (x13).
16. Connect petrol tank multiplug and secure to body
17. Install harness clips (x2).
18. Pull harness from passenger compartment and secure grommet.
19. Connect crash sensor, battery disconnect switch and pre-tensioner multiplugs (clip to body x2).
20. Install battery header.
21. Install earth headers (x2).
22. Secure in-line fuse to body.
23. Secure harness to floor (bolts x4).
24. Install clips (x8).
25. Feed harness into tailgate area and secure grommet (LH).
26. Connect LH tailgate harness multiplug (clip to body).
27. Install LH harness clips (x3).
28. Connect RH tailgate ha rness multiplug (clipped to
body).
29. Feed harness into tailgate area and secure grommet (RH).
30. Install RH harness clips (x4).
31. Install nuts (x7) harness to tunnel.
32. Install earth headers (x2).
33. Connect Airbag module (x2) multiplugs.
34. Install harness clips (x3).
35. Install nuts (x3) harness to tunnel.
36. Install earth headers (x2).
37. Connect Yaw sensor multiplug.
38. Install earth headers (x2).
39. Install nuts (x3) harness to front bulkhead.
40. Install harness clips (x4).
41. Connect fuel filler flap release and interior light
multiplugs.
42. Push rear light harness through body and secure grommet.
43. Install new harness clips (x7).
44. Pull harness from interior, connect Lucar connectors (x2) to AM/FM tuner and clip service loop.
45. Connect GPS (x2) and AM/FM tuner multiplugs.
46. Install bolts (x4) and earth strap for Satellite Navigation mounting plate access.
47. Connect rear bumper harness (x2) and Subframe harness multiplugs (clipped to body x1).
48. Push harness into w/arch area and secure grommet.
49. Install wires to earth headers (x3).
50. Push rear light harness through body and fit grommet. 51. Secure harness to body (x3).
52. Connect Interior light, a
ccessory sockets (x2), battery
disconnect switch, power plug (clipped to body x4).
53. Install new harness clips (x4).
54. Feed harness from cabin th rough bulkhead into under
bonnet area and secure grommet.
55. Connect multiplugs forward harness to main harness (x3) (clip to body).
56. Connect (bolted) multiplug forward harness to main harness (clip to body).
57. Install brake booster (see Workshop Manual procedure 06.07.AB Brake Booster - RHD - Renew
58. Install footrest (bolts x4).
59. Install handbrake lever (bolts x4).
60. Install front floor carpet and a post trim panel.
61. Install multimedia module (see Workshop Manual procedure 19.07.BB Module - Multi Media - Renew).
62. Position LH and RH rear lamp assemblies and connect
multiplugs (x2).
63. Install rubber seals (x3), plain washers (x3), and star washers (x3). Install and tighten nuts (x3).
64. Position fusebox, connect main battery feed, install and torque tighten nut, install terminal cover.
65. Connect multiplugs (x2) and install fusebox in mounting bracket.
66. Install mobility kit.
67. Install tyre sealant bottle.
68. Install power amplifier (see Workshop Manual procedure 15.01.AB Power Amplifier - Renew).
69. Fit rear floor carpet - check procedure
70. Connect multiplug (x1) subwoofer.
71. Install subwoofer (nut x1 and bolt x1).
72. Install seat belt bracket (bolts x4).
73. Install speaker to LH and RH trim moulding (nuts x6).
74. Connect multiplug (x2) LH and RH speaker
75. Feed seatbelt/s through quarter trim moulding.
76. Install quarter trim moulding (bolts x2 and screw x1).
77. Install RH and LH quarter trim middle panel, secure
with clips, Install and tighten screw.
78. Install RH rear wheel arch liner (see Workshop Manual procedure 01.02.JB Wheel Arch Liner - Rear - RH -
Renew).
79. Install central electronic module (see Workshop Manual procedure 18.01.LC Module - Central Electronic -
Renew).
80. Install instrument panel (see Workshop Manual procedure 01.12.AB Instrument Panel - Facia Assembly
- Remove for Access and Refit).
81. Install front header panel (see Workshop Manual procedure 01.05.BB Panel Assembly - Header - Renew).
82. Connect vehicle battery.
Active Anti-Theft System (19.01)
Electronic Features (19.00)19-1-6 Workshop ManualIssue 5, January 2010
5. Make sure that the clips that attach the switch are
correctly engaged.
6. Install the top and bottom steering column shrouds (Refer to ’Top and Bottom Shrouds for the Steering
Column - Remove and Install’, page 11-4-4).
Hood Latch Switch-Renew
Removal
1. Remove grille (see Workshop Manual procedure 01.08.AA Grille - Radiator - Renew).
2. Remove slam panel (bolts x12).
3. Remove bolts (x4) securing PAS oil cooler.
4. Remove bolts securing crossmember to inner wing (x4).
5. Remove bolts and spacers securing crossmember to wing (x2).
6. Move crossmember to one side and lift up clear of location (protect paintwork).
7 . D i s c o n n e c t b o n n e t l a t c h m u l t i p l u g .
8. Remove switch from latch body.
Installation
1. Install switch to latch body.
2. Connect bonnet latch multiplug.
3. Install crossmember (as removed).
4. Install bolts and spacers securing crossmember to wing (x2).
5. Install bolts securing crossmember to inner wing (x4).
6. Install bolts (x4) securing PAS oil cooler.
7. Install slam panel (bolts x12).
8. Install grille (see Workshop Manual procedure 01.08.AA
Grille - Radiator - Renew).
Alarm Siren Assembly - Remove and
Install
Removal
1. Remove the left rear wheel (refer to Workshop Manual procedure 04.04.EC).
2. Remove the four self-tapping screws and the scrivet that attach the rear of the left, rear wheelarch liner.
3. Move the wheelarch liner away to get access to the alarm siren assembly (siren).
4. Remove the the drain hose for the fuel filler from the clips.
5. Move the drain hose for the fuel filler away.
6. Remove the two M6 nuts that attach the siren to the mounting bracket. 7. Disconnect the electrical connector from the siren.
8. Remove the siren.
Installation
1. Connect the electrical connector to the siren.
2. Put the siren in position into the mounting bracket.
3. Install the two M6 nuts to attach the siren to the
mounitng bracket.
4. Install the drain hose for the fuel filler into the attachment clips,
5. Put the wheelarch liner into the fully installed position.
6. Install the four self-tapping screws and the scrivet that attach the wheelarch liner.
7. Install the left rear wheel(refer to Workshop Manual procedure 04.04.EC).
Repair Operation Time (ROT)
Repair Operation Time (ROT)
Torque Figures
Appendix & Glossary
May 2007 Workshop Manual 20-1-13
Mechanical Function Checks - x x Lubricate the bonnet secondary latch.
- x x Check security of the bonnet catch. Ch eck that the secondary catch moves freely
over its whole travel and returns smartly under spring pressure.
- x x Lubricate the upper portion of the door seals.
x x x Check/adjust accessory drive belt tension and renew if necessary. Every 240,000km
(150,000 miles)/15 Years Replace the accessory drive belt.
x - - Adjust handbrake cables if required. - x x Check condition of handbrake pads.
- x x Inspect service brake pads and warnin g leads for wear. Replace if 60% worn.
- x - Check wiper blade inserts and renew if necessary.
- - x Renew wiper blades.
- x x Inspect/clean out coolant radiator and A/C condenser.
x x x Check security of exhaust system mountings and heat shields. Check by-pass valve operation.
x x x Check brake hoses, pipes and unions. - - x Check power steering pipes and unions for corrosion and mechanical defects.
x x x Check cooling system hoses security and condition.
x x x Check A/C hoses security and condition.
x - x Check condition and security of steering unit joints and gaiters (column and rack).
x x - Check security and condition of suspension fixings.
x x - Check security and condition of susp ension ball joints, gaiters and bushings.
- - x Check tightness of driveshaft bolts.
- - x Check condition of underbody protection/wheel arch liners.
Every 64,000km
(40,000 miles)/4 Years Clean Throttle Butterfly
Electrical Function Checks Every 112,000km (70,000 miles) Renew spark plugs. x x x Check/record battery voltage and quiescent drain.
x x x Clean and grease battery connections if required.
x x x Check the battery disconnect/connect switches.
x - x Check and if necessary adjust headlamp alignment.
x x x Check operation of all lamps.
x x x Check operation of all warning indicators.
x x x Check audible warnings including security system.
x x x Check operation of the horns.
x x x Check operation of the windows/headlamp washers/jets.
x x x Check operation of the windscreen wipers.
x x x Check rear view mirrors for security and function.
x x x Check/operate power fold mirrors (option).
x x x Check/operate electric windows.
x x x Interrogate DTC P-codes and rectify if required
x x x Check service interval indicator. Reset.
1000mls
1500km
3 months10000mls
16000km
12 months20000mls
32000km
24 months