SAMAND

(XU7JPL3)

Service Manual
Electrical Components

Chapter:

Product:
SAMAND XU7JPL3

Section:

Electrical Components

SAMAND
Service Manual
Foreword:
This Service Manual contains descriptions of the following categories for the
Samand:
Electrical Components

This manual should be used as service manual and s workbook for

training instructors and technicians. We reserve the right to introduce
change without prior notice.

Contents
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charging system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7
10

Technical data

Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Technical description

System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Charge warning lamp, main instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13
14
15
16

Checking and charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the voltage regulator and alternator brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17
18
19
20

Starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

Adjustment and replacement

Technical data

Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Technical description

System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ignition switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustment and replacement

27
28
29
30

Changing the starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Lighting and Signalling System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Technical data

Exterior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Interior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Technical description

System overview, exterior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

System overview, interior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Adjustment and replacement

Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dipped beam bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main beam bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sidelight bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front direction indicator bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Light adjustment, headlamps low beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Light adjustment, headlamps main beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Light and indicator stalk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direction indicator, side bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fog lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fog light bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fog light adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of rear lamp bulbs, direction indicator and brake light . . . . . . . . . . . . . . . . . . .
Rear lights, trunk lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement of reverse and fog lamp bulbs, trunk lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Number plate light, boot lid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High mounted stop lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Courtesy and map reading lamp bulbs, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Courtesy lamp bulb, rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Courtesy lights, front and rear doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Courtesy lights, front and rear door switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horn switch, light and indicator stalk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wash/Wipe system

41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Technical data

Windscreen wiper motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Washer pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Technical description

System overview, wiper system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Adjustment and replacement

Windscreen wiper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Windscreen wiper motor and linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer fluid reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Washer pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Windscreen wiper stalk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Windscreen washer hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

71
72
74
75
76
77

Wiring Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79

Technical description

System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Adjustment and replacement

Front panel harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instrument harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trunk lid harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front roof lamp harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front driver door harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door switch harness, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front passenger door harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear door harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake wear harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main fuse box, engine bay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maxi board, engine bay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main relay board, fascia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

82
84
86
88
90
92
94
96
98
100
102
104
106
108
110
111

Special tools

Special tools
ACTIA

Diagnostic computer

S1251 Pack
Break out box

Peykan

Charging System

Technical data
Alternator
Type, Valeo
Class, 8

W711S001

Battery

Type, Atomic
Current, 12 volt
Grounding, Negative

W711S002

Technical description
System overview

1
3

W711D001

Charging system

1 Instrument cluster
2 Battery
3 Alternator

Role of the charging system

The charging circuit must recharge the battery as well

as supplying the electrical equipment of the vehicle.

14 Technical description

Alternator

5
2

1
7

W711D002

Alternator components
1
2
3
4
5
6
7
8

Rear flange
Front flange
Cooling fan
Drive pulleys
Rectifier
Rotor
Stator
Regulator

The alternator is an alternative generator. A diode

bridge located in the rear flange converts the alternating
current to direct current, necessary for charging the
battery. By construction, the alternator automatically
regulates current, but the voltage is controlled by a
regulator incorporated in the alternator.

Technical description 15

Battery

The terminal voltage of the battery is 12V.

The battery located on the left hand side of the engine
with the negative terminal connected to the body.

W711D003

16 Technical description

Charge warning lamp, instrument cluster

The charge warning lamp indicates to the driver

whether the generator is charging or not.
It is located in and powered by the instrument cluster
display. If the generator is not rotating or if it is not
charging for some reason, the lamp circuit is grounded
via the regulator field winding and the lamp goes on.

W711D004

Adjustment and replacement

Checking and charging the battery
Checking the battery

W711R001

1 Firstly visually examine the battery to eliminate

the following conditions:
Cracks or breaks in the battery casing.
General condition of the battery terminals.
General cleanness of the battery.
2 Use a voltmetre to check the state of charge
which is only valid when the battery is stabilised,
that is, has not been subject to charge or
discharged for at least one hour.
3 If the battery requires charging, proceed as
follows:
Remove battery from the car (see page 18 for
reference).
Voltage reading of 20% or 12volts
- Minimum Charge 24 hours
Voltage reading of 20% to 60% or
from 12 to 12.3volts
- Minimum Charge 12 hours
Voltage reading 60% or at 12.3volts
- Minimum Charge 6 hours
If the battery is completely discharged, due to
auxiliary equipment being left on, a weak starting
charge should be provided to initiate the chemical
process in the battery. Start charging at 1.5amp
current for 24 hours or until the charge current
has dropped to its lowest stable reading.

Safety precautions:

During charging, batteries discharge an explosive gas.It

is therefore imperative to follow these precautions:
Carry out charging in a ventilated location.
Do not smoke.
Avoid naked flames or sparks.
First connect the charger clamps to the battery
terminals, and then connect the charger to the
mains.
When charging is complete, switch of mains
before disconnecting the clamps.
A charger with an Auto-regulating constant voltage
variable current charger should be used.

18 Adjustment and replacement

Battery

It is important to check and look after the battery

regularly, since its ability to start the engine depends on
its state of charge.
The load on the starter motor is greater during the
winter and the capacity of the battery decreases in the
cold weather, which demands a battery in good
condition.
The water level in the battery must be checked at
regular intervals.
Keep the battery clean and dry to prevent dirt from
entering into it while refilling with distilled water or the
build up of oxide on the terminals.
To avoid oxidisation, coat the join between the battery
casing and the terminals with grease.
W711R001

To remove

1
1

The battery is located on the left hand side of the

engine.
1 Disconnect the battery terminals by unscrewing
the wing nut on the negative terminal and clamp
nut and bolt on the positive terminal.
Important
The negative terminal must always be
disconnected first and reconnected last.
2 Remove nuts securing battery clamp and remove
clamp.
3 Remove battery.

W711R003

To fit

Fit in reverse order.

Note
Smear battery terminals with grease,vaseline or
petroleum jelly before reconnecting terminal leads.
Important
The negative terminal must always be reconnected last.

Adjustment and replacement 19

Alternator

To remove
2

1 Disconnect the battery negative terminal.

2 Remove 2 rubber grommets and disconnect the
electrical connections at the rear of the alternator.
3 Raise vehicle and support securely.
4 Remove right road wheel.
5 Remove wheel arch liner.

2
W711R004

6 Release auxiliary belt tensioner and secure.

7 Remove auxiliary drive belt.
8 Remove the auxiliary belt tensioner, to gain
access to the alternator lower mounting bolt.
8
8

6
W711R005

9 Loosen the lower mounting bolt.

10 Remove the upper mounting nut and bolt, then
disengage the alternator from the lower mounting
bolt and remove.

10

To fit

Fit in reverse order.

9
W711R061

20 Adjustment and replacement

Changing the voltage regulator and alternator brushes

To remove

This method is described with the alternator already

removed.
1 Remove 3 screws and release the alternators
protective end cover.
2 Remove 2 screws securing the regulator.
3 Remove the regulator which is fitted with catches.
The alternator brushes are fixed to the regulator and
the whole unit must be replaced.

To fit

1 Carefully straighten the spring tab so that it is

against the regulator.
Clean and apply a thin layer of grease to prevent
oxidisation.
2 Clean the ground connection on the regulator and
apply grease.
3 Fit the voltage regulator.
4 Fit the protective end cover.

23

Starting System

Technical data
Starter motor
Type
Rotation
Voltage

W711S003

Valeo
Right
12 V

Technical description
System overview

Starter motor system

1
2
3
4

Starter motor
Ignition switch
Starter relay
A.C.U.

28 Technical description

Starter motor

W711D006

The starter motor is fitted to the engine block. A

solenoid engages a pinion with the ring gear on the
engines flywheel.
When the engine is started and the engine speed
exceeds the starter motor rpm, the pinion is disengaged
from its shaft via a free wheel. This prevents the starter
motor from over reeving.

Technical description 29

Ignition switch

Ignition switch

The starter motor operates when the ignition switch is

in the start position.
Releasing the ignition key breaks the starting circuit and
also the operating circuit to the starter solenoid,
whereby a spring returns the pinion to its rest position.

W711D007

30 Technical description

Starter relay

Starter relay

The starter relay is located on lower left hand side of

the instrument panel in the relay mounting plate.
11

10

As the ignition is turned to the start position, the starting

relay operates and the operating circuit to the starter
solenoid terminal closes,that is controled by A.C.U.

6
W711D026

Adjustment and replacement

Changing the starter motor

To remove

1 Disconnect the battery negative terminal.

2 For easier access to the starter motor remove the
air intake pipes (see page Book.....).
3 Remove 2 nuts and collect 2 washers, then
remove the electrical connections to the starter
motor solenoid. .

W711R008

4 Remove bolts and washers securing the starter

motor to gearbox housing, noting the position of
the bracket.
5 Unclip the crankcase breather pipe from the
bracket and swing the bracket rearward.
6 Manoeuvre the starter motor out from the gearbox
housing.

To fit
Note
5

6
W711R009

Before refitting clean the starter motor mounting

surface, electrical contacts, connecting cables and
apply grease.
Fit in reverse order.

33

Lighting and Signalling System

Technical data
Exterior lighting

1
2
3
4
5
6

Headlamps (main)
Headlamps (dipped beam)
Position lamp
Front fog lights
Direction indicators
Side repeater lights

55 watts
55 watts
5 watts
55 watts
21 watts
5 watts

36 Technical data

Exterior lighting

1
2
3
4
5
6

Rear fog lights

Reversing lights
Rear lights/Brake lights
High mounted brake light
Number plate lights
Door lights

21 watts
21 watts
5.21 watts
LED
5 watts
5 watts

Technical data 37

Interior lighting

1 Roof lights
2 Trunk lid
3 Glovebox light
4 Sun visor
5 Map light

5 watts
5 watts
5 watts
5 watts
5 watts

38 Technical data

Horn

W711S009

1 Frequency:
420 HZ 35 - low tone
500 HZ 35 - high tone
2 Current consumption, continuous 5.5 0.5

Technical description
System overview, exterior lighting

1 Front fog lights

2 Main/Side/Direction indicator lights
3 Reverse/Rear fog lights
4 Brake/Side/ Direction indicator lights
5 Side repeater
6 Number plate
7 High mounted lamp

40 Technical description

System overview, interior lighting

1
2
3
4
5
6
7
8
9

Door switch
Trunk lid lighting Switch
Trunk lid
Glove box light
Front roof light
Rear roof light
Sun visor lighting
Map light
Door lights

Adjustment and replacement

Main lighting, headlamps
To remove

1 Remove front bumper assembly (see

page...Book...).

Applies to RH and LH headlamps.

2 Remove 2 bolts from the top and 1 bolt from the
bottom of the headlamp.

3 Carefully pull the headlamp out and unplug the 3

electrical connectors.

To fit

Fit in reverse order.

Note

After fitting, check and adjust the headlamp beam (see

page....).

42 Adjustment and replacement

Replacement of headlamp bulbs

2

There are 4 bulbs incorporated within the headlamp

unit.

To remove, dipped beam bulb

1 Unscrew the centre rear cover.

2 Remove the spring clip by pushing in and lifting
up.
3 Remove bulb and bulb lead.
4 Remove bulb.

To fit

Fit in reverse order

4

Note
W711R012

Do not touch the new bulb glass with your fingers.

Adjustment and replacement 43

To remove, main beam bulb

1 Unscrew the rear cover.

2 Unplug the earth lead.
3 Remove the spring clip by pushing in and lifting
up.
3 Remove bulb and bulb lead.
4 Remove bulb.

To fit

Fit in reverse order

4

Note
W711R013

Do not touch the new bulb glass with your fingers.

44 Adjustment and replacement

To remove, sidelights

The sidelight bulb connector is situated at the base of

the headlamp unit.
1 Twist to remove connector and bulb.
2 Remove bulb from connector.

To fit

Fit in reverse order.

1
W711R014

Note

Do not touch the new bulb glass with your fingers.

Adjustment and replacement 45

2
1

To remove, front direction indicators

1 Turn bulb holder and connector anticlockwise and

remove complete from headlamp unit.
2 The bulb has a bayonet fitting, press bulb in and
turn anticlockwise to remove.

To fit

Fit in reverse order

Note
W711R015

Do not touch the new bulb glass with your fingers.

46 Adjustment and replacement

Light adjustment, headlamps

Y

30 Meters

X
Z

SCREEN
H1

h1

H1 DIPPED BEAM CENTER

MARK FOR (X7)

SCREEN
H 1*
h1
LOW BEAM
Low beam adjustment

15

Y
Z
Y=X-(Z*1.0%)
TOLERANCE: 0.25

W711R016

Adjustment and replacement 47

30 Meters

X
Z

SCREEN
H1

h1

LEFT

H1 DIPPED BEAM CENTER

MARK FOR (X7)

SCREEN
H2*
h2
L

MAIN BEAM
Main beam adjustment

h
h

Y
Z
Y=X-(Z*1.0%)
TOLERANCE: 0.25

W711R017

48 Adjustment and replacement

Light and indicator stalk

To remove

1 Remove top and bottom steering column shroud,

retained with 2 screws (see page ... Book...).
2 Remove 2 screws retaining combination switch
pack.
3 Withdraw switch pack and unplug 2 connectors.

To fit

Fit in reverse order.

Note

Ensure correct routing of wiring on re-connection.

W711R018

Fog lights

To remove

Access to front fog lights is gained from underneath the

front bumper.
1 Unplug 1 connector.
2 Remove 2 bolts and 1 screw and withdraw the fog
light unit from the rear of the bumper.

To fit

2
2
W711R020

Fit in reverse order.

On fitting, re-adjust fog light (see page... for reference).

Fog lights

To remove

Access to front fog lights is gained from underneath the

front bumper.
1 Unplug 1 connector.
2 Remove 2 bolts and 1 screw and withdraw the fog
light unit from the rear of the bumper.

To fit

2
2
W711R020

Fit in reverse order.

On fitting, re-adjust fog light (see page... for reference).

Replacement of fog lamp bulb

2

To remove

1 Remove rear cover.

2 Remove spring clip by pushing and lifting to
release.
3 Remove bulb and bulb holder.
4 Remove bulb.

To fit

Fit in reverse order.

4

Note

3
1
W711R022

Do not touch the new bulb glass with your fingers.

52 Adjustment and replacement

Fog light adjustment

To adjust

Turn to adjust fog light like main beam expect that

Y=X-(Z *2.0%) adjustment.

W711R050

Adjustment and replacement 53

Rear lights

To remove

Applies to LH and RH rear light cluster.

1 Remove luggage compartment trim as required
(see page...Book 9 for reference).
2 Unplug electrical connector.
3 Remove 3 nuts and carefully withdraw light
cluster.

To fit

3
3
W711R024

Fit in reverse order.

54 Adjustment and replacement

Replacement of rear lamp bulbs, direction indicator and brake light

To remove

1 Remove luggage compartment trim as required

(see page... Book 9 for reference).
2 Unplug the electrical connector.
3 Press the two plastic clips and remove the bulb
holder.
4 Remove bulbs by pushing in and turning
anticlockwise.

To fit

Fit in reverse order.

W711R025

Adjustment and replacement 55

Rear lights, trunk lid

To remove

Applies to LH and RH trunk lid light cluster.

1 Open trunk lid.
2 Unplug electrical connector.
3 Remove 4 nuts and carefully withdraw light
cluster.

To fit

Fit in reverse order.

3
W711R026

56 Adjustment and replacement

Replacement of reverse and fog lamp bulbs, trunk lid

To remove

1 Open trunk lid.

2 Unplug electrical connector.
3 Press the two plastic clips and remove the bulb
holder.
4 Remove bulbs by pushing in and turning
anticlockwise.

To fit

3
4

Fit in reverse order.

W711R027

Adjustment and replacement 57

Number plate light, boot lid

To remove
1
2
3
4

Push light to the left and lever down to remove.

Unplug connector.
Turn the bulb holder and remove.
Remove bulb from holder.

To fit

Fit in reverse order.

58 Adjustment and replacement

High mounted stop lamp

To remove

1 Lift rear of light cover and pull away from parcel

shelf.
2 Unplug electrical connector.

3 Turn light over and remove 4 retaining screws.

4 Remove bulb holder as complete assembly.

Note

This unit is replaced as a complete assembly.

W711R029

To fit

Fit in reverse order.

Note

Ensure the front lugs are secure before pressing rear

clips into place.

Adjustment and replacement 59

Front roof and map reading lamp bulbs

Roof light bulb

To remove

1 Insert a screwdriver carefully in the slot at the end

of the light unit and lever away from the front light
console.
2 Unplug the electrical connector.
3 Hold the light unit and unclip the bulb holder.
4 Remove the bulb.

3
4

To fit

Fit in reverse order.

Note
W711R030

Ensure bulb holder is securely clipped in light fitting on

refit.

Map reading light bulb

To remove

The map reading light can only be replaced as a

complete unit, so the bulb cannot be replaced alone.
1 Insert a screwdriver carefully at the top of the light
and lever away from the front light console.
2 Unplug the electrical connector.
3 Remove light unit.

To fit

Fit in reverse order.

3

W711R052

60 Adjustment and replacement

Rear roof lamp bulb

2

To remove

1 Insert a screwdriver carefully in the slot at the end

of the light unit and lever away from the
headlining.
2 Unplug the electrical connector.
3 Hold the light unit and unclip the bulb holder.
4 Remove the bulb.

3
4

To fit

Fit in reverse order.

Note
W711R032

Ensure bulb holder is securely clipped in light fitting on

refit.

Adjustment and replacement 61

Front and rear doors , roof lights

To remove, front door

1
2
3
4

Carefully lever out light from door.

Unplug the electrical connector.
Turn bulb holder and remove.
Remove bulb.

To fit

Fit in reverse order.

To remove, rear door

1
2
3
4

Carefully lever out light from door.

Unplug the electrical connector.
Turn bulb holder and remove.
Remove bulb.

To fit

Fit in reverse order.

62 Adjustment and replacement

Front and rear door switches , roof lights

Front door switch

Located on the bottom rear of the front doors.

1 Remove screw.
2 Unplug electrical connector.
3 Remove switch.

To fit

Fit in reverse order.

W711R034

Rear door switch

2

Located on the bottom of the D-post.

1 Remove screw.
2 Unplug electrical connector.
3 Remove switch.

To fit

Fit in reverse order.

1
W711R035

Adjustment and replacement 63

Horn

To remove

There is 1 horn on each side of the vehicle, located

bottom right and bottom left behind the front bumper.

W711R036

1 Disconnect the battery negative terminal.

2 Remove the wheel arch liner(s) (see page...
Book...).
3 Unplug the electrical connector.
4 Remove 1 bolt and withdraw the horn.

2
4

To fit

Fit in reverse order.

W711R037

64 Adjustment and replacement

Horn switch, light and indicator stalk

To remove

1 Remove top and bottom steering column shroud,

retained with 2 screws (see page ... Book...).
2 Remove 2 screws retaining combination switch
pack.
3 Withdraw switch pack and unplug 2 connectors.

To fit

Fit in reverse order.

Note

Ensure correct routing of wiring on re-connection.

W711R018

Interior light rheostat

To remove

1 Insert a screwdriver carefully in the end of the unit

and lever away from the steering shroud.
2 Unplug the electrical connector and remove
rheostat.

2
1

To fit

Fit in reverse order.

W711R055

65

Wash/Wipe System

Technical data
Windscreen wiper motor

Stroke (stroke/min) and current consumption at

13.5V on wet windscreen
-low speed
45 +/- 6rpm
-high speed
71 +/- 8rpm
Rated current consumption
-low speed
-high speed

W711S010

Current consumption at 13.5V, jammed motor (e.g.

frozen wiper blades) 26A
-low speed
-high speed
Maximum torque
-low speed
-high speed

8,5 Nm
6 Nm

Washer pump
Location
Type

W711S011

On washer fluid reservoir

Centrifugal pump

Technical description
System overview
2

3
2

1
4

W711D010

Wiper system
1
2
3
4
5

Windscreen wiper stalk switch

Windscreen wiper motor
Washer fluid motor
Windscreen wipper control unit
Washer fluid reservoir

The system consists of:

Windscreen wipers
The windscreen wipers are driven by a two-speed

motor. The wiper motor incorporates an automatic

parking function which always returns the wipers to the
same position when they are switched off. The
wipers/washers are operated by means of a stalk on
the steering column.
Washer assembly
The washer system consists of a fluid reservoir with a
pump and fluid level monitor (situated in the lower part
of the reservoir) hoses and nozzles for the windscreen.

Adjustments and replacements

Windscreen wiper arm
To remove
3

1 Disconnect the washer fluid hose from the end of

the connector on the scuttle grille panel.
2 Lift up the wiper arm spindle nut cover, remove
the spindle nut.
3 Lift the wiper blade off the windscreen, remove
the wiper arm off the spindle.

Note

Mark the position of the wiper arm on the spindle before

removal.
1

W711R038

To fit

Fit in reverse order

Note

Make sure the wiper arm is replaced in the same

position on the spindle.

72 Adjustments and replacements

Windscreen wiper motor and linkage

To remove

The assembly is located in the scuttle at the rear of the

engine compartment.
1 Disconnect the battery negative terminal.
2 Remove the wiper arms (see page... for
reference).
3 Remove 4 screws and lift up scuttle grill.
4 Disconnect the washer fluid hose from the end of
the connector on the left hand side in the scuttle.

5 Remove 2 screws and release plastic cover over

heater intake and washer fluid reservoir.
5

W711RO40

6
W711R041

6 Remove the expandable plastic cover on the

wiper motor and unplug the electrical connector to
the motor.

Adjustments and replacements 73

7 Remove 3 bolts and washers securing the motor
and linkage to scuttle, then remove complete
assembly.
7

W711R042

8 Remove 1 nut securing linkage to the wiper motor

spindle.
9 Remove 3 bolts securing wiper motor to the
mounting bracket, then remove motor.

9
9
9

8
W711R043

To fit

Fit in reverse order

74 Adjustments and replacements

Washer fluid reservoir

To remove

The reservoir is located in the left hand corner of the

scuttle at the rear of the engine.
1 Disconnect the battery negative terminal.
2 Remove scuttle grill and cover for heater intake
(see page... for reference).
3 Unplug electrical connector from the fluid pump.

3
W711R044

4 Remove 2 nuts securing reservoir to scuttle, then

lift reservoir from the scuttle.
5 If the reservoir contains any fluid, empty contents
and then disconnect fluid hose from the pump.
6 Remove reservoir.

To fit

Fit in reverse order

Adjustments and replacements 75

Washer pump

To remove

1 Disconnect the battery negative terminal.

2 Remove washer reservoir (see page... for
reference).

3
W711R046

3 After disconnecting the electrical connector and

fluid hose, carefully ease the pump out of its
sealing grommet in the reservoir.

To fit

Fit in reverse order.

W711R047

76 Adjustments and replacements

Wiper switch

To remove

1 Remove top and bottom steering column shroud

Adjustments and replacements 77

Windscreen washer hoses

To remove

1 Remove 3 screws and lift down the windscreen

washer hoses