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Windshield wipers

Replacing wiper arm, 940

- Fold up wiper arm. - Lift up cover while folding back wiper arm. - Slacken nut. - Use a pipe wrench to press off the wiper arm. Use the partially unscrewed nut to protect the thread. - Remove nut and wiper arm. - Start the wiper motor so that it returns to parking position.

Install wiper blade on wiper arm - The blade wings should be turned downwards (A). - Wing blade wings should be turned upwards (B). Install wiper arm - Install wiper arm in folded out position on wiper motor shaft. - Fold down wiper blade towards and slide downwards until the measurement below is reached (C). - Install new nut (P/N 981206–6) and tighten wiper arm to 13 Nm within 10 minutes. - Spray windshield so that the glass is wet and sweep wiper arm once so that it returns to parking position. The wiper blade should be free from trim strip in parking position. Distance is measured between blade and trim strip at wiper blade mounting in wiper arm. +12 Driver's side position 25 –5 mm

Passenger side position 40+12 mm. –5 - Check/adjust measurements according to instructions. - Open protective cover on wiper arms. - Tighten the nuts to 18 Nm. - Close protective cover. Replacing wiper unit and wiper motor, 940

- Disconnect battery negative lead. Remove wiper arm according to Replacing file://C:\Info\vv132023\ie\en\27\vcc-066633.htm 12/13/2008

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- Remove wiper arm according to Replacing wiper arm, 940 . - Remove rubber seals (1) - Open to normal position - Unclip washer hoses from clips (2). Remove the three screws retaining cover plate (3). Older models have plastic clips instead of screws on the outer edges. - Open hood to normal position - Remove cover plate by pulling it forward slightly and then lifting back and up. Take care not to damage paintwork. Close hood. - Remove four wiper unit retaining screws (4). One of the screws is concealed beneath a rubber plug (5) on cover (6). - Lift off protective cover - Cut off tie strap (7) and separate connector (8). Unscrew ground lead - Lift up wiper unit - Remove motor axle nut or screw (10) and the three motor retaining screws (9) and lift out the motor (11). - Assemble in reverse order. Reinstall in reverse order Check that spacers are in position before the screws (4) are replaced. Note! Always check that the axles on the new motor are identical to the ones being replaced. Check that the seal is installed between the motor shaft and wiper arm. Note! Before installing cover panel ensure that the motor arm and link arm are parallel to the wiper mounting. The motor should be in parking position. - Axle nut/screw must be tightened to 26/10 Nm. - The two screws (4) must be tightened to 22 Nm. Ensure that the clips on the back of the cover plate are installed correctly. - Adjust wiper arm according to Replacing wiper arm, 940 . Replacing wiper unit line Unit removed: - Undo line retaining nut - Remove line Hook line nipple into link arm

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- Hook line nipple into link arm - Pass line around pulley - Screw line into place in link arm with nut. Torque to 3.5 Nm. Tighten until any play between pulley and link arm disappears. Note! Check in parts catalogue that the correct P/N has been used for the line. Grease rail to prevent corrosion and noise.

Windshield washer

Replacing windshield washer pump motor

- Separate connector - Lift up pump motor - Disconnect hose - Before replacing pump, test the pump motor with polarity reversed to loosen any dirt blocking the pump. - Reinstall in reverse order. - Connect connector and hose - Install washer pump Note! Before installing pump immerse inlet pipe in water or a soap solution to avoid compressing the rubber seal. - Fill washer reservoir with windshield washer fluid and for leaks - Test pump. Replacing nozzle: If the nozzle is leaking check the pressure valve and blow clean, ensure that it is not blocked. If the pressure valve is not working replace it.

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Replacing nozzle: - Open the hood

- Squeeze catches on underside of nozzle and press up nozzle. - Disconnect nozzle from hose - Replace nozzle. Different P/Ns for right and left-hand side - Reinstall in reverse order. - Test and adjust target area on windshield if necessary according to instructions in Adjusting washer nozzle .

Adjusting washer nozzle Adjust target area of jets on windshield according to the following illustrations for each model. Mark the target area on the windshield by drawing a cross with a marker pen or using a strip of masking tape. Carefully adjust nozzles using an electrical screwdriver. The work is easier with the help of a colleague.

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Note! Take care not to damage the ends of the washer pipes. When work is complete wash off markings with undiluted windshield washer fluid or remove tape.

940

960

Replacing washer level sensor

- Undo front of air cleaner (ACL) and lift slightly - Unscrew cap of reservoir and remove sensor. - Separate connector and disconnect ground lead - Remove sensor cover and check seal - Screw new sensor into place - Reinstall in reverse order. Check for leaks. file://C:\Info\vv132023\ie\en\27\vcc-066633.htm 12/13/2008 "VCC-066633 EN 2008-12-13" Page 6 of 9

- Check for leaks.

Replacing windshield washer fluid reservoir

- Remove air cleaner - Remove bulb failure warning sensor - Disconnect washer pump wiring and disconnect hose. The 5–door model has 2 washer pumps - Cut off tie strap and lift filler pipe - Lift out windshield washer fluid reservoir - If the washer pump is OK transfer it to the new windshield washer fluid reservoir according to Replacing windshield washer pump motor . - Replace windshield washer fluid reservoir if it is damaged. Otherwise clean it and install a new filler filter. - Reinstall in reverse order. Some filler pipes have a small triangular mark at the top of the pipe which should point backward. - Install a new tie strap - Fill reservoir with windshield washer fluid, check for leaks and test.

Tailgate wiper and washer

Replacing tailgate wiper motor

- Remove tailgate panel, see Service Manual: Section 8 Body - Unscrew link system nut from motor - Remove motor retaining screws and remove motor - Reinstall in reverse order. Tightening torques for motor axle nut and 3 retaining screws: 20 Nm - Before installing wiper motor check that it is

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in its park position. Replacing tailgate washer motor

- Separate connector. Lift up motor. Disconnect hose - Before replacing pump, test the pump motor with polarity reversed to loosen any dirt blocking the pump. - Reinstall in reverse order - Check for leaks.

Headlamp wiper

Replacing wiper arm

- Fold up wiper arm - Lift up cover while folding back wiper arm. - Slacken nut - Use a pipe wrench to press off the wiper arm. Use the partially unscrewed nut to protect the threads - Disconnect wiper arm - Disconnect washer hose - Start the headlamp wiper motor - Stop the motor so that it returns to parking position. - Install wiper arm with blade so that it is positioned above the outer stop and below the inner stop, see illustration. - Install nut and tighten wiper arm to 3 Nm. - Lift wiper blade so that it is above both stops. Replacing headlamp wiper motor

Note! If suppressed wiper motors are installed, the same type should be used to replace them. - Disconnect battery negative lead - Remove wiper arm according to Replacing headlamp wiper arm . - Both left and right wipers are grounded at ground terminal on front left . - Unscrew the nut holding the motor to its bracket - Pull off plastic hose Remove motor

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- Remove motor - Replace - Assemble in reverse order. Before installing wiper arm, ensure that motor is in its parking position - Adjust wiper arm park position according to Replacing headlamp wiper arm . Replacing headlamp wiper motor

Note! If suppressed wiper motors are installed, the same type should be used to replace them. - Disconnect battery negative lead - Remove wiper arm according to Replacing headlamp wiper arm . - Separate combined lamp unit from headlamp according to Front lighting . - Remove headlamp housing from body mounting (two screws at the front to the fender, two screws at the side to the air intake). The air guide on radiator bracket will also come away - Separate connectors and remove headlamp housing - Remove the two wiper motor mounting screws - Fold out and pull out motor spindle - Replace - Assemble in reverse order. Reinstall in reverse order. When installing the headlamp housing, check its position in relation to bodywork, and hood. Note! Take care when closing the hood that headlamp is not too high. - Before installing wiper arms, run wiper motor until wiper returns to parking position. - Tighten wiper arms according to Replacing headlamp wiper arm .

Replacing headlamp wiper motor

- Remove wiper arm according to Replacing headlamp wiper arm . - Both left and right motors have their connector on the left front fender - Both left and right motor are grounded to the

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ground terminal on front left front fender. - Remove sleeves from connector - Route cable harness through lead-in in front side panel. Left wiper motor: - Detach and turn fog lamp/spot lamp assembly - Unscrew the nut retaining the motor on bracket - Disconnect plastic hose - Remove motor through fog lamp/spot lamp opening - Replace - Assemble in reverse order. Install wiper arm according to Replacing headlamp wiper arm . Right wiper motor: - Tie a 1.5 m length of cord to the cable harness next to the connector (to make reinstalling it easier). - Remove grille - Carefully lift the bottom of the air baffle and remove the two tie straps - Pull cable harness in front of the air baffle - Untie cord but leave it in front of air baffle - Detach and turn fog lamp/spot lamp assembly - Unscrew the nut retaining the motor on bracket - Disconnect plastic hose - Remove motor through fog lamp/spot lamp opening - Replace - Assemble in reverse order. Remove sleeves from connector on the new motor cable harness - Tie cord to the new cable harness and pull it in front of the air baffle - Secure all cables and hoses in front of the air baffle. - Install wiper arm according to Replacing headlamp wiper arm .

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