Part 2

Navigation system portable (Continued)

Illustration A




Remove the loudspeaker grille as follows:
- Insert special tool, 999-5919-46 in the joint between the loudspeaker grille and the dashboard approximately as illustrated, until it engages.
- Twist the tool 90° so that the bent section engages with the underneath of the loudspeaker grille.

Illustration B




- Pull upwards until the loudspeaker grille detaches. The loudspeaker grille is securely fastened by five clips. Move the tool closer to the clips to facilitate removal.

Note! Do not damage the dashboard.

- Lift out the loudspeaker grille.




- Take the template from the kit and cut out according to the loudspeaker's profile LHD or RHD.




- Tape the template to the loudspeaker grille.





Same hole image for RHD and LHD.
- Mark the holes in the centre using a scriber.
- Predrill the holes according to the template using a -3 mm (1/8") drill bit. Drill at right angles through the speaker grille.
- Remove the template.




- Press the grille into place again for drilling through the speaker bracket.




- Take a piece of cloth, spread it over the air vents and block the holes to prevent any swarf from entering.

Illustration A





Illustration B





Same hole image for RHD and LHD.
- Drill at right angles through the holes in the speaker grille and through the speaker bracket using a -3 mm (1/8") drill bit.
- Remove the speaker grille as before.




- Drill the three holes for the cradle's feet using a step drill -14 mm (9/16").




- Take the step drill and drill out the hole for the connection in the holder using a -28 mm (1 7/64") drill bit.
- File off the hole edges using a round file.




- Tape the cloth over the loudspeaker and the holes in the bracket.




- Drill the corresponding hole in the loudspeaker console using a -25 mm (1") hole saw.




- Drill the holes for the holder's stud screws using a -7 (9/32") mm drill bit.
- Remove the cloth with swarf from the loudspeaker and inside the dashboard.




- Take three nuts, washer and the cradle out of the kit and secure to the loudspeaker grille.
- Tighten the cradle.









- Take the foam tape from the kit and remove the protective tape.




- Wrap the foam tape around the fuse holder to prevent rattling.




- Take the long cable harness from the kit, pull up the end with the small connector into the hole where the radio unit was located and out through the hole for the ventilation nozzles.

Applies to 2005- model year cars




- Take the radio unit and connect the connector (1) that was disconnected from the 12V socket to the female connector (2) in the routed cable.
- Connect the remaining connector to the 12V outlet.




- Connect other disconnected connectors to the radio and dashboard environment panel, and reinstall the unit.

Note! Ensure that cables or fuse holders are not trapped when the unit is secured.

- Tighten using the existing screws.









Applies to cars up to and including model year 2004




- Check that the new adapter cable is not at risk of being cut off when the radio is reinstalled.
- Connect all connectors to the radio and telephone, if applicable. Reinstall and tighten using existing screws.




- Take the dashboard environment panel and connect the connector (1) that was disconnected from the 12V socket to the female connector (2) in the routed cable.
- Connect the remaining connector to the 12V outlet.




- Check that the new adapter cable is not at risk of being cut off when the dashboard environment is reinstalled.
- Connect the remaining connectors to the dashboard environment panel. Reinstall the dashboard environment panel.













Applies to all models




- Take the small cable from the kit and connect the large connector to the underneath of the holder.




- Insert the connector into the large hole in the loudspeaker bracket and route the cable forward.




- Connect the two routed connectors for the cable harnesses to each other.





Note! Ensure the stud bolts fit in their holes before securing the grille.

- Push the cable through the holes in the grille and loudspeaker bracket.
- Carefully push on the loudspeaker grille with the cradle on the loudspeaker console. File out the holes for the stud bolts if necessary.
- Remove any swarf and filings.




- Gather up any cable excess and tie up using a cable tie.




- Secure the two connected green connectors using a piece of butyl tape in front of/under the left air vent so that they do not come loose and cause rattles. Ensure that they are secure.




- Place the cable excess on top of the air ducts so that it does not impede the air vents.









Note! Ensure that the air ducts are not blocked by the cables.

- Secure the air vents and ensure that they are properly connected to the air ducts.




- Turn the ignition key to position II.
- Reconnect the battery negative lead.