Ok.. I finally managed to get the operating system to quick format the internal memory.
1. After quick format, I can access the Nuvi internal directory.
2. I found that my Favourites in the gpx file is still intact and quickly copy it out..
3. Detach from PC and let it boot up....No routable map found is the message.
4. Shut down Nuvi, slot in the SD card with the CN 2010.30 map inside and it can boot up.
5. Shut down Nuvi, reattached to PC. Go to backup and copy nearly all files except gmapbmap, gmapprom1, fs_image.ver, nuvi_drive.ico
6. Go to Garmin Map Update and download MSM 2010.40. The map was installed into the SD card where the CN 2010.30 map was.....I thought that was strange....Did all of you get the same installation to the SD card?
7. Detach Nuvi from PC and boot up...Go to Map info and I can only see the CN map....the MSM map was not shown.... Anybody knows why this is so???
8. Download 5.02 and copy to a different SD card....Nuvi can't see and tell me it need a routable map.
So now I have a different set of problems. Basically accessing the Nuvi is now not the problem. Getting the Nuvi to read the MSM Garmin map and our own compiled map is the new problems..
All advises and recommendations are welcome.....

Hey Joseph, long time no see.
I think the reason why the MSM NT 2010.40 map was not installed into your SD card was probably your card does not have enough space for it. Since you already have the Garmin CN map in it, do u know that the combined JCV files for both Garmin CN and MSM NT map is closed to 1GB (966MB to be exact)? If you add both maps, u need more than 1GB of space to store both maps including the JCV files in it. Just my conjecture.