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Aston Martin V8 Vantage, Workshop Manual

The Aston Martin V8 Vantage Workshop Manual is the essential guide for all car enthusiasts. This comprehensive manual provides step-by-step instructions, diagrams, and troubleshooting tips to ensure you can effectively maintain and repair your V8 Vantage. Download this manual for free from our website, manualshive.com, to unleash the full potential of your Aston Martin.

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Instrument Panel (IP) (01.12) 

Body System (01.00) 

3.  Remove the bolts (x3) that secure the airbag panel and 

door assembly plate to the chassis (see Fig. 2)

.

 

Fig. 2 

4.  Remove airbag panel and door assembly (5 clips) (see 

Fig.3). 

Fig. 3 

Installation 

1.   Install airbag panel and door assembly (5 clips). 
2.   Through glovebox aperture, install support right-angled 

bar and secure bolts (x3). 

3.   Remove and clean double-sided taped from glovebox 

shield, apply new tape and install. 

4.   Install glovebox assembly (see Workshop Manual 

procedure 01.12.AL Glovebox Assembly - Renew). 

5.   Install passenger lower panel assembly (5 clips and 1 

multiplug). 

Instrument Cluster Hood Assembly-

Renew 

Repair Operation Time (ROT) 
Item 

Code 

Instrument Cluster Hood Assembly-
Renew 

01.12.AK 

Removal 

1.   Remove hood assembly complete (6 clips). 

Installation 

1.   Install hood (6 clips). 

Glovebox Assembly-Renew 

Repair Operation Time (ROT) 
Item 

Code 

Glovebox Assembly-Renew 

01.12.AL 

Removal 

1.   Remove passenger lower panel assembly (5 clips & 

multiplug). 

2.   Remove the securing screws holding the glove box hinge 

to the chassis (x2). 

3.   Support the glove box and locate the latch mechanism. 
4.   Using a suitable tool press the latch mechanism to 

release the glove box. 

5.   Support the glove box and detach the buffer cord from 

the glove box. 

Installation 

1.   Support glovebox and attach the buffer cord (ensure the 

cord is through correct aperture). 

2.   Install glovebox into aperture and press top to latch. 
3.   Align the glovebox hinge and secure with screws (x2) 

including spacers between the hinge and chassis. 

4.   Install passenger lower panel assembly (5 clips and 1 

multiplug). 

Knee Protector-Renew 

Repair Operation Time (ROT) 
Item 

Code 

Knee Protector-Renew 

01.12.AN 

Removal 

1.   Remove driver's lower panel assembly (7 clips) and 

disconnect air temperature pipe. 

2.   Disconnect footwell light and remove unit from panel. 
3.   Mark one socket for relocation and remove diagnostic 

sockets (x2) from panel. 

4.   Remove pop-rivets (x5), screws (x4) and remove panel. 

Installation 

1.   Align knee protector panel in position and secure with 

screws (x4). 

2.   Install pop-rivets (x5). 
3.   Install diagnostic sockets (x2) (ensure marked socket is in 

correct location). 

4.   Install footwell light and reconnect multiplug. 
5.   Install driver's lower panel assembly (7 clips) and 

connect air temperature pipe. 

1-9-8  

Workshop Manual 

October 2005 

Summary of Contents for V8 Vantage

Page 1: ...Workshop Manual Issue 1 ...

Page 2: ...fallible guide to current specifications of any particular vehicle All rights reserved No part of this publication may be reproduced stored in a retrieval system or transmitted in any form electronic mechanical photocopying recording or other means without prior written permission from Aston Martin Lagonda Limited The manufacturer reserves the right to vary specifications without notice in accorda...

Page 3: ...nt Suspension 04 01 4 2 1 Rear Suspension 04 02 4 3 1 Road Wheels and Tyres 04 04 4 4 1 Driveline 05 00 Driveshaft 05 01 5 1 2 Rear Drive System 05 02 5 2 1 Halfshafts 05 05 5 3 1 Brake System 06 00 Description 6 1 2 Front Disc Brake 06 03 6 2 1 Rear Disc Brakes 06 04 6 3 1 Hand Brake 06 05 6 4 1 Brake Actuation System 06 06 6 5 1 Power Brake System 06 09 6 6 1 Transmission 07 00 Automatic Transmi...

Page 4: ...1 2 Vehicle Control System 18 08 18 2 1 Electronic Features 19 00 Active Anti Theft System 19 01 19 1 2 Appendix Glossary Fluids Capacities 20 1 2 Abbreviations 20 1 3 Terms 20 1 3 Special Tools Pictorial Index 20 1 4 Specialist Tool Operation 20 1 6 Maintenance Schedules 20 1 7 Torque Table 20 1 9 Torque Conversion Tables 20 1 10 ...

Page 5: ... A C System 0 7 Chemical Handling and Storage 0 7 Electrical Equipment 0 0 7 Exhaust Fumes 0 7 Fire Precautions 0 7 Tools and Equipment 0 0 8 Used Engine Oil 0 8 Health protection precautions 0 8 Environmental Protection 0 8 Lifting and Jacking 0 0 9 Safety 0 9 Jacking Points 0 0 9 Lifting 0 0 9 Workshop Hoist 0 9 Workshop Jack 0 9 Stands 0 9 Vehicle Recovery 0 0 10 General 0 10 Transporting 0 10 ...

Page 6: ...rences References to left right front or rear of the vehicle or of a component are referenced from sitting in the drivers seat facing forward Any such references to assemblies removed from the vehicle are to the normal orientation of the assembly when installed in the vehicle The following Warnings Cautions and Notes are used within this Owner s Guide to call your attention to specific types of in...

Page 7: ... identity they may be toxic Do not use petrol kerosene diesel fuel gas oil thinners or solvents for washing skin Containers whose capacity is over 25 litres 5 gallons require a bund wall in order to contain spillages Chemicals based on solvents such as paint should not be sprayed in a confined space work areas used for such operations should be well ventilated and fume extraction equipment should ...

Page 8: ...tive clothing including impervious gloves where practicable Do not put oily rags in pockets Avoid contaminating clothes with oil Overalls must be cleaned regularly Discard un washable clothes and oil impregnated footwear First aid treatment should be obtained immediately for open cuts or wounds Use barrier creams apply before each work period to help the removal of oil from the skin Wash with soap...

Page 9: ...acked on the front subframe front crossmember Always use a jack with a rubber contact pad Avoid use of jacks with sharp contact pads which would damage floor pan Always chock the opposite road wheels as well as applying the handbrake when using a hydraulic jack To prevent body distortion avoid single point or one side jacking with the tunnel shear panel removed Lifting Workshop Hoist Use of a work...

Page 10: ...aise the vehicle using a spectacle frame style lifting device where a cradle is positioned under each rear wheel as indicated below Adhere to Towing Regulations In certain countries the registration number of towing vehicle and an ON TOW sign or warning triangle must be displayed in a prominent position at the rear of vehicle being towed Towing by Another Vehicle This vehicle may be towed short di...

Page 11: ...ial configuration of the vehicle VIN Number Location The VIN number is shown on two labels in the vehicle 1 Under the lower edge of the windscreen 2 Front of the engine bay The VIN number is also engraved on the floorpan in the right front footwell S C F B C 3 A 4 5 G C 0 0 0 0 1 Code for AML Restraint System Transmission and Steering Body Type Engine Type Calculated Check Digit Model Year Manufac...

Page 12: ...Panel Assembly Quarter Trim Renew 4 4 Passenger Upper Panel Assembly Renew RH LH Middle Section Quarter Trim Panel Assembly Re Passenger Panel Assembly Renew RH LH Upper Quarter Moulding Trim Renew 4 5 Driver Lower Panel Assembly Renew RH LH Rear Heel Board Assembly Renew 4 5 Airbag Panel and Door Assembly Renew Tailgate Lid Trim Assembly Renew 4 5 Instrument Cluster Hood Assembly Renew RH LH Side...

Page 13: ...2 Maintenance 11 2 Windscreen Wiper Motor Assembly Renew 11 2 Wiper Linkage Assembly Renew 11 2 Driver Wiper Arm Assembly Renew 11 2 Passenger Wiper Arm Assembly Renew 11 3 Windshield Wash Filler Neck Renew 11 3 Low Level Water Sensor Renew 11 3 Washer Fluid Reservoir Renew 11 4 Bumpers 01 19 1 12 1 Front Bumper 12 1 Rear Bumper 12 1 Specifications 12 2 Maintenance 12 2 Front Bumper Cover Renew 12...

Page 14: ...d adhesive The rear quarter panels roof and side mouldings are bonded to the structure using cold cured 2810 MV adhesive The curing cycle is improved by using a hot air impingement system The composite front wings are bolted to the structure At no time should the body structure be subjected to temperatures in excess of 120 C 248 F 01 01 020 October 2005 Workshop Manual 1 1 3 ...

Page 15: ...Body Structure 01 01 Body System 01 00 1 1 4 Workshop Manual October 2005 ...

Page 16: ...5 0 5 Specifications Flush 0 0 0 0 0 0 0 5 Tolerance 1 5 0 0 0 5 1 5 0 5 Taper N A Symmetry N A Torque Figures Description Nm Wing Top 8 Wing Top Single nut Tight with Threadlock Lower Rear 8 Slam panel 8 PCM Bracket 10 Bonnet Damper 25 Wing Standard mm 1 2 4 3 Item 1 2 3 4 Nominal gap 3 5 2 0 3 75 3 0 October 2005 Workshop Manual 1 2 1 ...

Page 17: ...Front End 01 02 Body System 01 00 1 2 2 Workshop Manual October 2005 ...

Page 18: ...lerance 1 5 0 0 0 0 1 0 1 0 1 5 Taper 1 mm Max across the length Taper N A Symmetry 1 mm Max difference LH to RH Symmetry N A Flushness blends to 0 0 at the rear quarter Torque Figures Gap blends to 3 5 at rear quarter Description Nm Hinge to Body 25 Torque Figures Bonnet Description Nm Hinge to Door 47 5 Hinge to Body 36 Door Striker plate 1 Bonnet Standard mm Item 1 Nominal gap 3 5 Tolerance 0 7...

Page 19: ...ltiplug and remove securing bolts x3 for GPS aerial and place to one side 8 Disconnect multiplug and remove securing nuts x2 for central high stop lamp assembly place to one side 9 Disconnect multiplug and remove securing nuts x2 for tailgate release switch place to one side 10 Remove tailgate buffer stops and place to one side 11 Provide collision protection between tailgate corners and bodywork ...

Page 20: ...Plate Renew Front Sill Plate Renew RH LH 01 05 AJ 01 05 AK Removal 1 Remove screws x2 name plate to front plate 2 Remove bolts x6 front plate to sill 3 Remove front plate Installation 1 Position front plate and install bolts x6 2 Install front sill name plate RH LH Front Sill Name Plate Renew Repair Operation Time ROT Item Code Front Sill Name Plate Renew Front Sill Name Plate Renew RH LH 01 05 AL...

Page 21: ...panel Installation 1 Connect multiplug position panel and secure with fir tree clip 2 Install nut x1 panel to body 3 Install rear header RH Sun Visor Renew Repair Operation Time ROT Item Code Sun Visor Renew RH 01 05 BH Fig 2 5 Remove sunvisor see Fig 3 Removal 1 Remove front header trim panel see Workshop Manual procedure 01 05 BB Panel Assembly Header Renew 2 Remove rear header trim panel screws...

Page 22: ...bly Renew Repair Operation Time ROT Item Code Door Trimboard Assembly Renew 01 05 CA Removal 1 Lower door glass fully 2 Disconnect vehicle battery 3 Release door handle bolts x2 4 Remove door handle trim plate and disconnect door catch inner release cable and remove bolts x2 from outer retaining plate 5 Remove screw x1 securing trim panel to top front of door frame 6 Remove door trim panel bolts x...

Page 23: ...le securing screws x2 and unclip x3 from panel 4 Remove upper door trim panel securing screw x1 and drill out 7 pop rivets Installation 1 Install upper door trim panel securing screw x1 and pop rivets x7 2 Install speaker grille clips x3 and screws x2 3 Install upper veneer door trim panel screws x9 and clip x1 4 Install door trimboard assembly see Workshop Manual procedure 01 05 CB Trimboard Asse...

Page 24: ...r trim to body 3 Feed seatbelt through trim panel aperture and remove panel 4 Disconnect speaker multiplug 5 Remove nuts securing speaker to trim panel x3 Installation 1 Install speaker nuts x3 2 Connect speaker multiplug 3 Feed seat belt harness through panel and secure panel to body 4 Install RH quarter trim middle panel see Workshop Manual procedure 01 05 CT 01 05 CU Panel Assembly Quarter Trim...

Page 25: ...moval 1 Release and remove rear luggage compartment floor carpet Installation 1 Install rear luggage compartment floor carpet Tailgate Scuff Plate Renew Removal 1 Remove screws x2 securing tailgate striker and remove striker 2 Remove screws securing tailgate scuff plate Installation 1 Position tailgate scuff plate and install screws x3 2 Install tailgate striker 3 Adjust striker as necessary LH Si...

Page 26: ... x12 Installation 1 Position centre stack assembly and install multiplugs x12 2 Install and torque tighten screws x4 3 Install bezel assembly instrument panel see Workshop Manual procedure 01 12 AV Bezel Assembly Instrument Panel Renew 4 Install panel assembly console see Workshop Manual procedure 01 12 DB Panel Assembly Console Renew October 2005 Workshop Manual 1 4 7 ...

Page 27: ...Interior Trim 01 05 Body System 01 00 1 4 8 Workshop Manual October 2005 ...

Page 28: ...ove mesh Installation 1 Position mesh to side strake and install nuts x3 1 Install engine control module LH Side Strake Mesh Renew Repair Operation Time ROT Item Code Side Strake Mesh Renew LH 01 08 CF Removal 1 Remove nuts x3 mesh to side strake 2 Remove mesh Installation 1 Position mesh to side strake and install nuts x3 RH Wing Side Strake Renew Repair Operation Time ROT Item Code Wing Side Str...

Page 29: ...em Code Rear Undertray Renew 01 02 PB Rear Wheel Arch Liner Renew RH 01 02 HB Removal Rear Wheel Arch Liner Renew LH 01 02 JB 1 Raise vehicle on ramp 2 Remove Torx screws x10 rear undertray to subframe 3 Remove rear undertray Installation 1 Install rear undertray install and tighten Torx screws x10 to 8 10 Nm 2 Lower vehicle on ramp Undertray Vehicle Set Renew Repair Operation Time ROT Item Code U...

Page 30: ...ror rubber cheater panel 4 Disconnect multiplug and release harness from fir tree clips x2 and self adhesive clip 5 Remove Torx bolts x3 and screw from glass channel remove mirror assembly Installation 1 Position mirror install and torque tighten Torx bolts x3 and screw glass channel 2 Connect multiplug and secure harness fir tree clips x2 and self adhesive clip 3 Install rubber mirror cheater pan...

Page 31: ...Mirrors 01 09 Body System 01 00 1 6 2 Workshop Manual October 2005 ...

Page 32: ...is detected by the heated seat module Confirmation that the heated seat function is active is indicated by the illumination of an amber light on the switch Specifications Torque Figures Description Nm Seat mountings 20 25 Seatbelt 30 40 Maintenance RH LH Front Seat Renew Repair Operation Time ROT Item Code Front Seat Renew Front Seat Renew RH LH 01 10 AA 01 10 AB Removal 1 Power seat fully forward...

Page 33: ...Seating 01 10 Body System 01 00 1 7 2 Workshop Manual October 2005 ...

Page 34: ...motor securing screws x3 8 Carefully remove regulator mechanism and regulator motor out of the large aperture Installation 1 Install regulator mechanism and motor and secure with nuts x4 and screws x3 2 Connect multiplug x1 to regulator motor 3 Fit glass into door and engage the clamping brackets install clamping bolts and partially tighten 4 With power on raise glass to fully up and adjust alignm...

Page 35: ...icator 15 Attach suction handles to windshield 16 Apply sealer to glass 17 With assistance lift windshield into place and align in aperture Lightly press glass to sealer 18 Remove suction handles from windshield 19 Remove all protective covers and tape 20 Check screen for leaks 21 Connect multiplug x1 to windshield and install plate 22 Install wiper arm passengers side see Workshop Manual procedur...

Page 36: ...de tread plates Instrument Panel Renew 7 Release door seal from door aperture see Fig 2 Specifications Repair Operation Time ROT Item Code Instrument Panel Renew 01 12 AA Removal 1 Disconnect vehicle battery 2 Drain cooling system see Workshop Procedure 03 03 AD Coolant Drain Refill 3 Evacuate air conditioning system see Workshop Procedure 12 03 FA Tank Receiver Drier Renew 4 Remove RH door see Wo...

Page 37: ...rim panels see Fig 6 9 Remove LH and RH A post trim panels 10 Disconnect multiplugs x5 from instrument panel RH side 15 Remove rear centre console see Workshop Manual 11 Disconnect multiplugs x6 from instrument panel LH XREF 266 Centre Console Rear Renew side 16 Disconnect multiplugs x8 and remove centre column 12 Release both door seals from body switch panel see Fig 7 and Fig 8 Fig 4 Fig 6 Fig 7...

Page 38: ...chanism Fig 10 18 Remove screws x6 and remove gear lever mechanism 21 Remove bolt securing heater fan to bulkhead see Fig 19 Remove Allen bolts x4 from securing carpet retaining 11 plate to bulkhead drivers side see Fig 9 Fig 11 22 Remove steering wheel see Workshop Manual 11 06 AB Steering Wheel Renew 23 Remove screws x7 from steering column upper and lower shrouds see Fig 12 Fig 9 Fig 12 October...

Page 39: ...clips x7 and disconnect air temperature pipe see Fig 14 31 Remove bolts securing instrument panel to both A posts x6 32 With assistance position tool 501 F116 to instrument panel see Fig 16 Fig 14 26 Pull back steering column bulkhead gaiter 27 Remove and discard pinch bolt from upper column to intermediate shaft 28 Disconnect multiplugs x14 from instrument panel to main body harness Fig 16 33 Att...

Page 40: ...in clips x7 15 Install steering column upper and lower shrouds and install and tighten screws x7 16 Install steering wheel see Workshop Manual 11 06 AB Steering Wheel Renew 17 Install and tighten bolt from heater fan to bulkhead 18 Install and torque tighten bolts x2 from instrument panel to tunnel 19 Install footwell carpet 20 Install drivers side carpet retaining plate to bulkhead 21 Install and...

Page 41: ...sembly 4 clips 2 Install instrument cluster hood assembly 6 clips Passenger Upper Panel Assembly Renew Repair Operation Time ROT Item Code Passenger Upper Panel Assembly Renew 01 12 AE Removal 1 Remove air bag panel and door assembly see Workshop Manual 01 12 AJ Panel Door Assembly Air Bag Renew 2 Remove panel 2 clips 2 screws Installation 1 Install panel 2 clips 2 screws 2 Install air bag panel a...

Page 42: ...g Installation 1 Install passenger s lower panel 5 clips 1 multiplug Driver Lower Panel Assembly Renew Repair Operation Time ROT Item Code Driver Lower Panel Assembly Renew 01 12 AH Removal 1 Remove driver s lower panel assembly 7 clips and disconnect air temperature pipe see Fig 1 Fig 1 Installation 1 Install driver s lower panel assembly 7 clips and connect air temperature pipe Airbag Panel and ...

Page 43: ...is x2 3 Support the glove box and locate the latch mechanism 4 Using a suitable tool press the latch mechanism to release the glove box 5 Support the glove box and detach the buffer cord from the glove box Installation 1 Support glovebox and attach the buffer cord ensure the cord is through correct aperture 2 Install glovebox into aperture and press top to latch 3 Align the glovebox hinge and secu...

Page 44: ... glovebox and shield see Workshop Manual procedure 01 12 AP Shield Glovebox Renew 2 Remove securing screws x2 from damper spring unit Installation 1 Install damper spring unit with screws x2 2 Install shield and glovebox see Workshop Manual procedure 01 12 AP Shield Glovebox Renew Cluster Bezel Panel Renew Repair Operation Time ROT Item Code Cluster Bezel Panel Renew 01 12 AT 4 Remove instrument c...

Page 45: ...ent cluster hood assembly 6 clips Instrument Panel Bezel Assembly Renew Repair Operation Time ROT Item Code Instrument Panel Bezel Assembly Renew 01 12 AV Removal 1 Using special tool release instrument panel bezel assembly clips x4 from IP 2 Restrain panel movement and disconnect starter button multiplug 3 Remove panel assembly Installation 1 Position panel assembly and connect starter button mul...

Page 46: ...anel and disconnect multiplugs x6 and Lucar connectors x2 9 Remove switch panel 10 Remove boot release and central locking switch 11 Remove switches below ashtray x4 12 Remove Ashtray from panel assembly Allen screws x4 Installation 1 Install ashtray to panel 2 Install switches x4 3 Install switch panel screws x2 4 Install boot release and central locking switch to panel assembly console 5 Positio...

Page 47: ...Body System 01 00 2 Remove PDC switch from panel Installation 1 Install PDC switch to panel 2 Install console panel assembly see Workshop Manual procedure01 12 DB Panel Assembly Console Renew 1 9 12 Workshop Manual October 2005 ...

Page 48: ...ransmitter The remote control system consists of a transmitter and an antenna radio frequency system The remote control transmitter for the radio frequency system will operate without the transmitter being directed at the vehicle The normal range between the transmitter and the antenna is up to 5 meters Before the remote control system can be used each transmitter must be initialized to the vehicl...

Page 49: ...ee Workshop Manual procedure 01 11 DA 01 11 DB Regulator Door Glass RH LH Renew 10 Install trimboard assembly see Workshop Manual procedure 01 05 CB Trimboard Assembly Door Remove for Access Refit 0114BD Latch Assembly Hood Renew Repair Operation Time Item Code Hood Latch Assembly Renew 01 14 BD Removal 1 Remove grille see Workshop Manual procedure 01 08 AA Grille Radiator Renew 2 Remove slam pane...

Page 50: ...CB Trimboard Assembly Door Remove for Access Refit Driver Window Lift Switch Renew Removal Repair Operation Time Item Code Repair Operation Time ROT Driver Window Lift Renew 01 11 FB Item Code Removal Passenger Airbag On Off Switch Renew 01 14 EB 1 Disconnect battery and wait ten minutes for airbag capacitor to discharge 2 Disconnect multiplug from passenger airbag on off switch 3 Open passenger d...

Page 51: ...Handles and Lock Mechanisms 01 14 Body System 01 00 1 10 4 Workshop Manual October 2005 ...

Page 52: ...wash wipe switch is depressed for longer than 1 2 seconds the wash pump will be activated for the duration of switch depression a 10 second duration is the maximum available Vertical wiper park routine to aid servicing the wiper blades Hold buttons 8 and 9 centre console on continuously for 500ms within 3 seconds of switching the ignition ON Once ignition is ON the wipers will move to the most ver...

Page 53: ...10 Unclip windscreen heater harness RHS 11 Disconnect motor multiplug and unclip harness x2 12 To prevent damage protect A C pipe with tape before wiper linkage removal 13 Remove plate securing screws x10 through plenum 14 Remove plate securing bolts x8 under bonnet 15 Remove wiper linkage Installation 1 Install wiper linkage 2 Install plate securing bolts x8 under bonnet 3 Install plate securing ...

Page 54: ...into position 2 Connect filler pipe clip x1 3 Install fixing screws x3 4 Clip windscreen Washer pipe into reservoir and install to motor 5 Clip headlamp washer pipe connect pipe quickfit and multiplug 6 Connect windscreen washer motor multiplug 7 Raise ramp 8 Connect clip x1 securing level sensor harness to reservoir 9 Connect clips x2 securing battery harness to bottom of reservoir 10 Remove RH w...

Page 55: ...d manoeuvre reservoir into position 3 Connect filler pipe clip x1 4 Install fixing screws x3 5 Clip W Washer pipe into reservoir and install to motor 6 Clip H lamp washer pipe connect pipe quickfit and multiplug 7 Connect windscreen washer motor multiplug 8 Raise ramp 9 Connect clip x1 securing level sensor harness to reservoir 10 Connect clips x2 securing battery harness to bottom of reservoir 11...

Page 56: ...multiplug 9 Connect windscreen washer motor multiplug 10 Raise ramp 11 Connect clip x1 securing level sensor harness to reservoir 12 Connect clips x2 securing battery harness to bottom of reservoir 13 Remove RH wheel arch liner see Workshop Manual procedure 01 02 GB Wheel Arch Liner Front RH Renew 14 Fill washer reservoir October 2005 Workshop Manual 1 11 5 ...

Page 57: ...Wipers and Washer System 01 16 Body System 01 00 1 11 6 Workshop Manual October 2005 ...

Page 58: ...m 01 00 Body System 01 00 Bumpers 01 19 Front Bumper 6FUHZV WR URQW LQJ URQW XPSHU VV OLS OLS RZHU 0HVK URQW 9DODQFH Rear Bumper XPSHU UPDWXUH KDXVW UDFNHW DQG LQLVKHU XPSHU 0RXQWLQJ UDFNHWV October 2005 Workshop Manual 1 12 1 ...

Page 59: ... 03 BB XREF 280 Lamp Assembly Rear RH Renew 5 Remove wheel arch liner LH see Workshop Manual procedure 01 02 JB Wheel Arch Liner Rear RH Renew 6 Remove wheel arch liner RH see Workshop Manual procedure 01 02 HB Wheel Arch Liner Rear LH Renew 7 Remove tyre mobility kit from the rack 8 Remove torx bolts located behind carpets to rear wings x2 9 Remove bolts x2 in rear light recess 10 Remove bolts se...

Page 60: ...al procedure 01 19 BA Cover Assembly Rear Bumper Renew Rear Diffuser Renew Repair Operation Time ROT Item Code Rear Diffuser Renew 01 19 CC Removal 1 Remove Allen bolts x4 diffuser to parking distance sensor brackets Installation 1 Align diffuser and install Allen bolts x4 Rear Lower Assembly Centre Mesh Renew Repair Operation Time ROT Item Code Rear Lower Assembly Centre Mesh Renew 01 19 CD Remov...

Page 61: ...Bumpers 01 19 Body System 01 00 1 12 4 Workshop Manual October 2005 ...

Page 62: ...ensioner and Load Limiting Systems The driver and front passenger seat belts are equipped with pre tensioner and load limiting systems In most moderate frontal or near frontal accidents the front airbag and pre tensioner systems will deploy simultaneously In some moderate frontal or near frontal accidents only the pre tensioner system will deploy The pre tensioners take up slack in the front seat ...

Page 63: ... deceleration or under lateral load when cornering at speed a sensor weight within the safety belt retractor moves a locking pawl against the teeth on the retractor reel which then locks the retractor preventing any further release of webbing As soon as the load applied onto the retractor through the safety belt webbing is removed the locking pawl releases the retractor reel and normal movement is...

Page 64: ...ring wheel the cover forming the outer surface of the steering wheel boss The cover has a split line moulded into its surface allowing the airbag to exit through the cover when the system deploys No routine maintenance is required and there are no serviceable parts The driver airbag module is replaced as an assembly Passenger Airbag Module The passenger airbag module is located above the glove com...

Page 65: ...se see the Owner s Guide for the full deactivation procedure Warning Unnecessary deactivation of the passenger airbag is dangerous The passenger will not receive the added protection from the airbag and serious injuries or even death could occur With the exception of installing a child seat on the passenger seat do not turn the passenger airbag deactivation switch to the off position Warning Never...

Page 66: ...anual procedure 01 05 CB Trimboard Assembly Door Remove for Access Refit 2 Remove door module securing bolts x4 swing downwards 3 Remove door impact sensor plate securing bolts x3 and disconnect sensor multiplug x1 4 Remove sensor securing nuts x2 from plate Installation 1 Install sensor on plate and secure nuts x2 2 Connect sensor multiplug x1 and fit plate securing bolts x3 3 Install door module...

Page 67: ... Front Subframe Renew 1 2 Front Subframe Remove Refit 1 4 Rear Subframe Renew 1 6 Rear Subframe Remove Refit 1 7 RH LH Transmission Rear Hydro mount Isolator Assembly Renew 1 10 RH LH Engine Bracket Renew 1 11 Engine Hydro mount Isolator Assembly Renew 1 11 October 2005 Workshop Manual 2 1 1 ...

Page 68: ... from vertical link 9 Disconnect ABS sensor multiplugs then release sensor harness clips x6 from upper suspension arm and vertical link 10 Disconnect brake pad wear sensor multiplug then release sensor harness clips x2 from upper suspension arms 11 Remove Allen bolts x4 from brake callipers to vertical link and tie callipers aside 12 Remove Torx screws x4 from brake disc to hub and remove brake di...

Page 69: ...ing rack nuts x3 and tighten 6 Install engine mounting nuts x2 and tighten 7 Install ride height sensor 8 Install undertray see Workshop Manual procedure 01 02 NB Undertray Front Renew 9 Lower ramp 10 Remove engine lifting beam 11 Remove special tool SPX M553D 12 Remove engine lifting brackets from engine 303 749 13 Remove cross brace support bracket fixings x6 14 Install EGR valve and tighten 15 ...

Page 70: ...kshop Manual procedure 01 02 GB Wheel Arch Liner Front RH Renew 5 Remove LH wheel arch liner See Workshop Manual procedure 01 02 FB Wheel Arch Liner Front LH Renew 6 Remove front spring and damper assemblies See Workshop Manual procedure 04 03 AA Spring Damper Assembly Front Pair Renew 7 Remove nuts x2 from track rod ends to vertical link 8 Using special tool 204 52 release track rod end from vert...

Page 71: ...move engine lifting beam 9 Remove special tool SPX M553D 10 Remove engine lifting brackets from engine using special tool 303 749 11 Remove cross brace support bracket fixings x6 12 Install EGR valve and tighten 13 Install front spring and damper assemblies See Workshop Manual procedure 04 03 AA Spring and Damper Assembly Front Pair Renew 14 Install RH wheel arch liner See Workshop Manual procedur...

Page 72: ...ir Operation Time ROT Item Code Rear Subframe Renew 02 01 CA Removal 1 Disconnect vehicle battery 2 Remove rear subframe assembly See Workshop Manual procedure 02 01 DB Subframe Assembly Rear Remove for Access Refit 3 Mark driveshafts to transaxle flanges for assembly purposes 4 Remove and discard Allen bolts x12 and collect plates x6 from driveshaft flanges to transaxle see Fig 1 Fig 1 7 8 Attach...

Page 73: ...s 14 Connect brake pad wear sensor multiplugs and install in subframe brackets 15 Connect ABS sensor multiplugs x2 and install harness clips x4 in toe control arms 16 Install anti roll bar and bolts x4 do not torque tighten at this stage 17 Align anti roll bar links to lower suspension arms and install nuts x2 do not torque tighten at this stage 18 Install spring and damper assemblies x2 and insta...

Page 74: ...nd plug brake pipes see Fig 4 Fig 1 18 Remove bolts x2 and nuts x2 from handbrake cables to subframe see Fig 2 Fig 2 19 Use tool 206 103 and release handbrake cables from subframe brackets see Fig 3 Fig 4 22 Remove bolt from fuel filler pipe to damper mounting 23 Remove nut securing fuel filler pipe to body and tie filler pipe aside 24 Remove bolts x4 each side that secure spring and damper assemb...

Page 75: ...7 Remove drain tray 31 Lower vehicle until subframe rests on support trolley 28 Disconnect multiplug and release harness clips x2 from see Fig 10 transaxle harness to RH rear wheel arch see Fig 7 Fig 10 Fig 7 32 Remove bolts x6 that secure subframe to body see Fig 29 Mark subframe position to body see Fig 8 11 Fig 8 Fig 11 33 Raise vehicle to gain access to gear selector cables October 2005 Worksh...

Page 76: ...transaxle harness multiplug and secure harness clips x2 17 Install shear plate and tighten bolts x8 18 Install heat shield and torque tighten bolts x4 19 Clean exhaust pipe connections and apply exhaust sealant to connections 20 Install centre pipe to mountings and catalysts and tighten clamp nuts 21 Install rear exhaust pipes to centre pipe and tighten clamp nuts 22 Position subframe cross brace ...

Page 77: ...Operation Time ROT Item Code Engine Bracket Renew Engine Bracket Renew LH RH 02 03 BE 02 03 BF Removal 1 Remove LH RH exhaust manifold see Workshop Manual procedure 09 00 CA 09 00 CB Manifold Exhaust LH RH Renew 2 Remove engine mount lower fixing nut x1 3 Raise engine with suitable equipment 4 Remove mount and bracket from engine bolts x4 5 Remove bracket from mounting nut x1 Installation 1 Instal...

Page 78: ...rame and Mounting 02 00 5 Install engine mount lower fixing nut x1 torque 6 Install RH LH exhaust manifold see Workshop Manual procedure 09 00 CA 09 00 CB Exhaust Manifold RH LH Renew 2 1 12 Workshop Manual October 2005 ...

Page 79: ...pansion Tank Assembly Renew 5 7 Coolant Recovery Tank Assembly Renew 5 7 Radiator Overflow Hose Renew 5 7 Radiator Supply Tank to Radiator Hose Renew 5 8 Engine Coolant Reservoir Hose Renew 5 8 Expansion Tank to Atmospheric Catch Tank Hose Renew 5 8 Coolant Level Switch Renew 5 8 Radiator Hose Renew 5 8 Heater Feed Hose Renew 5 9 Heater Return Hose Assembly Renew 5 9 Heater Outlet Hose Renew 5 9 H...

Page 80: ... LH Ignition Coil Cover Renew 12 3 Power Conversion 03 11 3 13 1 Maintenance 3 13 1 Crankshaft Timing Sensor Renew 13 1 Air Charging 03 12 3 14 1 Maintenance 14 1 RH LH Air Filter Box Renew 14 1 RH LH Air Cleaner Filter Renew 14 1 RH LH Mass Airflow Assembly Sensor Renew 14 1 RH LH Mass Airflow Meter to Throttle Body Flexible Duct Renew 14 1 Evaporative Emissions 03 13 3 15 1 Description 15 1 Syst...

Page 81: ... uses the oxygen sensor signals together with other engine information to fine tune fuelling levels and ignition timing This helps to achieve the best possible fuel burn with minimum exhaust emissions Inlet camshaft variable timing to improve engine performance and emissions Inlet manifold is design with tuned length runners to improve volumetric efficiency and performance The engine is fitted wit...

Page 82: ... vacuum hose from booster P A S Removal 28 Remove oil rom reservoir syringe 29 Disconnect H P pipe from pump 30 Remove PAS reservoir from bracket bolt x1 31 Remove hoses x2 from PAS reservoir 32 Remove suction hose to body p clip bolt x1 33 Remove pipes from steering rack bolt x1 Oil Tank Removal 34 Drain oil tank 35 Disconnect breather hose from tank quickfit 36 Disconnect oil pipes from tank x3 ...

Page 83: ...p clip bolt x1 20 Install pipes to steering rack bolt x1 torque and fit new o rings x2 Oil Tank Install 21 Connect oil pipe from oil thermostat torque 22 Install oil tank bolts x3 torque 23 Connect breather hose to tank quickfit 24 Connect oil pipes to tank x3 torque 25 Refill oil tank A C Install 26 Fit new o rings to A C pipes lubricate 27 Install pipes to compressor bolts x2 torque 28 Install b...

Page 84: ...er cover from fuse box 2x leads 86 Remove multiplugs x10 from fusebox 87 Remove earth terminal 1x nut rubber cover from fusebox 88 Remove fuse box from bracket bolt x2 89 Release harness fir tree clips x3 from engine bracket 90 Feed harness from inner wing and over engine to gain access to cam cover 91 Remove purge pipe p clip bolt x1 and move pipe aside 92 Remove harness bracket from engine bolts...

Page 85: ...lip 159 Install ECM see Workshop Manual procedure 03 14 BB Engine Control Module RH Renew 160 Install coil cover Installation LH Side 161 Connect breather hose to manifold quickfit 162 Connect IAT multiplug 163 Unclip injector harness from cam cover x2 164 Connect injector multiplugs x4 165 Install pipe support bracket nuts x2 bolts x2 166 Install harness support bracket bolt x1 nut x2 release har...

Page 86: ...for purge line p clip 225 Install manifold bolts x10 torque tightening sequence 226 Install bolts x2 bracket to manifold rear 227 Connect EGR pipe union 228 Connect EGR vacuum hose 229 Connect air cleaner duct clip x1 230 Connect breather pipe quickfits x2 to air cleaner duct 231 Connect throttle body multiplug and harness clip 232 Connect manifold heating hoses x2 Installation RH Side 233 Connect...

Page 87: ...Engine Assembly 03 00 Engine 03 00 October 2005 Workshop Manual 3 1 9 267 Install cross brace torque bolts with vehicle on level ground ...

Page 88: ...Engine Assembly 03 00 Engine 03 00 3 1 10 Workshop Manual October 2005 ...

Page 89: ...block with dry cast liners Viewed from the driving position the right hand cylinder bank is designated A bank and the left hand cylinder bank as B bank Cylinder Block Drain Plug The coolant drain plug is located on the rear left side of the cylinder block On vehicles supplied with a cold climate package i e vehicles operating in conditions regularly below 30 C a cylinder block heater unit is fitte...

Page 90: ...n Bedplate This is a structural casting bolted to the bottom of the cylinder block to retain the crankshaft and to further improve overall rigidity Main bearing clearance changes due to expansion are minimized by means of iron inserts cast into the bedplate main bearing supports Two hollow dowels align the bedplate with the cylinder block and the joint is sealed by a continuous bead of sealant Eng...

Page 91: ...A steel shim in the top of each lifter allows adjustment of valve clearances Collets valve collars and spring seats locate the valve springs on the intake and exhaust valves Valve stem seals are integrated into the spring seats Four 14mm spark plugs are located in a recess on the center line of each cylinder head Inlet Exhaust Manifolds Intake air is filtered and passed through mass air flow meter...

Page 92: ...er hoses from cam cover x2 for access 27 Disconnect purge line from manifold quickfit and support clip for access 28 Disconnect heater hose from pipe quick fit 29 Release heater hose x2 and throttle body hose x2 from support bracket 30 Remove booster hose from manifold and support clip 31 Remove harness support bracket bolt x1 nut x2 release harness clips fir tree x3 32 Release pipe support bracke...

Page 93: ...Install harness bracket to engine 24 Feed harness into inner wing area 25 Install fusebox to bracket 26 Install earth lead to fusebox 27 Install battery lead to fusebox 1x nut rubber cover 28 Install multiplugs to fuse box 29 Install fusebox bracket fixings 30 Refit harness fir tree clips to cylinder head 31 Refit engine breather hose 32 Install VVT solenoid multiplug position coil and CMP harness...

Page 94: ...Engine Structure 03 01 3 2 6 Workshop Manual October 2005 ...

Page 95: ...es to isolate sump oil from the rotating assembly runs the full length of the sump This keeps the rotating assembly free of windage and allows it to spin freely and make more power In addition the extra crankcase vacuum created by the dry sump pump helps to improve ring seal for additional power gain Other advantages of a dry sump system include increased oil capacity more consistent oil pressure ...

Page 96: ...oil filter plates screws x4 4 Use suitable bolt to aid removal of filters 5 Clean filter mating face Installation 1 Install oil filter lube seal 2 Install oil filter plates screws x4 Engine oil Europe Aus USA Castrol Formula RS 10W 60 To achieve the required high performance of synthetic lubricants do not mix with mineral oils Capacity Europe Litres UK Pints USA Qts Full System 13 23 11 Service Fi...

Page 97: ...ngine 03 00 October 2005 Workshop Manual 3 3 3 3 Clean off excess oil 4 Remove container 5 Lower vehicle on ramp 6 Fill tank with approximately amount of displaced oil and replace cap 7 Use handbook procedure to check oil level ...

Page 98: ...Lubrication System 03 02 Engine 03 00 3 3 4 Workshop Manual October 2005 ...

Page 99: ... coolant hose through the radiator and returns to the water pump through the lower coolant hose and water cross over housing Radiator The radiator is of aluminium construction with plastic end tanks Foam seals are installed to the radiator to prevent the cooling air from by passing the radiator core The radiator is located by four isolator mountings and supported by the radiator support beams A co...

Page 100: ...rain container 10 Install front undertray see Workshop Manual procedure 01 02 NB Undertray Front Renew 11 Lower vehicle on ramp 12 Fill cooling system with specified coolant mix to maximum level in coolant reservoir 13 Install and tighten pressure cap 14 Run engine until normal operating temperature is reached 15 Stop engine allow to cool down 16 Re check coolant level top up as necessary Antifree...

Page 101: ...anel screws x12 2 Remove horn and bracket assembly for access bolts x2 3 Disconnect fan multiplugs x2 4 Remove nuts x2 securing fans to radiator 5 Remove fan assembly unclip from radiator Installation 1 Install fan assembly clip to radiator 2 Install nuts x2 securing fans to radiator torque 3 Connect fan multiplugs x2 4 Install horns and bracket bolts x2 torque 5 Install slam panel screws x12 Ther...

Page 102: ...ottle body duct 6 Connect breather pipe quickfits x2 to air cleaner duct Water Pump Pulley Renew Removal 1 Disconnect breather pipe quickfits x2 from air cleaner duct 2 Remove throttle body duct for access clips x3 3 Remove pump pulley bolts x3 4 Release tensioner and slip belt from idler 5 Remove pump pulley Installation 1 Fit pulley to pump with bolts 2 Torque pulley bolts bolt x3 3 Release tens...

Page 103: ... wing 3 Install undertray see Workshop Manual procedure 01 02 NB Undertray Front Renew 4 Install RH air filter box see Workshop Manual procedure 03 12 BB Air Filter Box RH Renew 5 Lower vehicle on ramp 6 Install pipe to oil tank torque ensure correct alignment in oil tank bracket 7 Fill tank with approximately amount of displaced oil and replace cap 8 Use handbook procedure to check oil level Oil ...

Page 104: ...d replace cap 9 Use handbook procedure to check oil level Oil Thermostat Cooler Pipe Assembly Renew Removal 1 Raise vehicle on ramp 2 Remove undertray see Workshop Manual procedure 01 02 NB Undertray Front Renew 3 Remove LH air filter box see Workshop Manual procedure 03 12 AB Air Filter Box LH Renew 4 Remove pipe from oil thermostat position container to catch oil 5 Unclip pipe x4 from inner wing...

Page 105: ...orque 3 Install hoses x3 on expansion tank secure with clips x3 4 Install LH cross brace install bolts x4 torque with vehicle on level ground 5 Refill expansion tank to correct level with correct coolant fluid mixture 6 Clean up any spilled coolant fluid Coolant Recovery Tank Assembly Renew Removal 1 Raise vehicle 2 Remove LH front wheel arch liner see Workshop Manual procedure 01 02 FB Wheel Arch...

Page 106: ...Hose Renew Removal 1 Drain engine coolant see Workshop Manual procedure 03 03 AD Coolant Drain Refill 2 Remove screws x14 securing radiator cover remove cover 3 Release clips x2 remove bottom hose Installation 1 Install bottom hose and secure with clips 2 Install radiator cover install and torque tighten screws x14 3 Refill coolant system see Workshop Manual procedure 03 03 AD Coolant Drain Refill...

Page 107: ...Installation 1 Install hose behind inlet manifold and into bulkhead clip 2 Connect hose to engine pipe quickfit and into clips 3 Refit I P see Workshop Manual procedure 01 12 AB Facia Assembly LHD Remove for Access Refit Heater Inlet Hose Renew Removal 1 Remove I P see Workshop Manual procedure 01 12 AB Facia Assembly LHD Remove for Access Refit 2 Disconnect hose from engine pipe quickfit and rele...

Page 108: ...sconnect top hose clip x1 14 Connect bottom hose clip x1 15 Install reservoir bracket assy vac system see Workshop Manual procedure 03 08 AE Reservoir and Bracket Assembly Vacuum System Renew RH LH Cooling Fan Motor Renew Removal 1 Remove cooling fan assembly see Workshop Manual procedure 03 03 DB Fan Motor Assembly Radiator Renew 2 Disconnect motor multiplug 3 Remove fan motor nuts x3 Installatio...

Page 109: ... working area NO SMOKING signs must be posted around the working area Warning Any operation which could involve sparks or naked lights e g battery testing welding metal grinding etc must not be allowed near the working area Warning A CO2 fire extinguisher must be available close at hand Warning Dry sand must be available close at hand to soak up any accidental fuel spillage Warning If necessary em...

Page 110: ...hrottle body hose x2 from support bracket 30 Remove booster hose from manifold V difficult and support clip 31 Remove harness support bracket bolt x1 nut x2 release harness clips fir tree x3 32 Release pipe support bracket nuts x2 bolts x2 move aside 33 Disconnect injector multiplugs x4 34 Unclip injector harness from cam cover x2 35 Disconnect IAT multiplug 36 Disconnect breather hose from manifo...

Page 111: ...e 10 01 EK Fuel System Depressurise 2 Disconnect vacuum hose 3 Remove sensor from fuel rail bolts x2 4 Disconnect multiplug Installation 1 Install sensor to fuel rail bolts x2 torque 2 Connect multiplug 3 Connect vacuum hose Fuel Temperature Sensor Renew Removal 1 Depressurise fuel rail see Workshop Manual procedure 10 01 EK Fuel System Depressurise 2 Disconnect vacuum hose 3 Remove sensor from fu...

Page 112: ...epressurise fuel rail see Workshop Manual procedure 10 01 EK Fuel System Depressurise 2 Remove corner cross brace 3 Remove coils see Workshop Manual procedure 03 07 GB Coil Assembly Engine Set LH Renew 4 Disconnect breather hoses from cam cover x2 for access 5 Disconnect purge line from manifold quickfit and support clip for access 6 Disconnect heater hose from pipe quick fit 7 Release heater hose...

Page 113: ...nut x2 6 Connect EGR x1 fuel rail pressure sensor x1 and injector multiplugs x4 7 Refit harness to coolant pipe bracket fir tree x3 8 Connect heater hose to pipe quick fit 9 Refit heater hose clipx2 and EGR vacuum lines clips x2 to bracket 10 Install fuel feed pipe 11 Install purge pipe p clip 12 Install harness bracket to engine 13 Feed harness into inner wing area 14 Install fusebox to bracket 1...

Page 114: ...ss to cam cover 13 Remove purge pipe p clip bolt x1 and move pipe aside 14 Remove harness bracket from engine bolts x2 nut x1 15 Release fuel feed hose from rail clip x1 move aside 16 Disconnect heater hose from pipe quick fit 17 Release heater hose clips x2 and EGR vacuum line clips x2 from bracket 18 Release harness from coolant pipe bracket fir tree x3 19 Disconnect EGR x1 fuel rail pressure se...

Page 115: ... breather hoses x2 4 Install duct and clip to throttle body Throttle Body Gasket Renew Removal 1 Remove duct from throttle body clip x1 2 Disconnect breather hoses x2 for access 3 Disconnect multiplug and harness from clip 4 Remove throttle body and gasket bolts x4 Installation 1 Install throttle body and gasket bolts x4 2 Reconnect multiplug and harness clip 3 Reconnect breather hoses x2 4 Instal...

Page 116: ...Fuel Charging System 03 04 3 5 8 Workshop Manual October 2005 ...

Page 117: ...o engine 2 Install tensioner to engine bolt x1 torque 3 Release tensioner and slip belt on idler 4 Install throttle body duct 5 Connect breather pipe quickfits x2 to air cleaner duct Engine Drive Belt and Bracket Assembly Oil Pump Tensioner Renew Removal 1 Remove throttle body duct for access clips x3 2 Disconnect breather pipe quickfits x2 from air cleaner duct 3 Release tensioner and slip belt f...

Page 118: ...embly Renew Removal 1 Remove throttle body duct for access clips x3 2 Disconnect breather pipe quickfits x2 from air cleaner duct 3 Release tensioner and slip belt from idler 4 Remove idler from engine bolt x1 Installation 1 Install idler to engine bolt x1 torque 2 Release tensioner and slip belt on idler 3 Install throttle body duct 4 Connect breather pipe quickfits x2 to air cleaner duct Repair ...

Page 119: ...to starter motor 3 Install battery cable from starter motor 4 Switch battery isolation switch ON 5 Install RH exhaust manifold see Workshop Manual procedure 09 00 CA Manifold Exhaust RH Renew Starter Button Renew Removal 1 Remove veneer panel using special tool to hook into either one of two centre air flow vents 2 Disconnect starter button multiplug squeeze the retaining clips and remove button f...

Page 120: ...Engine Cranking System 03 06 3 7 2 Workshop Manual October 2005 ...

Page 121: ...il Assembly Engine Set LH Renew 2 Remove spark plugs x4 Installation 1 Install spark plugs x4 torque 2 Install coils see Workshop Manual procedure 03 07 GB Coil Assembly Engine Set LH Renew Spark Plugs RH Bank Renew 1 Remove coils see Workshop Manual procedure 03 07 HC Coil Assembly Engine Set RH Renew 2 Remove spark plugs x4 Installation 1 Install spark plugs x4 torque 2 Install coils see Worksho...

Page 122: ...Ignition System 03 07 Engine 03 00 3 8 2 Workshop Manual October 2005 ...

Page 123: ...ir bolts x3 torque 2 Clip harness to bracket 3 Connect hose to SAI module 4 Connect vacuum hose to reservoir 5 Install inlet manifold see Workshop Manual procedure 03 01 BB Gasket Manifold Assembly Intake Upper Renew Oil Tank Breather Hose Renew Removal 1 Disconnect hose from cam cover quickfit 2 Disconnect hose from oil tank quickfit and remove hose from clip Installation 1 Install hose to clip a...

Page 124: ...connect vacuum tube from solenoid valve 5 Disconnect vacuum tubes x2 from actuator valves 6 Loosen unions and disconnect secondary air injection tubes x2 7 Disconnect multiplug air injection pump Release multiplug from mounting bracket 8 Release harness and vacuum tube fir tree clips x6 from mounting bracket 9 Remove bolts x3 securing secondary air injection pump assembly to engine 10 Remove secon...

Page 125: ...Disconnect hose from throttle body adaptor assembly quickfit 2 Disconnect hose from PCV valve quickfit remove hose Installation 1 Install hose to PCV valve quickfit 2 Connect hose to throttle body adapter assembly quickfit EGR Module Renew Removal 1 Disconnect vacuum tube and multiplug from EGR module 2 Loosen and disconnect pipe union EGR module to exhaust manifold 3 Remove bolts x2 securing EGR ...

Page 126: ...Emission Control 03 08 Engine 03 00 3 9 4 Workshop Manual October 2005 ...

Page 127: ...r Renew 2 Disconnect camshaft sensor multiplug and remove from bracket 3 Remove cam sensor from cylinder head bolt x2 Installation 1 Install cam sensor from cylinder head bolt x2 2 Connect camshaft sensor multiplug and fit to bracket 3 Install inlet manifold see Workshop Manual procedure 03 01 BB Gasket Manifold Assembly Intake Upper Renew Repair Operation Time ROT Item Code Cam Timing Sensor Rene...

Page 128: ...Valve Train 03 09 Engine 03 00 3 10 2 Workshop Manual October 2005 ...

Page 129: ...coils see Workshop Manual procedure 03 07 GB Coil Assembly Engine Set LH Renew 15 Install corner cross brace torque bolts with vehicle on level ground RH Cylinder Head Cover Renew 1 Pull back carpet to gain access to CEM cover 2 Remove CEM cover 7x screws 3 Remove fuel pump relay 4 Start engine allowing it to idle until it cuts out turn ignition off 5 Install fuel pump relay 6 Install CEM cover 7 ...

Page 130: ...new 3 Disconnect breather hoses from cam cover x2 for access 4 Disconnect purge line from manifold quickfit and support clip for access 5 Disconnect heater hose from pipe quick fit 6 Release heater hose x2 and throttle body hose x2 from support bracket 7 Remove booster hose from manifold V difficult and support clip 8 Remove harness support bracket bolt x1 nut x2 release harness clips fir tree x3 ...

Page 131: ...ts x2 27 Disconnect EGR vac pipe from sensor and manifold move aside 28 Remove cam cover bolts x14 29 Remove cam cover seals Installation 1 Install new cam cover seals clean mating faces 2 Install cam cover bolts x14 3 Connect EGR vac pipe to sensor and manifold 4 Install coolant pipe bracket bolt x2 nut x2 5 Connect EGR x1 fuel rail pressure sensor x1 and injector multiplugs x4 6 Refit harness to...

Page 132: ...Engine Sealing 03 10 Engine 03 00 3 11 4 Workshop Manual October 2005 ...

Page 133: ...nsor Renew Removal 1 Raise vehicle on ramp 2 Disconnect cranksensor multiplug 3 Remove sensor bolt x1 Installation 1 Install sensor bolt x1 2 Connect cranksensor multiplug 3 Lower vehicle on ramp 4 WDS Check see Workshop Manual procedure 00 06 AD WDS Operation Check Repair Operation Time ROT Item Code Crankshaft Timing Sensor Renew 03 02 AR ...

Page 134: ...Power Conversion 03 11 Engine 03 00 3 12 2 Workshop Manual October 2005 ...

Page 135: ... Removal 1 Remove LH RH intake air filter box see Workshop Manual procedure 03 12 AB 03 12 BB Air Filter Box LH RH Renew 2 Remove screw securing mass airflow meter release remove airflow meter from intake air filter box Installation 1 Clean mass airflow meter and mating face on air cleaner box 2 Install mass airflow meter to intake air filter box install and tighten screw 3 Install LH RH intake ai...

Page 136: ...Air Charging 03 12 Engine 03 00 3 13 2 Workshop Manual October 2005 ...

Page 137: ...pen canister vent valve through the carbon canister through the vapour management valve and into the primary inlet manifold This fresh air flow progressively purges any absorbed fuel vapour from the carbon canister Maintenance Fuel Vapour Valve Assembly Renew Removal 1 Remove washer reservoir securing screws x and tie aside for access 2 Remove bolts x 2 bracket to body 3 Disconnect multiplug x1 4 ...

Page 138: ...rkshop Manual procedure 01 02 GB Wheel Arch Liner Front RH Renew DMTL and Filter Bracket Assembly Renew Removal 1 Remove LH rear wheel arch liner see Workshop Manual procedure 01 02 JB Wheel Arch Liner Rear LH Renew 2 Disconnect hose from valve clip x1 3 Release harness from bracket and disconnect multiplug 4 Remove valve bolts x3 Installation 1 Install valve bolts x3 2 Install harness to bracket ...

Page 139: ...enew Removal 1 Raise vehicle on ramp 2 Remove rear exhaust silencer see Workshop Manual procedure 09 00 KA Silencer and Bypass Valve Assembly Remove for Access and Refit 3 Disconnect multiplugs x2 HEGO sensors 4 Secure sufficient lengths of string to HEGO sensor multiplugs for assembly purposes 5 Loosen LH and RH clamp nuts catalysts to centre pipes 6 With assistance manoeuvre exhaust centre pipe ...

Page 140: ...ccess Refit 10 Lower vehicle on ramp RH Front Upper Heated Exhaust Gas Oxygen HEGO Sensor Renew Removal 1 Raise vehicle on ramp 2 Remove rear exhaust silencer see Workshop Manual procedure 09 00 KA Silencer and Bypass Valve Assembly Remove for Access Refit 3 Disconnect multiplugs x2 HEGO sensors 4 Secure sufficient lengths of string to HEGO sensor multiplugs for assembly purposes 5 Loosen LH and R...

Page 141: ...se HEGO sensor leads from behind heat shield Remove string from HEGO multiplugs 10 Remove catalyst assembly 11 Remove and discard gasket 12 Remove HEGO sensors from catalyst Installation 1 Clean catalyst mating joint faces and HEGO sensors 2 Install and tighten HEGO sensor to catalyst 3 Apply proprietary exhaust sealant around clamp joints 4 Install new gasket to exhaust manifold 5 Position cataly...

Page 142: ...Engine Management System 03 14 Engine 03 00 3 15 4 Workshop Manual October 2005 ...

Page 143: ...ed by the PCM to indicate power demand from the engine If not already at the desired position the PCM will drive the throttle motor to open or close the throttle by the required amount At idle the throttle butterfly is almost closed and idle speed is controlled by small throttle movements The throttle butterfly is spring loaded to fail in the idle position In the event of the throttle butterfly sp...

Page 144: ...Throttle Control 03 16 Engine 03 00 3 16 2 Workshop Manual October 2005 ...

Page 145: ...10 AB Seat Assembly Front LH Remove for Access Refit 2 Remove securing bolts 3 see Fig 1 3 With unit free disconnect two connectors see Fig 2 Installation 1 Connect two electrical connectors 2 Position throttle unit and secure with three bolts 3 Install drivers seat see Workshop Manual procedure 01 10 AB Seat Assembly Front LH Remove for Access Refit Repair Operation Time ROT Item Code Throttle Pe...

Page 146: ... 2 RH LH Arm Assembly Toe Control Rear Renew 3 3 Anti Roll Bar Rear Renew 3 3 Anti Roll Bar Bushing Rear Pair Renew 3 3 RH LH Anti Roll Bar Link Rear Renew 3 3 RH LH Hub Vertical Link Rear Renew 3 4 Rear Suspensions Sensor Assembly Renew 3 4 Shock Absorber System 04 03 4 4 1 Description 4 1 Specifications 4 1 Maintenance 4 1 Spring and Damper Assembly Front Pair Renew 4 1 Spring Front Pair Renew 4...

Page 147: ...ear Toe individual 3 2 10 5 0 Total Toe 6 4 20 10 0 Camber 30 5 105 1 45 5 Cross Camber 0 10 0 10 Castor 5 0 5 0 25 N A Cross Castor 0 0 25 N A KPI 11 22 N A Normal Ride Height 2 x 37 5kg in front seats 37 5kg in each seat plus a full fuel tank Ride height is measured from the centre of the road wheel vertically up to the road wheel arch Check tyre pressures before checking road wheel alignment Fr...

Page 148: ... wheel bearing including the ABS encoder ring the wheel speed sensor the brake caliper and the brake disc and shield The position of the Vertical link is determined by the movement of the steering rack which is connected to the Vertical link by the steering track rod Specifications 8SSHU UP DOO RLQW DQG XVKHV DOO RLQW DQG XVKHV 9HUWLFOH LQN ROWV WR RG RZHU UP QWL UROO DU URS LQNV FFHQWULF DP ROWV ...

Page 149: ... road wheel alignment Refer to Road Wheel Alignment 04 00 page 4 1 2 Tyres out of balance tyres cupped or dished Balance tyres Shimmy or Road Wheel Tramp Loose road wheel nut s Check and tighten road wheel nuts to specification Loose front suspension Check and tighten suspension fixings to specification Front road wheel bearing s Check road wheel bearings Road wheel tyres Check road wheels tyres S...

Page 150: ...units Steering components Check Install new components as required Vehicle Leans to One Side Unevenly loaded or overloaded vehicle Notify customer of incorrect vehicle loading Front or rear suspension components Inspect front and rear suspension systems Spring and damper assemblies Check spring and damper assemblies Incorrect ride height Lateral tilt out of specification Suspension bushes not torq...

Page 151: ... from body 6 Remove nuts x3 damper top mounting Remove engine cross brace support 7 Remove nut bolt securing damper to lower mounting 8 Remove spring damper assembly 9 Remove nut securing upper suspension arm ball joint to vertical link 10 Install tool 204 523 ball joint remover and release ball joint from vertical link 11 Remove upper suspension arm assembly Installation 1 Clean upper suspension ...

Page 152: ...tall washers x2 and nuts x2 Do not torque tighten 4 Align damper to lower mounting install bolt nut Do not torque tighten at this stage 5 Final tightening of suspension components must be carried out with the suspension arms at normal ride height 6 Install road wheel s 7 Lower vehicle in ramp 8 Torque tighten link nuts x2 9 Torque tighten lower damper bolt RH LH Front Hub Vertical Link Renew Remov...

Page 153: ...el s 14 Pump brake pedal 15 Lower vehicle on ramp 16 4 wheel alignment check adjust see Workshop Manual procedure 04 00 AD 4 Wheel Alignment Check Adjust Front Suspension Sensor Assembly Renew Removal 1 Raise vehicle on ramp 2 Remove nut bolt securing ride height sensor link to lower suspension arm see Fig 1 3 Remove nut Torx bolt ride height sensor to subframe 4 Disconnect ride height sensor mult...

Page 154: ...ccentric cam bolt Anti roll Bar An anti roll bar mounted on the rear subframe connects to the LH and RH lower suspension arms via drop links The drop links with a ball joint at either end transmit vertical movement of the rear suspension to the anti roll bar minimising body roll Vertical Link The vertical link carries the hub the cartridge wheel bearing the ABS rotor the wheel speed sensor the bra...

Page 155: ...n lower suspension arm and mating faces on vertical link subframe damper and anti roll bar link 2 Install lower suspension arm to subframe and vertical link 3 Install bolt and bolts nuts x2 lower suspension arm to subframe and vertical link Do not torque tighten at this stage 4 Align damper to lower suspension arm install bolt Do not torque tighten at this stage 5 Align anti roll bar link to lower...

Page 156: ...arm to vertical link and subframe Do not torque tighten at this stage 4 Install ABS sensor harness clips in toe control arm 5 Final tightening of suspension components must be carried out with the suspension arms at normal ride height 6 Install road wheel s 7 Lower vehicle on ramp 8 4 wheel alignment check adjust see Workshop Manual procedure 04 00 AD 4 Wheel Alignment Check and Adjust Rear Anti R...

Page 157: ...S sensor multiplug 6 Remove Torx screw securing ABS sensor remove sensor 7 Ease calliper pistons to release pads 8 Remove calliper Allen bolts x2 release calliper and tie aside 9 Remove handbrake calliper bolts x2 and tie calliper aside 10 Remove brake disc Torx screws x2 remove disc 11 Remove nut bolt securing lower suspension arm to vertical link 12 Remove nut bolt securing vertical link to uppe...

Page 158: ...nt check adjust see Workshop Manual procedure 04 00 AD 4 Wheel Alignment Check and Adjust Rear Suspension Sensor Assembly Renew Removal 1 Raise vehicle on ramp 2 Remove nut bolt ride height sensor link to upper suspension arm 3 Remove bolts x2 ride height sensor to subframe 4 Disconnect sensor multiplug and remove sensor Installation 1 Position ride height sensor to subframe install and torque tig...

Page 159: ...Rear Suspension 04 02 Suspension 04 00 4 3 6 Workshop Manual October 2005 ...

Page 160: ...nt Spring and Damper Assembly Pair Renew Removal 1 Raise vehicle on ramp 2 Remove road wheel s 3 Disconnect ABS sensor multiplug see Fig 1 4 Release sensor harness clips x3 from upper suspension arm and vertical link see Fig 2 5 Remove Torx bolts x4 from LH and RH side securing engine cross brace and remove cross brace 6 Remove nuts and bolts x2 each side from upper suspension arm to body see Fig ...

Page 161: ...ing and install bolts and nuts each side do not torque tighten 4 Position upper suspension arm to body and install bolts and nuts x2 each side do not torque tighten 5 Connect ABS sensor multiplug and install harness clips in upper suspension arm and vertical link 6 Install road wheel s 7 Lower vehicle on ramp 8 Tighten upper arm nuts and bolts 9 Torque tighten top mounting nuts x3 and lower mounti...

Page 162: ...oss brace support see Fig 5 9 Remove nuts and bolts each side from damper lower mountings see Fig 6 10 Remove spring and damper assembly 11 Position spring compressor to spring and compress spring 12 Hold damper shaft and remove top mounting retaining nut 13 Remove top mounting and spring assembly 14 Remove spring compressor from spring Installation 1 Clean spring and top mounting 2 Position sprin...

Page 163: ...ound bumper and spring seat flange Installation 1 Clean spring spring seat flange bumper dust shield and top mounting 2 Install spring seat flange rebound bumper and dust shield onto damper 3 Install spring and top mounting and install and tighten retaining nut 4 Remove spring compressor 5 Install spring and damper assembly and install engine cross brace support 6 Install top mounting nuts x3 each...

Page 164: ...nsor harness clips x2 from toe control arm see Fig 3 10 Remove bolts x2 each side from handbrake calliper to rear hub and release calliper and position aside see Fig 4 11 Remove nuts and bolts both sides from toe control arms see Fig 5 12 Remove nuts and bolts each side from lower damper mountings see Fig 6 Fig 2 Fig 3 Fig 4 Fig 5 Fig 6 ...

Page 165: ...x2 each side and tighten bolts to the correct torque 8 Connect ABS sensor multiplugs each side 9 Install clips x2 each side from sensor harness to toe control arms 10 Install LH wheel arch liner see Workshop Manual procedure 01 02 HB Wheel Arch Liner Rear RH Renew 11 Install RH wheel arch liner see Workshop Manual procedure 01 02 JB Wheel Arch Liner Rear LH Renew 12 Install road wheel s 13 Lower v...

Page 166: ... pipe aside see Fig 1 8 Disconnect ABS sensor multiplug see Fig 2 9 Release sensor harness clips x2 from toe control arm see Fig 3 10 Remove bolts x2 each side from handbrake calliper to rear hub and release calliper and position aside see Fig 4 11 Remove nuts and bolts both sides from toe control arms see Fig 5 Fig 1 Fig 2 Fig 3 Fig 4 Fig 5 ...

Page 167: ...ting plate to damper and torque tighten retaining nuts x3 each side 6 Install spring and damper assembly and torque tighten upper bolts x4 each side 7 Install damper assembly to lower arm each side and torque tighten nuts and bolts 8 Position fuel filler pipe to body and install and tighten nut 9 Position fuel filler pipe and install and tighten bolt 10 Position toe control arm each side and insta...

Page 168: ...p mounting and spring assembly 19 Remove dust shield rebound bumper and spring seat flange Installation 1 Clean spring spring seat flange rebound bumper dust shield and top mounting 2 Install spring seat flange rebound bumper and dust shield onto damper 3 Install spring and top mounting and fit and tighten retaining nut 4 Remove spring compressor 5 Position mounting plate to damper and torque tigh...

Page 169: ...Shock Absorber System 04 03 Suspension 04 00 4 4 10 Workshop Manual October 2005 ...

Page 170: ...d wheel nuts torque at 32 km 20 miles after any wheel change or any time the wheel nuts are loosened Warning When changing a wheel make sure that the vehicle cannot move Always apply the parking brake and select the transmission park position Automatic transmission only Warning Reduce air pressure as much as possible by pushing the valve core plunger in before removing the valve core Warning Each ...

Page 171: ...p to and including the full rated load capacity Correct tyre pressures and driving technique have an important influence on tyre life Heavy cornering excessively rapid acceleration and unnecessary sharp braking increase tyre wear Replacement tyres should follow the recommended The use of any other size or type may seriously affect Wheels need to be renewed when Safety Warning Do not mix different ...

Page 172: ...e customer s concern by driving the vehicle Visually inspect for obvious signs of damage Visual Inspection Chart 1 If an obvious cause for an observed or reported concern is found correct the cause if possible before proceeding to the next step 2 If the concern is not visually evident verify the symptom and refer to Symptom Chart Tyre Wear Tread wear indicators A are moulded into the bottom of the...

Page 173: ...es with the contact between the tyre and the road surface A thumping noise usually means that the tyre has a flat or soft spot making a noise as they slap the roadway Tyre whine may be distinguished from axle noise Tyre whine remains the same over a range of speeds Symptoms Symptom Possible Source s Action s Tyres show excess wear on edge of treads Tyres under inflated Correct pressure to specific...

Page 174: ...w driveshaft Damaged wheel hub stud threads Sliding wheel across the wheel studs during installation Loose wheel nuts Install new wheel studs Broken wheel studs Loose or over tightened wheel nuts Install new wheel studs Corrosion and contamination streaks from the wheel hub wheel stud holes Loose wheel nuts Check complete assembly Install new parts Damaged wheel nuts Loose wheel assembly Install n...

Page 175: ...able and sharp pattern edges may be caused by road camber even when the road wheel alignment is correct In such cases it is better to make sure by checking with an alignment gauge Road camber affects the direction of the vehicle by imposing a side thrust and if left to follow its natural course the vehicle will drift towards its nearside This is instinctively corrected by steering towards the road...

Page 176: ...e tyre and road wheel assembly to rotate about its centre due to gravity but the weight may be unevenly distributed each side of the tyre centre line Laterally the eccentric road wheels give the same effect During rotation the offset weight distribution sets up a situation which tends to steer the road wheel to the right and left alternately Dynamic imbalance of the tyre and road wheel assemblies ...

Page 177: ... are always installed in their original positions i e after new tyres are installed Road wheel Colour Front right Front Left Rear Right Rear Left Green Red Blue Yellow Instrument Cluster Lamp constant Message Check Tyres Control module Tyre LED constant red Fault Tyre pressure below specification Action Reduce speed to 48 km h 30 mph Stop in safe place as soon as possible One of the coloured LEDs ...

Page 178: ...tive the display will show three dashes to indicate the absence of data for that tyre 5 To return to normal mode press the SET button System Programming The system may be programmed by the user on three different levels Enter Programming Mode by pressing the Set button 2 seconds to enter level 1 5 seconds to enter level 2 10 seconds to enter level 3 The following parameters may be set in each leve...

Page 179: ...gramming 2 Press Mode repeatedly until the icon is displayed 3 Press Tyre to display the current value 4 Press Tyre to increase or Mode to decrease the current value 5 Press Set to save the amended value 6 Press Set again to revert to normal operation High Temperature Alert 1 Press Set for 2 seconds to enter level 1 programming 2 Press Mode until alert icon is displayed 3 Press Tyre to display the...

Page 180: ... Tyre to scroll to the desired position 1 5 To delete a transmitter press the Mode once 1 6 If required scroll to other positions using Tyre and if required delete any other transmitters using Mode button 2 Add new Transmitters 2 1 Press Set for 5 seconds to enter level 2 programming 2 2 Press Mode to select Transmitter Learn mode 2 3 Press Tyre to display possible tyre positions filled rectangles...

Page 181: ...ual 5 1 1 Driveline 05 00 Contents Driveshaft 05 01 5 1 2 Description 1 2 Specifications 1 2 Maintenance 1 2 Torque Tube Remove for Access Refit 1 2 RH LH Drive Shaft Assembly Renew 1 4 Halfshafts 05 05 5 2 1 Specifications 2 1 ...

Page 182: ...s and crash worthiness Specifications Maintenance Torque Tube Remove for Access Refit Remove 9 Remove transaxle see Workshop Manual 07 03 AA Transaxle Assembly Manual Remove for Access Refit 10 Remove LH exhaust manifold see Workshop Manual 09 00 CB Manifold Exhaust LH Renew 11 Allow torque tube to lower until engine is balanced Torque Figures Description Nm lb ft Torque Tube front M10 43 57 Nomin...

Page 183: ... clutch hydraulics bleed nipple and with suitable container below press clutch pedal fully and retain pedal in that position Tighten bleed nipple see Fig 3 15 Disconnect the clutch slave cylinder supply pipe at the flexible pipe union and cap pipes see Fig 4 16 With assistance support torque tube and remove bolts x16 that secure torque tube to engine see Fig 5 Fig 1 Fig 2 Fig 3 Fig 4 Fig 5 ...

Page 184: ...embly Renew Removal 1 Raise vehicle on ramp 2 Remove road wheel s 3 Remove rear undertray see Workshop Manual procedure 01 02 PB Undertray Rear Renew 4 With assistance remove drive shaft nut 5 Remove and discard Allen bolts x6 collect plates x3 drive shaft to differential 6 Release drive shaft from rear hub remove drive shaft Installation 1 Clean drive shaft and mating faces on differential flange...

Page 185: ...fshafts 05 05 Driveline 05 00 October 2005 Workshop Manual 5 2 1 Driveline 05 00 Halfshafts 05 05 Specifications Torque Figures Description Nm lb ft Halfshaft nut 300 221 5 Halfshaft to differential 70 52 ...

Page 186: ...ly Vehicle Set Renew 3 2 Brake Actuation System 06 06 6 4 1 Description 4 1 Tandem Master Cylinder 4 1 Specifications 4 1 Maintenance 4 2 Brake Fluid Reservoir Renew 4 2 Manual Brake and Clutch Pedal Bleed Renew 4 2 Brake Modulator RHD Vehicle Renew 4 2 Brake Master Cylinder Assembly Renew 4 2 Brake Master Cylinder Assembly LHD Renew 4 2 Flexible Brake Hose LHS Front Renew 4 3 Power Brake System 0...

Page 187: ...ed pistons act directly on the brake pads mounted one each side of the disc Specifications Oils Greases Brake Fluid Castrol Response SuperDOT 4 Not silicon based brake fluid Brake discs Front Brake disc initial thickness 32 mm Brake disc Min thickness 30 mm Brake Disc Runout 70 m measured 2 mm in from the brake disc edge Brake pads New pad thickness 9 4 mm Minimum lining thickness 2 5 mm Torque Fi...

Page 188: ... 1 Clean components pads pins shims spring 2 Install new calliper and secure bolts x2 torque 3 Apply anti seize compound to pads pins and shims 4 Install pads and shims to calliper 5 Install retaining pins and spring to calliper 6 Install brake pipe torque using alignment tool 206 100 7 Install pad wear sensor 8 Remove bleed nipple dust cap 9 Fit bleed bottle 10 Top up brake fluid 11 Bleed brake c...

Page 189: ...p up brake fluid 6 Bleed brake calliper with assistance 7 Remove bleed bottle 8 Fit bleed nipple dust caps 9 Clean off excess fluid 10 Top up brake fluid 11 Install road wheel s 12 Lower vehicle on ramp RH LH Front Brake Disc Shield Assembly Renew Removal 1 Raise vehicle on ramp 2 Remove RH hub and bearing assembly see Workshop Manual procedure 04 01 AA Hub Bearing Assembly Front RH Renew 3 Remove...

Page 190: ...ifications DOLSHU ROW 5HDU DOLSHU UDNH RVH VV UDNH 3DG LW UDNH 3DG 6HQVRU VV 5HDU UDNH LVF 6KLHOG URRYHG UDNH LVF Oils Greases Brake Fluid Castrol Response Super DOT 4 Not silicon based brake fluid Brake discs Brake disc initial thickness 28 0 mm Brake disc Min thickness 26 0 mm Brake Disc Runout 70 mm measured 2 mm in from the brake disc edge Brake pads Minimum lining thickness 2 5 Torque Figures...

Page 191: ... orifices 8 Remove calliper bolts x2 and calliper Installation 1 Clean components pads pins shims spring 2 Install new calliper and secure bolts x2 torque 3 Apply anti seize compound to pads pins and shims 4 Install pads and shims to calliper 5 Install retaining pins and spring to calliper 6 Install brake pipe torque 7 Install pad wear sensor 8 Remove bleed nipple dust cap 9 Fit bleed bottle 10 To...

Page 192: ...move pedal support 5 Top up brake fluid 6 Bleed brake calliper with assistance 7 Remove bleed bottle 8 Fit bleed nipple dust caps 9 Clean off excess fluid 10 Top up brake fluid 11 Install road wheel s 12 Lower vehicle on ramp RH LH Rear Brake Disc Shield Assembly Renew Removal 1 Raise vehicle on ramp 2 Remove RH hub and bearing assembly see Workshop Manual procedure 04 02 AB 04 02 AA Hub and Beari...

Page 193: ...Rear Disc Brakes 06 04 Brake system 06 00 6 2 4 Workshop Manual October 2005 ...

Page 194: ...each calliper retract the pads when the parking brake is released Wear in the parking brake pads is compensated for automatically by a mechanism within the calipers Cable stretch is compensated by cable adjusters A handbrake switch is wired normally closed The switch is held open whilst the handbrake is off and closes when the handbrake is applied The handbrake warning lamp on the instrument panel...

Page 195: ...rake lever bracket 4 x bolts 7 Remove clevis pin and clip from lever Installation 1 Install cable to lever 2 Install lever to body bolts x4 and tighten 3 Connect warning light switch Lucar connection 4 Install driver s seat see Workshop Manual procedure 01 10 AB Seat Assembly Front LH Remove for Access Refit 5 Adjust handbrake cable see Workshop Manual procedure 06 05 DC Handbrake Cable Assembly R...

Page 196: ...des 7 Remove handbrake bracket to access clevis pin and clip and disconnect from lever see Workshop Manual procedure 06 05 CB Handbrake Lever Assembly Renew 8 Unclip cable in the cabin 9 Remove screws x4 from cable clips and unclip grommet from body clip see Fig 1 10 Withdraw cable from body 11 Release inner cable eyelets from caliper levers compress ring clip and remove cable see Fig 2 12 Remove ...

Page 197: ...ake 06 05 Brake Systems 06 00 6 3 4 Workshop Manual October 2005 9 Adjust handbrake cable see Workshop Manual procedure 06 05 DC Handbrake Cable Assembly Renew 10 Install road wheel s 11 Lower vehicle on ramp ...

Page 198: ...s braking and is used as an aid for the ABS DSC to achieve accurate brake pressure control Brake Fluid Reservoir The brake fluid reservoir is mounted directly on the tandem master cylinder and secured with a pin Two stub pipes on the base of the reservoir locate into the primary and secondary chambers of the tandem master cylinder An integral fluid level switch is incorporated in the reservoir If ...

Page 199: ...er to servo nuts x 2 torque 3 Install clutch cylinder feed pipe 4 Connect pressure switch multiplug 5 Install brake pipe unions x2 torque 6 Connect level indicator multiplug 7 Fill reservoir 8 Bleed Brakes see Workshop Manual procedure 06 06 AD Pad Kit Manual Brake Clutch Pedal Renew LHD Brake Master Cylinder Assembly Renew Removal 1 Remove corner cross brace 2 Move expansion tank aside for access...

Page 200: ...tall cylinder retaining nuts x2 torque 8 Install clevis pin and clip 9 Bleed clutch system XREF 574 Clutch Hydraulic System Bleed 10 Top up coolant RH LH Front Calliper Hose Assembly Renew Removal 1 Raise vehicle on ramp 2 Remove road wheel s 3 Remove RH LH front wheel arch liner see Workshop Manual procedure 01 02 FB 01 02 GB Wheel Arch Liner Front RH LH Renew 4 Remove bleed nipple dust caps 5 Po...

Page 201: ...eed hose to LHR calliper open bleed nipples x1 6 Position bleed container connect bleed hose to LHF calliper open bleed nipples x1 7 Depress brake pedal 60 mm and secure with support 8 Tighten LHR bleed nipple disconnect bleed hose remove bleed container and fit dust cap 9 Tighten LHF bleed nipple disconnect bleed hose remove bleed container and fit dust cap 10 Loosen and disconnect brake tube uni...

Page 202: ...fit dust cap 10 Remove screws x5 securing RH LH rear wheel arch liner to body 11 Ease wheel arch liner downwards to access brake tube rear in line connection 12 Loosen and disconnect RH LH rear brake tube union from front line connection 13 Loosen and disconnect RH LH brake tube union from rear in line connection 14 Release brake tube from clips x6 remove brake tube Installation 1 Install brake tu...

Page 203: ...stance 6 Remove bleed bottle 7 Install bleed nipple dust caps 8 Clean off excess fluid 9 Top up brake fluid 10 Install road wheel s 11 Lower vehicle on ramp Stop Lamp Switch Renew Removal 1 Power drivers seat fully rearwards 2 Rotate stop lamp switch clockwise to release from pedal bracket 3 Disconnect multiplug remove stop lamp switch Installation 1 Position stop lamp switch connect multiplug 2 I...

Page 204: ...to body install and torque tighten Torx bolts x3 3 Remove plugs Install and torque tighten brake unions x6 to modulator 4 Connect modulator multiplug 5 Install wheel arch liner see Workshop Manual procedure 01 02 FB Wheel Arch Liner Front LH Renew 6 Bleed braking system see Workshop Manual procedure 06 07 DD Brake Hydraulic System Flush Refill Bleed 7 Install road wheel s 8 Lower vehicle on ramp ...

Page 205: ...Brake Actuation System 06 06 Brake System 06 00 6 4 8 Workshop Manual October 2005 ...

Page 206: ... reaction After the initial application many drivers do not brake hard enough because of concerns that they might cause the vehicle to skid To aid the driver the panic brake assist PBA intervenes in bringing the vehicle to a halt sooner and in a controlled manner in emergency braking situation The PBA system monitors the speed of brake pedal activation and at a calibrated pedal activation speed th...

Page 207: ...cylinder to booster nuts x2 Installation 1 Install booster assembly 2 Connect brake pipes to master cylinder 3 Install bolts x2 clutch pipe bracket 4 Connect clutch reservoir feed pipe 5 Connect multiplugs x4 6 Install vacuum hose 7 Install expansion tank aside bolt x1 nut x1 hose clips x2 multiplug x1 8 Install corner cross brace torque only fully tighten when vehicle on level floor 9 Install ser...

Page 208: ... clutch pipe bracket 4 Connect clutch reservoir feed pipe 5 Connect multiplugs x4 6 Install vacuum hose 7 Install expansion tank aside bolt x1 nut x1 hose clips x2 multiplug x1 8 Install corner cross brace torque only fully tighten when vehicle on level floor 9 Install servo retaining nuts x4 torque 10 Install clevis pin and clip 11 Bleed Brakes see Workshop Manual procedure 06 07 DD Brake Hydraul...

Page 209: ...Power Brake System 06 07 Brake System 06 00 6 5 4 Workshop Manual October 2005 9 Bleed Brakes see Workshop Manual procedure 006 07 DD Brake Hydraulic System Flush Refill Bleed 10 Top up coolant ...

Page 210: ...ally it is possible to an extent to steer the vehicle This principle can be used to enhance driving safety by correcting the vehicle s yaw moment turning force when the vehicle fails to follow the driver s steering inputs Concept Satisfactory handling is determined according to whether a vehicle maintains a path which accurately reflects the driver s input steering wheel angle while at the same ti...

Page 211: ...PCM receives signals from the DSC system via the CAN bus and reduces engine torque as follows The throttle is positioned to provide the requested engine target torque During the transient phase of torque reduction caused by mechanical and combustion delays other alternative torque reduction methods are used to provide a quicker response The ignition is retarded and or the fuel is cut off at the in...

Page 212: ...U 05 Module ABS OBD2 Body B Earth Module ABS Earth Module ABS C1184 18 C2410 6 Sensor Brake Pressure Sensor Brake Pedal Travel Sensor Rear ABS LH C0746 7 C0746 6 C0746 5 Switch Brake Boost Sensor Yawrate Acceleration C2411 6 C2411 5 C2411 4 C2411 3 C0144 7 C0144 3 C0144 2 Sensor Front ABS LH Sensor Front ABS RH C2410 10 C2410 9 C2410 8 Sensor Rear ABS RH C0746 4 C0144 1 C2410 7 C0877 7 K LINE SPL5...

Page 213: ... 4 Install road wheel s 5 Lower vehicle on ramp Rear Wheel Speed Sensor Renew 1 Raise vehicle on ramp 2 Remove road wheel s 3 Remove ABS sensor multiplug 4 Remove ABS sensor and screw x1 Installation 1 Clean knuckle 2 Install new sensor and secure screw x1 torque 3 Install sensor multiplug 4 Install road wheel s 5 Lower vehicle on ramp Fig 1 Fig 2 Repair Operation Time ROT Item Code Rear Wheel Spe...

Page 214: ...sion Oil Inlet Hose Renew 1 3 Manual Transmission 07 03 7 2 1 Description 2 1 Cooling 2 1 Specifications 2 2 Maintenance 2 2 Transaxle Assembly Remove for Access Refit 2 2 Transmission Axle Assembly Drain Refill 2 5 Transaxle Assembly Oil Check Top up 2 5 Transaxle Assembly Renew 2 6 Manual Control System 07 06 7 3 1 Maintenance 3 1 Gearshift Assembly Mechanism Renew 3 1 Transmission Gearshift Cab...

Page 215: ...encer heatshield see Workshop Manual procedure 02 06 AG Heatshield Exhaust Muffler Renew 3 Position drain container to collect oil spillage 4 Loosen oil cooler pipe unions x2 see Fig 1 5 Remove nuts x4 from oil cooler to rear bumper armature 7UDQVPLVVLRQ 2LO RROHU QOHW 7XEH 2XWOHW 7XEH 3LSH 8QLRQV Torque Figures Description Nm lb ft Cooler to subframe 8 10 6 7 5 Repair Operation Time ROT Item Code...

Page 216: ...n bolt and nuts x2 to correct torque 4 Connect and tighten hose unions to correct torque 5 Remove drain container 6 Install transaxle breather hose clip to oil cooler pipe 7 Install rear exhaust silencer heatshield see Workshop Manual procedure 02 06 AG Heatshield Exhaust Muffler Renew 8 Lower vehicle on ramp Manual Transmission Oil Inlet Hose Renew Removal 1 Raise vehicle on ramp 2 Remove rear ex...

Page 217: ...Transmission Cooling 07 02 Transmission 07 00 7 1 4 Workshop Manual October 2005 ...

Page 218: ... to this vehicle incorporates a six speed transmission plus reverse with synchromesh on all gears Gear selection is via an Integrated Shifter Bellcrack System Cable Operated Cooling The manual transaxle has an external cooling circuit which operates continuously by a fixed displacement pump driven by the input shaft The cooler is mounted at the rear attached to the subframe ...

Page 219: ... Plate Type Limited Slip Differential Synchronisers Triple Cone Syncros on 1st and 2nd double cone on all other gears incl reverse Lubrication Pressure fed system with integrated pump driven by the input shaft Filter filter is serviceable item Transaxle Oil Shell Transaxle 75W 90 very important that this is the transaxle type Do not use Shell Spirax 75W90 Transaxle Quantity Coolant System Quantity...

Page 220: ...to transaxle and collect plates x6 see Fig 3 13 Release drive shafts from transaxle and position aside see Fig 4 14 Position drain container to collect oil spillage 15 Loosen unions and disconnect oil cooler pipes x2 from transaxle interconnecting pipes see Fig 5 16 Plug pipe connections x4 17 Remove drain container 18 Disconnect transaxle breather pipe see Fig 6 19 Remove nuts x2 from hydra mount...

Page 221: ...ts 23 Lower transaxle using tool 308 642 and release selector cable ball joints from selector levers see Fig 10 24 Remove horseshoe clips and release selector cables from bracket 25 Release reverse light harness clip from transaxle 26 Release reverse lamp switch multiplug from bracket and disconnect multiplug see Fig 11 27 Position lifter to support torque tube see Fig 12 28 Remove bolts x8 from t...

Page 222: ...ove for Access Refit 25 Install road wheel s 26 Lower vehicle on ramp and remove securing straps 27 Connect vehicle battery 28 Test drive vehicle 29 Raise vehicle on ramp and check transaxle oil level 30 Lower vehicle on ramp Transmission Axle Assembly Drain Refill Removal 1 Position vehicle on ramp 2 Remove rear undertray see Workshop Manual procedure 01 02 PB Undertray Rear Renew 3 Position cont...

Page 223: ...move slings 5 Position container and drain transaxle oil 6 Remove bolt securing oil cooler pipes bracket to transaxle see Fig 1 7 Loosen and disconnect oil cooler pipe unions and remove oil cooler pipe assembly see Fig 2 8 Remove reverse light switch from transaxle see Fig 3 9 Remove bolts x3 from selector cable bracket to transaxle and collect bracket see Fig 4 10 Remove nuts x2 from selector lev...

Page 224: ...ly 6 Install and torque tighten oil cooler pipe unions and support bracket bolt 7 Fill transaxle with the specified oil to the correct level 8 Attach slings to transaxle and connect hoist 9 With assistance remove transaxle from workbench and position on lifter 10 Install transaxle assembly see Workshop Manual procedure 07 03 AA Transaxle Assembly Manual Remove for Access Refit 11 Install road whee...

Page 225: ...Manual Transmission 07 03 Transmission 07 00 7 2 8 Workshop Manual October 2005 ...

Page 226: ...e shaft flanges to transaxle 16 Release drive shafts from transaxle and position aside 17 Position drain container to collect oil spillage 18 Loosen unions and disconnect oil cooler pipes x2 from transaxle interconnecting pipes Plug pipe connections x4 19 Remove drain container 20 Remove nuts x2 hydra mounts to subframe mountings 21 Position hydraulic lifter to support transaxle 22 Remove and disc...

Page 227: ...Valve Assembly Remove for Access Refit 15 Install road wheel s 16 Lower vehicle on ramp remove securing straps 17 Position selector cable in bracket install horseshoe clip 18 Install selector cable ball joint to gear lever mechanism 19 Install panel assembly console 20 Connect vehicle battery 21 Test drive vehicle 22 Raise vehicle on ramp Check transaxle oil level ...

Page 228: ...Specifications 1 2 Maintenance 1 2 Clutch and Flywheel Assembly Renew 1 2 Slave Clutch Cylinder Renew 1 3 Clutch Bleed Hose Assembly Renew 1 3 Clutch Hydraulic System Bleed 1 4 Clutch Assembly 08 01 8 1 2 Description 1 2 Specifications 1 2 Maintenance 1 2 Clutch Assembly 1 2 Remove 1 2 Installation 1 3 ...

Page 229: ... procedure 05 01 CA Torque Tube Remove for Access and Refit 4 Remove bolts x2 from inspection cover to lower crankcase and remove cover 5 Install special tool SKAM14546 OT to restrain flywheel and install and tighten bolts x2 see Fig 1 6 Remove bolts x6 from clutch cover to flywheel see Fig 2 7 Release clutch cover from dowels remove cover and collect drive plate 8 Remove bolts x8 from flywheel to...

Page 230: ...slave cylinder to torque tube see Fig 2 7 Remove slave cylinder and collect spacer Installation 1 Clean slave cylinder spacer and pipe adaptors 2 Install spacer and slave cylinder and tighten bolts x2 3 Install pipe adaptors x2 in slave cylinder 4 Install bleed and supply pipes onto slave cylinder adaptors x2 and secure with clips 5 Install torque tube see Workshop Manual procedure 05 01 CA Torque...

Page 231: ...ed nipple 4 Remove cap from bleed nipple 5 Position bleed container containing clean hydraulic fluid and connect hose to bleed nipple 6 Depress clutch pedal to floor 3 times and hold pedal down on third application 7 Loosen bleed nipple allowing any air fluid to escape 8 Tighten bleed nipple 9 Repeat procedure until air free fluid emerges 10 Disconnect bleed hose remove container and install dust ...

Page 232: ...9 1 1 Exhaust 09 00 Contents Exhaust Overview 9 1 2 Silencer Assembly 09 01 9 1 3 Variable Flow Silencer Assembly 1 3 Pipes and Supports 09 03 9 2 1 Specifications 2 1 Maintenance 2 1 Exhaust System 2 1 Removal 2 1 Installation 2 2 ...

Page 233: ...sensors and a single variable flow silencer assembly Exhaust gasses flow from the exhaust manifolds through the catalysts and on to the rear silencer assembly Two engine management oxygen sensors are mounted before the catalysts Two catalyst monitor oxygen sensors are mounted in the catalysts between the primary and secondary catalyst brick RXU UDQFK 0DQLIROGV DWDO WLF RQYHUWHU ORZ 6LOHQFHU 2 JHQ ...

Page 234: ...silencer Collect springs from bolts 6 Remove bolts x4 securing LH and RH silencer rear hanger brackets to body 7 Remove bolts x4 silencer front mountings to subframe 8 Position suitable lifter to support weight of silencer With assistance remove silencer 9 Remove both rear rubber mountings and hanger brackets from silencer Installation 1 Clean muffler and mating faces on rear pipes 2 Position sile...

Page 235: ...oth by pass vacuum valves 10 Position mounting brackets install rear bumper diffuser Install and tighten Allen bolts 11 Install rear undertray see Workshop Manual procedure 01 02 PB Undertray Rear Renew 12 Lower vehicle on ramp Exhaust Rear Silencer Mounting Rubber Renew Removal 1 Raise vehicle on ramp 2 Remove Allen bolts x4 bumper diffuser to mounting brackets Remove diffuser collect mounting br...

Page 236: ...ncer and Bypass Valve Assembly Remove for Access Refit 10 Lower vehicle on ramp Exhaust Centre Pipe Renew Removal 1 Raise vehicle on ramp 2 Remove pipe assembly exhaust rear RH see Workshop Manual procedure 09 00 Pipe Assembly Exhaust Rear RH Renew 3 Remove pipe assembly exhaust rear LH see Workshop Manual procedure 09 00 JB Pipe Assembly Exhaust Rear LH Renew 4 Loosen clamp nuts x2 centre pipe to...

Page 237: ...fold to cylinder head 4 Remove exhaust manifold remove and discard gasket Installation 1 Clean manifold and mating face on engine Install new gasket to engine 2 Install manifold to engine 3 Install nuts x8 securing manifold to cylinder head torque 4 Install LH front wheel arch liner see Workshop Manual procedure 01 02 FB Wheel Arch Liner Front LH Renew 5 Install heatshield deflector front floor se...

Page 238: ...ue tighten clamp nut 9 Install cross brace install and torque tighten bolts x4 10 Install rear undertray 11 Lower vehicle on ramp Exhaust System Excluding Manifold Downpipes Renew Removal 1 Raise vehicle on ramp 2 Remove undertrays vehicle set see Workshop Manual procedure 01 02 PD Undertrays Vehicle Set Renew 3 Remove Allen bolts x4 bumper diffuser to mounting brackets Remove diffuser 4 Disconnec...

Page 239: ... Install both rear rubber mountings and hanger brackets to silencer 10 Position silencer on lifter Install silencer position hangers install and tighten bolts x4 11 Install front mountings to silencer install and tighten bolts x4 12 Align silencer to rear pipes install springs x4 and bolts x4 Do not torque bolts at this stage 13 Install and align stub pipes x2 to muffler and to trims in bumper Ali...

Page 240: ...ly Remove for Access Refit 3 Lower vehicle on ramp Tunnel Heatshield Renew Removal 1 Remove centre exhaust pipe assembly see Workshop Manual procedure 09 00 BC Pipe Exhaust Centre Renew 2 Remove bolts washers x4 securing tunnel heatshield to body remove heatshield Installation 1 Install tunnel heatshield install washers nuts x torque tighten nuts 2 Install centre exhaust pipe assembly see Workshop...

Page 241: ...ns 1 8 Specifications 1 8 Maintenance 1 8 Fuel System 1 8 Fuel Filter Assembly Renew 1 8 Fuel Pump and Reservoir Assembly Renew 1 8 Depressurise Fuel System Procedure 1 9 Fuel Tank and Canister Assembly Remove for Access Refit 1 9 Fuel Tank Sender Assembly Renew 1 9 Fuel Vapour Pipe Assembly Renew 1 10 Fuel Supply and Vapour Pipe Assembly Renew 1 10 Manifold Supply Fuel Pipe Assembly Renew 1 10 Fu...

Page 242: ...n to supply fuel through one in tank filter to the fuel rail Refer to Fuel Charging System 03 04 page 3 5 1 A pressure sensor and a temperature sensor are fitted on the primary fuel rail The fuel pump speeds are varied as required to regulate the fuel pressure in the fuel rails GG QR LQ LOOXVWUDWRU 6DYH DV SGI 5H RSHQ LQ SKRWRVKRS DQG VDYH DV GSL SGI 3XPS XHO LOWHU XHO 5DLOV XHO 3XPS ULYHU 0RGXOH ...

Page 243: ...hrough an 3 micron in tank fuel filter to one of the two fuel rails on the engine Fuel temperature is measured on the primary fuel rail If fuel temperature becomes excessive the fuel pressure is increased to prevent fuel vaporisation boiling Fuel pressure is measured by sensors on each fuel rail The fuel pressure to each rail is regulated as required by continuously changing the run speed of the a...

Page 244: ...ler Neck and Check Valve Incoming fuel passes through a check valve at the base of the filler neck This valve is normally held closed by light spring pressure The valve opens under the pressure of incoming fuel and closes again when fuel flow ceases The check valve prevents surging of fuel in the filler neck The filler neck also forms part of the on board refuelling vapour recovery system Incoming...

Page 245: ... to vent the highest point of the tank If the tank is grossly overfilled e g many clicks over the normal filler nozzle cut off the FLVV will suffer a hydraulic lock The roll over vent valve allows venting of the tank at the highest possible level in this situation All three valves allow the tank to breath until it is inverted when they will close to prevent fuel spill The fuel level vent valve con...

Page 246: ...ve is only closed during diagnostic pressure testing of the fuel system During normal engine running the single vapour management valve in the engine bay is periodically opened when negative pressure exists in the intake manifold allowing fresh air flow into the open canister vent valve through the carbon canister through the vapour management valve and into the primary inlet manifold This fresh a...

Page 247: ...ous risk and the following precautions must be strictly observed Specifications Warning Operations on refuelling and the fuel system must only be performed by personnel who have completed training on fuel handling Warning Smoking must not be allowed near the working area NO SMOKING signs must be posted around the working area Warning Any operation which could involve sparks or naked lights e g bat...

Page 248: ...emove fuel tank cover 7 Remove nuts x7 and release fuel tank service cover and clamp 8 Install the fuel tank drainage adaptor 9 Connect the external pipe to a fuel recovery unit Recover the fuel in accordance with the recovery unit instructions 10 Remove recovery unit and fuel tank drainage adaptor 11 Release the fuel filter hoses x2 quick release unions 12 Disconnect wiring harness plugs x2 13 Di...

Page 249: ...pring damper assembly 13 install fuel filler cap 14 Install rear subframe see Workshop Manual procedure 02 01 DB Subframe Assembly Rear Remove for Access Refit Carbon Canister Assembly Renew Removal 1 Disconnect vehicle battery 2 Remove fuel tank assembly see Workshop Manual procedure 10 01 GA Tank Canister Assembly Fuel Remove for Access Refit 3 Remove cable tie carbon canister to bracket 4 Relea...

Page 250: ...new 5 Connect vehicle battery Manifold Supply Fuel Pipe Assembly Renew Removal 1 Depressurise fuel system see Workshop Manual procedure 10 01 EK Fuel System Depressurise 2 Disconnect vehicle battery 3 Remove RH wheel arch liner see Workshop Manual procedure 01 02 GB Wheel Arch Liner Front RH Renew 4 Position container to collect fuel spillage 5 Release fuel supply and vapour pipe from pipe clips 3...

Page 251: ...ipe and sealing washer to body 3 Install nut filler neck pipe and hose to body 4 Install bolt filler pipe bracket to spring damper assembly 5 Install filler cap 6 Install LH rear wheel arch liner see Workshop Manual procedure 01 02 JB Wheel Arch Liner Rear LH Renew Fuel Fill Overflow Pipe Assembly Renew Removal 1 Remove LH rear wheel arch liner see Workshop Manual procedure 01 02 JB Wheel Arch Lin...

Page 252: ...ing Reservoir and Cap Renew 2 2 Power Steering Pump to Rack Hose Assembly Renew 2 2 Power Steering Rack to Cooler Hose Renew 2 3 Power Steering Reservoir to Pump Hose Assembly Renew 2 3 Power Steering Cooler to Reservoir Hose and Clip Assembly Renew 2 3 Steering Column 11 04 11 3 1 Description 3 1 Specifications 3 1 Maintenance 3 1 Upper Steering Column Assembly Renew 3 1 Steering Column Switches ...

Page 253: ...ight ahead with the steering wheel held firmly Incorrect tyre size or pressure Check for correct tyre size Adjust tyre pressures Vehicle unevenly loaded or overloaded Adjust load Loose or worn tie rods or tie rod ends New tie rod end or steering gear Steering gear bolts loose or damaged Tighten New bolts Loose or worn suspension ball joint s New suspension ball joint assembly Steering column unive...

Page 254: ... and for damaged coil springs in the front suspension New rear suspension components Check the rear suspension for loose or worn suspension components Tighten New components Incorrect underbody alignment Check underbody alignment Feedback whining or knocking noises in the steering gear Condition where roughness is felt in the steering wheel by the driver when the vehicle is driven over rough surfa...

Page 255: ...sory drive belt tensioner New accessory drive belt tensioner Hose or oil cooler external leak New hose or oil cooler as required Hose or cooler line restriction New hose as required Fluid aeration Damaged pump Bleed system Replace pump Fluid leakage Overfilled system Correct fluid level Component leak Locate suspect component and repair as required Accessory drive belt squeal Check accessory drive...

Page 256: ...system The high pressure line contains a pressure transducer which sends an electronic signal to the engine management system This ensures engine RPM is maintained when the steering system draws higher loads from the engine i e during parking manoeuvres In order to regulate system temperatures a wire wound cooler is incorporated into the return line Specifications 6WHHULQJ HDU RROLQJ RRS 3RZHU 6WH...

Page 257: ...ttle body duct for access clips x3 3 Remove top bolts x2 from engine oil tank and loosen bottom bolts x2 allows tank to move to access pipe support fixings 4 Remove bolts x2 securing pipe to body 5 Disconnect sensor multiplug 6 Remove hose from pump union 7 Remove pipes from steering rack bolt x1 8 Remove pipe from vehicle Installation 1 Renew o rings on PAS pipes and pump pipe 2 Install hose to v...

Page 258: ...lamp bolt from reservoir bracket 5 Move reservoir from bracket to access clip remove clip and hose 6 Remove hose from support clip and radiator side seal Installation 1 Install hose to support clip and radiator side seal 2 Install hose and clip and reservoir to bracket 3 Install hose to cooler clips x1 4 Install radiator grille see Workshop Manual procedure 01 08 AA Grille Radiator Renew 5 Top up ...

Page 259: ...Power Steering 11 02 Steering 11 00 11 2 4 Workshop Manual October 2005 ...

Page 260: ...l see Workshop Manual procedure 11 06 AB Steering Wheel Renew 7 Secure rotary coupling in position with masking tape 8 Remove screws x7 and remove steering column shrouds see Fig 1 9 Disconnect steering column switch multiplugs x5 10 Remove screw securing load spread plate to column and collect column shrouds mounting bracket 11 Release clips x2 from column switch harness to load spread plate 12 P...

Page 261: ... column assembly and connect to intermediate shaft 7 Connect multiplug to steering sensor 8 Position upper column to mounting bracket install and torque tighten Torx bolts x4 9 Install and torque tighten column pinch bolt 10 Connect multiplugs x5 11 Position load spread plate and secure harness clips x2 12 Install load spread plate and secure with screw 13 Install upper steering column shrouds and...

Page 262: ...nel 10 Connect vehicle battery 11 Re position driver s seat and reach rake positions Steering Column Stalk Assembly Switch Renew Removal 1 Power driver s seat to its lowest and most rearward position 2 Disconnect vehicle battery 3 Release and remove driver s side lower instrument panel clips x7 and disconnect air temperature pipe 4 Unlatch reach rake lever and pull steering column forward 5 Centra...

Page 263: ...Workshop Manual procedure 11 06 BC Module Drivers Airbag Renew 2 Remove cruise control switch Installation 1 Install cruise control switch 2 Ensure switch harness is routed correctly 3 Install Airbag module see Workshop Manual procedure 11 06 BC Module Drivers Airbag Renew Repair Operation Time ROT Item Code Cruise Control Switch Renew 11 06 BL ...

Page 264: ...ring wheel retaining Torx bolt see Fig 1 6 Disconnect multiplug from cruise control 7 Remove steering wheel 8 Secure rotary coupler to steering column with tape Installation 1 Remove tape from rotary coupler 2 Ensure steering is set in the straight ahead position 3 Install steering wheel on column 4 Install and tighten retaining Torx bolt 40 Nm 5 Connect multiplug cruise control 6 Install driver s...

Page 265: ... 3 3 Handling Compressor Oil 3 3 Refrigeration Cycle 3 3 Specifications 3 4 Refrigerant and Lubricant 3 4 Capacities 3 4 Torque Figures 3 4 Diagnostics 3 5 Electrical Connectors 3 5 DTC Inspection 3 7 Single Fault Codes 3 7 Multiple Fault Codes 3 8 Maintenance 3 9 Connections 3 9 Recovery 3 9 Evacuation 3 9 Charging 3 9 A C System Testing 3 10 Leaks 3 11 System Pressure Fault Classification 3 11 M...

Page 266: ...ertures in the rear parcel shelf The air is exhausted from the vehicle through extraction vent assemblies incorporating one way flaps in the lower part of the rear bumpers concealed by the bumper trim Recirculation mode The air in the passenger compartment is drawn into the A C system via the re circulation air inlets on the blower unit The A C unit is linked and sealed to the defrost demisting an...

Page 267: ... Actuator operation as shown in the graph below LHD RHD If the operation condition is not normal replace the Air Intake Actuator Terminal C0149 Air Intake Actuator Operation 1 3 Ground B Fresh Recirculate B Ground Recirculate Fresh If the operation condition is not normal replace the Air Mix Actuator Terminal C2130 Air Intake Actuator Operation 1 3 B Ground Cold Hot LHD Hot Cold RHD Ground B Hot C...

Page 268: ... and 3 and 5 matches the Airflow Mode Actuator operation as shown in the graph below If the operation condition is not normal replace the Airflow Mode Actuator Terminal Airflow Mode Actuator operation 6 7 B Ground Defroster Vent Ground B Vent Defroster If the operation condition and resistance are not normal replace the Airflow Mode Actuator 90 32 3 5 1 6 7 3 5 1 6 7 VENT DEFROSTER VENT DEFROSTER ...

Page 269: ...ion 1 Install LH vent outlet in IP aperture and secure with screws x3 2 Install driver s upper outer panel assembly and secure in clips x4 3 Install instrument cluster hood and secure in clips x6 RH Facia Ventilator Outlet Renew Removal 1 Remove airbag panel and door assembly see Workshop Manual procedure 01 12 AJ Panel Door Assembly Air Bag Renew 2 Remove passenger s upper outer panel assembly 2 ...

Page 270: ...Body Ventilation system 12 01 Climate Control 12 00 12 1 6 Workshop Manual October 2005 ...

Page 271: ... heater unit to IP unit 4 Disconnect tube from In car temperature sensor unit and remove heater unit from IP Installation 1 Connect tube to In car temperature sensor install heater unit in position on IP 2 Position heater unit in IP Install and torque tighten bolt and nuts x2 3 Connect multiplugs x6 to heater unit 4 Install IP unit in vehicle see Workshop Manual procedure 01 12 AB Facia Assembly L...

Page 272: ...Heater System 12 02 12 2 2 Workshop Manual October 2005 ...

Page 273: ... 2005 Workshop Manual 12 3 1 Climate Control 12 00 Air Conditioning A C System 12 03 Item 1 Condenser 2 Trinary switch 3 Compressor assembly 4 High side charge port 5 Receiver drier 6 Low side charge 7 Blower Unit 8 Switch A C Cut Off 9 Expansion valve 10 A C Unit ...

Page 274: ...ssor discharge pipe Provides a signal via the A C module to the PCM to disengage the compressor clutch should the refrigerant pressure be less than 2 bar or greater than 30 bar Provides a hard wired signal to the PCM to switch the cooling fans to HIGH speed at 22 bar rising pressure and to LOW speed at 17 5 bar falling pressure Provides a hard wired signal to the PCM to switch the radiator cooling...

Page 275: ...xtures of air and R 134a have been shown to be combustible at elevated pressures These mixtures if ignited may cause injury or property damage Additional health and safety information may be obtained from refrigerant manufacturers Warning Do not allow refrigerant to leak near a fire or any kind of heat A poisonous gas may be generated if refrigerant gas contacts fire or heat such as from cigarette...

Page 276: ...ncorporated in the compressor which will open if the system pressure rises above 41 bar The valve will reseat when the pressure drops below 27 6 bar When the safety valve is open the compressor will free Caution If an insufficient refrigerant level is detected while troubleshooting do not charge add the refrigerant Because an accurate amount of refrigerant cannot be determined from the pressure in...

Page 277: ...witch condenser receiver drier and expansion valve The low side starts at the expansion valve outlet and includes the evaporator and all connections back to the compressor The trinary switch 6 monitors system pressure between the compressor and condenser If the pressure rises above 30 bar or falls below 2 bar the compressor clutch is de energised to prevent damage to system components Specificatio...

Page 278: ...emperature actuator input 13 Evaporation sensor input 14 In vehicle temperature sensor input 15 Ground 16 Sensor ground In vehicle Evaporator Air flow mode actuator Temperature mode actuator A C Module C0791 Pin Specification 1 Air flow mode actuator output 2 Temperature actuator output 3 Blank 4 Blank 5 Blank 6 A C On A C pressure sensor 7 Blank 8 Recirculation actuator output 9 Blank 10 Blank 11...

Page 279: ...ween the A C module and the evaporator temperature sensor Code Description Possible Cause 12 Ambient temperature sensor system inspection 1 Ambient temperature sensor fault 2 Open or short circuit in the wiring harness between the A C module and the ambient temperature sensor Code Description Possible Cause 14 ECT sensor system inspection 1 ECT fault 2 A C module fault 3 PCM fault 4 Open or short ...

Page 280: ...spection Past fault 1 Air mix actuator fault 2 A C unit air mix link and air mix crank fault 3 Open or short circuit in the wiring harness between the A C module and the air mix actuator Code Description Possible Cause 59 Airflow mode actuator motor lock system inspection Past fault 1 Airflow mode actuator fault 2 A C unit airflow mode link and airflow mode crank fault 3 Open or short circuit in t...

Page 281: ... the A C system Warning Under no circumstances should connections be made with the A C system in operation or valves open Should valves be open and a vacuum pump or refrigerant container attached an explosion could occur as a result of high pressure refrigerant being forced back into the vacuum pump or container Caution Do not attempt to adapt this unit for R 12 as an A C system failure will resul...

Page 282: ...se all the doors and windows 8 Wait until the A C output temperature stabilizes 9 After the blower air is stabilized read the dry bulb thermometer 10 Verify the ambient temperature 11 Verify the temperature is in the shaded zone If there is any fault inspect the refrigerant system according to the troubleshooting chart Vacuum Check 1 Stop the vacuum pump note the high and low pressure side reading...

Page 283: ...entations of High side pressure ambient temperature and Low side pressure evaporator temperature Caution Observe ALL safety precautions associated with ultraviolet equipment If erratic or unusual gauge movements occur check the equipment against known Recovery Recycling Recharging unit gauges Low side gauge reading High side gauge reading Fault Cause Normal Normal Discharge air initially cool then...

Page 284: ...rque tighten bolts x6 6 Position PAS fluid cooler to cross member and install and torque tighten bolts x4 7 Install front grille see Workshop Manual procedure 01 08 AA Grille Radiator Renew 8 Refrigerant gas re charge A C system see Workshop Manual procedure 12 03 FA Tank Receiver Drier Renew Liquid Receiver Drier Renew Removal 1 Refrigerant gas recovery A C system see Workshop Manual procedure 12...

Page 285: ...ve clip from pipe Installation 1 Install P clip to pipe in same position as old pipe 2 Install pipe and connect to lower pipe 3 Install pipe to evaporator connection bolt x1 4 Install pipe support clip to body RHS 5 Install bolt x1 to pipe support P clip 6 Install wiper linkage see Workshop Manual procedure 01 16 BA Linkage Assembly Wiper Renew 7 Recover recharge refrigerant see Workshop Manual pr...

Page 286: ... Power Steering Renew Condenser to Receiver Drier Tube Assembly Renew Removal 1 Remove condenser see Workshop Manual procedure 12 03 BB Air Con Condenser Renew 2 Remove pipe from clip support to body 3 Remove bolt pipe support to body 4 Remove pipe from receiver drier and vehicle Installation 1 Install pipe to vehicle and receiver drier 2 Install bolt pipe support to body 3 Install pipe to clip su...

Page 287: ...are the cause of any intermittent malfunctions If there is a problem check to make sure connectors terminals and wiring harnesses are connected correctly and undamaged Symptom 5 Description Possible Cause No temperature control with A C Module Temperature does not change with operating temperature control dial Air Mix Actuator 5 V signal system fault A C Module potentiometer GND signal system faul...

Page 288: ...ch does not operate Fault in PCM A C cut control system Fault in A C Module Fault in refrigerant pressure switch Fault in PCM A C signal Fault in PCM IG1 signal Fault in A C compressor Fault in A C relay Fault in Evaporator Temperature Sensor Shake the wiring harness and connectors while performing the inspection to discover whether poor contact points are the cause of any intermittent malfunction...

Page 289: ... Depress clips and remove A C re circulation switch from centre stack Installation 1 Install A C re circulation switch and secure with clips 2 Install centre stack assembly see Workshop Manual procedure 15 01 CB Centre Stack Assembly Remove for Access and Refit A C Request Switch Renew Removal 1 Remove centre stack assembly see Workshop Manual procedure 15 01 CB Centre Stack Assembly Remove for Ac...

Page 290: ...iption 1 2 Information and Warning Lamps 1 3 DIM Display layout 1 4 Maintenance 1 5 Driver Information Module Renew 1 5 Horn Subsystem 13 06 13 2 1 Maintenance 2 1 Horn Renew 2 1 Parking Reversing Aids 13 13 13 3 1 Maintenance 3 1 Rear Centre Parking Aid Sensor Renew 3 1 Parking Aid Module Renew 3 1 Parking Aid Speaker Renew 3 1 ...

Page 291: ...nted by an array of warning lights Red indicate immediate danger warnings Amber indicate conditions which are serious but not immediately dangerous Green and Blue indicate normal actuation of items such as turn signals or fog lamps The message centres and the shift position Sensor display are used to present information on the distance recorders trip meters current gear mode and current gear engag...

Page 292: ...gnal CAN Yes 5 Seconds Brake General Controlled externally by either the CEM or the ABS DSC module It indicates low brake fluid level brake fault and park brake The tell tale is triggered by two low side inputs or a CAN signal Low side x 2 and CAN Yes 5 Seconds Side Lights Controlled externally by the CEM Indicates that the side lights are on High side Oil Pressure Controlled externally by the PCM...

Page 293: ...is used to display the odometer C the Cruise control status C and the T1 or T2 trip distance A Shift Position Sensor The Shift Position Sensor display indicates when the shift lights are activated The display is duel colour Green normal operation Red defined situations Message Centre Right The Message Centre Right is used to display the trip function information and warning information messages 0H...

Page 294: ... see Workshop Manual procedure 01 12 AT Panel Bezel Cluster Renew 2 Remove driver s information module x4 screws and x1 multiplug Installation 1 Install driver s information module x1 multiplug and x4 screws 2 Install instrument cluster bezel panel see Workshop Manual procedure 01 12 AT Panel Bezel Cluster Renew Repair Operation Time ROT Item Code Driver Information Module Renew 13 01 AA ...

Page 295: ...Instrument Cluster 13 01 Information Gauge and Warning 13 00 13 1 6 Workshop Manual October 2005 ...

Page 296: ...g 13 00 Horn Subsystem 13 06 Maintenance Horn Renew Removal 1 Remove slam panel screws x12 2 Remove horn and bracket assembly bolts x2 and disconnect multiplug Installation 1 Install horns and bracket bolts x2 torque connect multiplug 2 Install slam panel screws x12 Repair Operation Time ROT Item Code Horn Renew 13 06 A B ...

Page 297: ...Horn Subsystem 13 06 Information Gauge and Warning 13 00 13 2 2 Workshop Manual October 2005 ...

Page 298: ...screws x3 3 Connect multiplug to PDC sensor 4 Install screws x3 mesh to bumper armature 5 Install diffuser Allen bolts X4 6 Install rear bumper see Workshop Manual procedure 01 19 BA Cover Assembly Rear Bumper Renew Parking Aid Module Renew Removal 1 Remove sub woofer assembly 2 Remove nuts x2 parking distance control unit to body 3 Disconnect multiplugs x2 and remove PDC control unit Installation...

Page 299: ...1 4 Battery Conditioner Renew 1 5 Jump Start Terminal Renew 1 5 Battery to Ground Cable Assembly Renew 1 5 Battery to Battery Disconnect Switch Cable Assembly Re new 1 5 Bulkhead Stud to Starter Cable Assembly Renew 1 6 Bulkhead Stud to Engine Bay Fusebox Cable Assembly Re new 1 6 Bulkhead to Starter Jump Terminal Harness Renew 1 6 BDS to Bulkhead Dirty Feed Harness Renew 1 7 Engine Earth Strap Re...

Page 300: ...er connecting the battery the radio preset stations and the door window controllers will require to be reset adaptive learning data in the PCM module will require to be re learned by driving the vehicle for some miles in a range of driving conditions driveability may be slightly compromised until the vehicle systems have completed their adaptive learning routines again Battery Disconnection and Al...

Page 301: ...start terminal are also fed directly from the charging circuit Go to page 18 X XX for complete power distribution circuit diagram Circuit Sheet 25 12 Volt Distribution The 12 volt supply comes from the battery to the battery disconnect switch BDS Assuming that this switch is not activated 12 volt power is then available from C0046 8 on the BDS to all of the clean feed battery studs The following c...

Page 302: ...uring battery cables to battery disconnect switch 9 Release battery cables x4 from battery disconnect switch Note fitted position of spacer washer between RH battery cables 10 Remove Torx screws x3 securing battery disconnect switch to mounting bracket 11 Release multiplug from bracket disconnect multiplug remove battery disconnect switch 12 Remove battery cable bolts from battery disconnect switc...

Page 303: ...nnect vehicle battery Jump Start Terminal Renew Removal 1 Disconnect vehicle battery 2 Remove nuts x2 securing jump start terminal to mounting bracket 3 Remove nut securing battery cable to jump start terminal Release cable remove terminal Installation 1 Clean jump start terminal and cable connection 2 Position jump start terminal connect cable install and torque tighten nut 3 Position jump start ...

Page 304: ...r cover remove nut securing cable to bulkhead stud Remove cable 4 Remove rubber cover from cable Installation 1 Clean cable connection on bulkhead stud and fusebox 2 Install rubber cover onto cable 3 Position cable to bulkhead stud install and torque tighten nut 4 Install engine bay fusebox see Workshop Manual procedure 18 01 KD Fuse Box Engine Bay Renew 5 Connect vehicle battery Bulkhead to Start...

Page 305: ...n nuts x2 and screws x2 7 Install RH rear floor carpet and secure with fasteners x4 8 Install front floor carpet retaining brackets x2 install and tighten screws x4 9 Install RH seat see Workshop Manual procedure 01 10 AA Seat Assembly Front RH Remove for Access and Refit 10 Connect vehicle battery Engine Earth Strap Renew Removal 1 Raise vehicle on ramp 2 Remove rear undertray see Workshop Manual...

Page 306: ...Battery System 14 01 Power Supply 14 00 14 1 8 Workshop Manual October 2005 ...

Page 307: ...ter Oil Canister Renew 16 Reposition heatsheild to gain access to top bolt 17 Unclip harness from bracket for access to top bolt and move aside 18 Remove top securing nut and bolt 19 Remove nut from bottom fixing and withdraw bolt will foul on front subframe 20 Lever alternator forward to release clamping of sliding bushes 21 Using suitable grips remove bottom front sliding bush together with bolt...

Page 308: ...2 Power Supply 14 00 14 2 2 Workshop Manual October 2005 21 Release tensioner and slip belt on idler 22 Install throttle body duct 23 Connect breather pipe quickfits x2 to air cleaner duct 24 Battery isolation switch ON 25 Top up coolant ...

Page 309: ...ne Switchpack Renew 1 2 Infotainment Control Module Renew 1 2 Display Screen Renew 1 3 Clock Renew 1 3 Satellite Navigation Switchpack Renew 1 3 CD Player Renew 1 3 Tuner AM FM Renew 1 3 Removal 1 3 GPS Tuner Renew 1 3 Antenna 15 02 15 2 1 Maintenance 2 1 GPS Antenna Renew 2 1 Speakers 15 03 15 3 1 Maintenance 3 1 RH LH Front Door Speaker Renew 3 1 Centre Facia Speaker Renew 3 1 ...

Page 310: ...e power amplifier to mounting plate and remove amplifier see Fig 3 12 Collect spacers between amplifier and mounting plate see Fig 4 Installation 1 Position amplifier and spacers to mounting plate 2 Install nuts and bolt amplifier to mounting plate 3 Connect multiplugs x3 from amplifier to audio harness 4 Position amplifier and bracket assembly to body and connect multiplugs x3 5 Secure luggage co...

Page 311: ...ess 3 Position amplifier and bracket assembly to body and connect multiplugs x3 4 Secure luggage compartment lamp harness and connect and install lamp assembly 5 Install Torx screws x6 from amplifier bracket to body 6 Position power socket bracket to body and install bolt x1 and nuts x2 7 Install RH luggage compartment carpet see Workshop Manual procedure 01 05 FB Carpet Assembly Luggage Compartme...

Page 312: ...ws x2 2 Install Infotainment Control Module see Workshop Manual procedure 15 01 CF Infotainment Control Module Renew Satellite Navigation Switchpack Renew Removal 1 Remove centre stack support bracket and Infotainment Control Module from centre stack assembly see Workshop Manual procedure 15 01 CF Infotainment Control Module Renew 2 Remove satellite navigation switchpack securing screws x2 and mul...

Page 313: ...kshop Manual procedure 01 02 JB Wheel Arch Liner Rear LH Renew GPS Tuner Renew 1 Remove RH rear wheel arch liner see Workshop Manual procedure 01 02 JB Wheel Arch Liner Rear LH Renew 2 Remove bolts x4 from tuner base plate to wheel arch see Fig 1 3 Remove bolts x2 from GPS tuner to bracket see Fig 2 4 Disconnect harness connections and remove GPS tuner Installation 1 Position GPS tuner to bracket ...

Page 314: ...dule Renew Removal 1 Disconnect vehicle battery 2 Remove LH rear pillar upper panel assembly see Workshop Manual procedure 01 05 BG Panel Assembly Rear Pillar Upper LH Renew 3 Release boot carpet LH side rear see Workshop Manual procedure 01 05 FM Carpet Assembly Side Front LH Renew 4 Remove bolts x3 securing multi media module to body 5 Remove module and disconnect multiplugs x3 6 Remove screws x...

Page 315: ... Renew 2 Disconnect multiplug and release harness socket from GPS aerial plate 3 Remove GPS aerial plate bolts x3 and place aerial to one side 4 Remove aerial unit from plate Installation 1 Fit aerial to plate 2 Install plate to tailgate 3 Fit harness socket to plate and connect multiplug 4 Install tailgate trim panel see Workshop Manual procedure 01 05 EF Trim Tailgate Lid Assembly Renew Repair O...

Page 316: ...Antenna 15 02 Vehicle Entertainment 15 00 15 2 2 Workshop Manual October 2005 ...

Page 317: ...ve speaker Installation 1 Install speaker install and tighten nuts x3 2 Connect speaker multiplug 3 Feed seat belt harness through panel and secure panel to body 4 Install quarter trim middle panel LH RH see Workshop Manual procedure 01 05 CU 01 05 CT Panel Assembly Quarter Trim Middle Section LH RH Renew Premium Subwoofer Enclosure Renew Removal 1 Remove rear console see Workshop Manual procedure...

Page 318: ...October 2005 Workshop Manual 16 1 1 Vacuum Distribution 16 00 Contents Body Vacuum System 16 01 16 1 2 Description 1 2 Maintenance 1 3 Vacuum Assembly Pump Renew 1 3 ...

Page 319: ...silencer directionally varies the flow of exhaust gas to give acceptable exhaust noise levels at low engine speeds and reduce exhaust back pressure for engine protection at high engine speeds The exhaust valves are linked and operated via the engines ECU by means of a vacuum distribution system consisting of an electrically operated pump solenoid vacuum storage tank and connecting pipework An illu...

Page 320: ...ssembly Rear Bumper Renew 2 Disconnect vacuum pump multiplug 3 Remove vacuum pump tubes 4 Remove vacuum pump from bracket Installation 1 Install vacuum pump to mounting bracket 2 Connect vacuum pump tubes 3 Connect vacuum pump multiplug 4 Install rear bumper see Workshop Manual procedure 01 19 BA Cover Assembly Rear Bumper Renew Repair Operation Time ROT Item Code Vacuum Assembly Pump Renew 16 00 ...

Page 321: ...sembly Renew 1 3 Interior Lighting 17 02 17 2 1 Specifications 2 1 Rear Lights 17 03 17 3 1 Specifications 3 1 Maintenance 3 1 RH LH Rear Lamp Assembly Renew 3 1 High Mounted Stop Lamp HMSL Assembly Renew3 1 RH LH Reflector Renew 3 2 RH LH Licence Plate Lamp Renew3 2 Lighting Mechanisms 17 04 17 4 1 Headlamp Levelling HID Only 4 1 Maintenance 4 1 Headlamp Levelling Module Renew 4 1 Lighting Switch...

Page 322: ...Fig 1 6 Disconnect headlamp washer supply hose see Fig 2 7 Remove bolts x3 from headlamp to bracket 8 Remove headlamp unit see Fig 4 Installation 1 Position headlamp unit 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 A...

Page 323: ...nnect vehicle battery 2 Remove rubber cover see Fig 1 3 Disconnect multiplug and remove spring clip and bulb unit see Fig 2 Installation 1 Insert a new bulb unit and secure with spring clip 2 Connect multiplug 3 Fit rubber cover 4 Connect vehicle battery Main Beam Bulb Renew Removal 1 Disconnect vehicle battery 2 Remove access panel from wheel arch liner 3 Remove head light access cover 4 Disconne...

Page 324: ... looking at the lens and remove Installation 1 Install assembly into front wing and turn counter clockwise until the stop 2 Install bulb and holder assembly 3 Connect side repeater multiplug 4 Install wheel arch liner see Workshop Manual procedure 01 02 FB 01 02 GB Wheel Arch Liner Front LH RH Renew ...

Page 325: ...Interior Lighting 17 02 Lighting 17 00 October 2005 Workshop Manual 17 2 1 Lighting 17 00 Interior Lighting 17 02 Specifications Bulbs Rating Type Reading lamp 3W W3W Boot lamp 10W C10W ...

Page 326: ...Interior Lighting 17 02 Lighting 17 00 17 2 2 Workshop Manual October 2005 ...

Page 327: ...ee Fig 3 Installation 1 Position rear lamp assembly and connect multiplug 2 Install rubber seals x3 plain washers x3 and star washers x3 3 Install and tighten nuts x3 4 Secure carpet to body 5 Install tailgate seal to body 6 Install tyre sealant container RH only 7 Close talgate High Mounted Stop Lamp HMSL Assembly Renew Removal 1 Remove tailgate trim panel see Workshop Manual procedure 01 05 EF T...

Page 328: ...mper and install speed nuts 2 Install rear bumper see Workshop Manual procedure 01 19 BA Cover Assembly Rear Bumper Renew RH LH Licence Plate Lamp Renew Removal 1 Remove rear bumper see Workshop Manual procedure 01 19 BA Cover Assembly Rear Bumper Renew 2 Remove number plate lamp mounting bracket clips x5 3 Remove number plate lamp assemblies Installation 1 Install number plate lamp assemblies 2 I...

Page 329: ... occupant load condition Dynamic condition Compensates for suspension movements due to acceleration and deceleration The sensitivity of the system is dependent on vehicle speed and the rate of change of the vehicle speed High amplitude low frequency inputs such as those caused by potholes are filtered out to desensitise the system in constant speed situations Maintenance Headlamp Levelling Module ...

Page 330: ...Lighting Mechanisms 17 04 Lighting 17 00 17 4 2 Workshop Manual October 2005 ...

Page 331: ...s side lower instrument panel clips x7 disconnect air temperature pipe 2 Remove screws x3 securing master lighting switch to Instrument panel 3 Disconnect multiplugs x2 Installation 1 Connect multiplugs x2 2 Install master lighting switch 3 Connect air temperature pipe and Install driver s side lower instrument panel Repair Operation Time ROT Item Code Master Lighting Switch Assembly Renew 17 05 A...

Page 332: ... Renew 1 11 Centre Stack Harness Renew 1 11 Passenger Door Harness Renew 1 11 Driver s Door Harness Renew 1 11 Rear Bumper Harness Renew 1 12 Tailgate Harness Renew 1 12 Boot Fusebox Fuse Each Renew 1 13 Boot Fusebox Renew 1 13 Engine Bay Fusebox Fuse Each Renew 1 13 Engine Bay Fuse Box Renew 1 13 Central Electronic Module CEM Renew 1 13 Vehicle Control System 18 08 18 2 1 Module Configuration 2 1...

Page 333: ...terials The Central Electronic Module CEM fuse box is always located on the passenger side RRW XVHER DELQ XVHER QJLQH D XVHER Engine Bay Fuse Relay Box Fuse Relay Rating Function F1 10A Spare F2 10A Tracker option Clock F3 10A Cooling fan module F4 20A Engine management Module ABS Key Reader and Steering angle sensors F5 20A Spare F6 15A Spare F7 15A Spare F8 10A Engine coolant level sensor Valve ...

Page 334: ...9 10A Occupant detect Driver and passenger seat Airbag module F50 F51 10A Diagnostic connectors Centre stack switches F52 5A Start button F53 10A Module HID lighting F54 10A Engine fuse box Boot fuse box Tyre pressure monitor module Satellite navigation relay F55 F56 10A Centre console module Sounder module Hazard switch F57 15A Diagnostic connectors Brake pedal switch F58 10A High beam RH F59 10A...

Page 335: ... This is used more on sensors and audio speakers Screened and Twisted Screen Wires The signals through a wire can be affected by externally generated electrical noise To reduce the external interference the wires are placed inside a conductive sleeve One end of the conductive sleeve is always open whilst the other end can be terminated to a ground to a component or left open Boot Fusebox Fuse Rela...

Page 336: ... second Mainly for engine management and powertrain associated systems such as ABS All wiring in the CAN is twisted The twisted wires always consist of one wire with a black trace in it for the negative side and one with a brown trace in it for the positive High Speed CAN wire Low Speed CAN wire The symbol below shows a module or a component connector with the pin numbers that have CAN wires comin...

Page 337: ... The CAN sends signals around the vehicle where the modules or components remove their specific signals The fibre optic is in a loop with the module components in that loop one fibre goes in and one fibre goes out This is shown below Connectors There are 2 types of interconnect shown on the circuits Each connector is given a dedicated C number The number after the dash is the pin number also known...

Page 338: ...entified in the circuits with the letter G which stands for gold after the connector number An example of this is shown below Splices A splice is used where more than 2 wires that have the same requirement i e they need the same signal and meet in the same harness In the example below the Front Position Lamp LH and Front Side marker LH require the same output signal from the CEM Therefore the 2 wi...

Page 339: ...pulls the switch from it s normally open contact to a normally closed contact The normally closed contact has a path to an earth in this case it goes through a lamp The high power current then flows through the high power normally open switch through the lamp and then to an earth This can be seen more clearly in the diagram below Lamp Illuminates Busbars A busbar is where a electrical supply is fe...

Page 340: ...the current flowing through it A resistors unit of measure is the Ohm The diagrams below show a resistor and a variable resistor Variable Resistors A variable resistor works in the same manner as a normal resistor but the resistance values can fluctuate The construction of a variable resistor depends upon its use and environment One example is for the fuel tank level sensor The tank full level is ...

Page 341: ...ing is controlled by electronics and currents etc rather than a physical switch being operated The main difference between this and the type of transistor shown above is this one operates using a magnetic field Earth Ground For an electrical current to flow around a circuit it has to start from a power source and go to an earth ground If there are any breaks in this circuit then current will not f...

Page 342: ...iplug install and torque tighten screws x2 3 Install centre stack assembly see Workshop Manual procedure 15 01 CB Centre Stack Assembly Remove for Access Refit 4 Connect vehicle battery Passenger Door Harness Renew Removal 1 Remove LH door glass regulator see Workshop Manual procedure 01 11 DB Regulator Door Glass LH Renew 2 Remove bolts x4 door control module to door 3 Disconnect multiplugs x3 an...

Page 343: ...ift transfer retro control pdl rod 7 Connect multiplug to vacuum pump 8 Connect harness multiplugs in RH wheel arch 9 Connect multiplugs x2 PDC sensors 10 Install rear bumper see Workshop Manual procedure 01 19 BA Cover Assembly Rear Bumper Renew Tailgate Harness Renew Removal 1 Battery isolator switch OFF 2 Remove trim tailgate lid assembly see Workshop Manual procedure 01 05 EF Trim Tailgate Lid...

Page 344: ...al procedure 01 05 FB Carpet Assembly Luggage Compartment Side RH Renew 6 Connect vehicle battery Engine Bay Fusebox Fuse Each Renew Removal 1 Open Bonnet 2 Remove fuse box lid 3 Remove fuse Installation 1 Install fuse 2 Install fuse box lid 3 Close bonnet Engine Bay Fuse Box Renew Removal 1 Remove RH wheel arch liner see Workshop Manual procedure 01 02 GB Wheel Arch Liner Front RH Renew 2 Remove ...

Page 345: ...tober 2005 3 Remove screws x2 CEM to floor 4 Disconnect 8 multiplugs and remove CEM 5 Remove relays x2 6 Remove fuses x37 Installation 1 Install fuses 2 Install relays x2 3 Connect multiplugs x8 and install screws X2 CEM to floor 4 Install plate screws and nuts 5 Install carpet and sound deadening around plate ...

Page 346: ...ation Install the new module s and download the As is data using the vehicle configuration software on WDS Customer Configuration There are certain modules functions that the customer may or may not want reconfigured or enabled Some of these preferences are accessed through the in car menus available on the infotainment centre Others are set in the vehicle configuration or specific software files ...

Page 347: ...Vehicle Control System 18 08 Electric Distribution Electronic Control 18 00 18 2 2 Workshop Manual October 2005 Module Locations RHD ...

Page 348: ...Vehicle Control System 18 08 Electric Distribution Electronic Control 18 00 October 2005 Workshop Manual 18 2 3 ...

Page 349: ...Vehicle Control System 18 08 Electric Distribution Electronic Control 18 00 18 2 4 Workshop Manual October 2005 Module Locations LHD ...

Page 350: ...Vehicle Control System 18 08 Electric Distribution Electronic Control 18 00 October 2005 Workshop Manual 18 2 5 ...

Page 351: ... Twin Horns 8 C0575 C6 ENGINE BAY FUSEBOX Various C0560 Earth Eyelet Clutch Compressor Air Condition 5 C1210 Earth Eyelet Underbonnet Fusebox 25 C0576 C7 ENGINE BAY FUSEBOX Various C0562 Earth Eyelet Cooling Fan Module 5 C1971 Earth Eyelet Wash Fluid Level Sensor 7 C0577 C8 ENGINE BAY FUSEBOX Various C0709 Earth Eyelet Driver Information Module 13 C0554 Earth Eyelet Wash Wipe Switch 7 C0578 C9 ENG...

Page 352: ...520 Module Sounder 9 C0417 Sensor Evap 1 C0524 Injector 3 1 C2838 Module Tracker 9 C0516 Sensor F L ABS 4 C0525 Injector 4 1 C1537 Module Tyre Pressure Monitor 13 C0517 Sensor F R ABS 4 C0526 Injector 5 1 C2052 Motor Boot Latch 15 C1652 Sensor Front Impact Left 2 C0527 Injector 6 1 C2465 Motor Electronic Throttle A 1 C1653 Sensor Front Impact Right 2 C1875 Keep Alive Fuse 25 C0690 Motor Fuel Flap ...

Page 353: ...et Fusebox Battery Feed Eyelet 25 C0054 Switch Pack Drivers Door 10 C2472 Valve Electric Vapour Management 1 C0087 Switch Window Passenger Door 11 C1685 Valve Exhaust Bypass 1 C1494 Switch Aircon Request 5 26 C0740 Window Motor Drivers Door 10 C1822 Switch Battery Off 25 C0741 Window Motor Passenger Door 11 C1271 Switch BDS 22 25 C1609 GPS Tuner Antenna 24 C0046 Switch BDS Stud 25 C2512 Antenna AM...

Page 354: ...4 4 Interior Illumination Excluding Puddle Boot Lamps 1 15 5 Exterior Lighting Including Boot Lamps 1 16 6 Exterior Lighting H I D Lamps only 1 17 7 MOST 1 18 8 Audio System Alpine Amplifier Lo Line 1 19 9 Audio System Alpine Amplifier Hi Line 2 20 0 Exterior Lighting 2 21 1 Exterior Lighting 2 22 2 Starting Charging 2 23 3 Auxiliary Engine Operated Systems 2 24 4 Infotainment System 2 25 5 Power ...

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Page 388: ...ced guard mode 1 3 Alarm Cycle 1 3 Panic Alarm 1 3 Remote Transmitter 1 4 Key Learning Operations 1 4 Integrated Passive Anti Theft System IPATS 1 4 Description 1 4 Disarming IPATS 1 4 Arming IPATS 1 4 IPATS LED 1 4 Key Programming 1 5 Maintenance 1 5 Alarm Siren Renew 1 5 Electronic Features Modules 19 05 19 2 1 Maintenance 2 1 Electronic Passenger Door Module Renew 2 1 Electronic Driver s Door M...

Page 389: ...ent within the cabin of the car using microwaves It is specifically designed to protect the ignition barrel and lock Central Electronics Module CEM This module controls the vehicle alarm system The CEM controls all alarm system inputs and outputs Driver Information Module DIM Instrument Cluster The message centre right provides text messages displaying alarm information to the user Ajar switches p...

Page 390: ...to be left in the vehicle With doors boot and bonnet closed ignition key in position 0 or I or within 60 sec after removing the keys the reduced guard button can be activated When the alarm is set the vehicle will enter reduced guard mode To deactivate reduced guard mode simply insert and turn the ignition key to position II If the alarm is deactivated and then activated without turning the igniti...

Page 391: ...prevent the engine from starting the IPATS disables the fuel pumps injectors and the crank circuit Disarming IPATS When the ignition key is located in the ignition barrel and turned to position II the key is validated If successful subsequent requests for crank and engine start will be allowed If the key validation fails then engine starting will be prevented Arming IPATS To arm the system the use...

Page 392: ...curity Maintenance Alarm Siren Renew Removal 1 Remove rear bumper see Workshop Manual procedure 01 19 BA Cover Assembly Rear Bumper Renew 2 Remove nuts x3 siren control cover to bracket 3 Loosen nuts x3 siren control bracket to body 4 Remove siren control cover 5 Remove siren control from bracket 6 Disconnect siren control multiplug Installation 1 Connect multiplug 2 install siren control to brack...

Page 393: ...Active Anti Theft System 19 01 Electronic Features 19 00 19 1 6 Workshop Manual October 2003 ...

Page 394: ...procedure 01 05 CB Trimboard Assembly Door Remove for Access Refit 2 Remove securing bolts x4 and multiplugs x3 Installation 1 Connect multiplugs x3 and secure control unit to door frame 2 Replace door trim see Workshop Manual procedure 01 05 CB Trimboard Assembly Door Remove for Access Refit Tyre Pressure Monitor Module Renew Removal 1 Disconnect multiplug from tyre pressure monitor module 2 Remo...

Page 395: ...Electronic Features Modules 19 05 Electronic Features 19 00 19 2 2 Workshop Manual October 2003 ...

Page 396: ...3 01 AA Module Driver Information Renew 2 Remove remote keyless entry module securing screws x2 and multiplug x1 Installation 1 Refit RKE unit secure with screws x2 and connect multiplug x1 2 Replace DIP see Workshop Manual procedure 13 01 AA Module Driver Information Renew Repair Operation Time ROT Item Code Remote Keyless Entry Module Renew ...

Page 397: ...Glossary Contents Diagnostic Ports 20 1 2 Fluids Capacities 20 1 3 Terms 1 3 Special Tools Pictorial Index 20 1 4 Maintenance Schedules 20 1 11 Torque Figures 20 1 14 General Torque Figures 1 14 Vehicle Torque Figures Torque Conversion Tables1 15 ...

Page 398: ...Diagnostic Ports Appendix Glossary 20 1 2 Workshop Manual October 2005 Appendix Glossary Diagnostic Ports Diagnostic ports are provided for OBD II Body including i Þ 3 5 1 5 8 6 0 6 7 ...

Page 399: ...al drive 2 0 litres 3 5 pints 2 2 Qts Fuel tank 80 0 litres 17 6 galls 88 0 Qts Recommended Fluids Engine oil Initial fill Castrol Formula RS 10w60 Do not mix Engine oil with any mineral oils Engine coolant 50 water 50 OAT Coolant Arteco Havoline XLC only Do not mix OAT coolant with any glycol based anti freeze Gearbox oil Shell Transaxle Oil 75w90 Final drive oil Mobil 1 80w140 Brake fluid Castro...

Page 400: ... No Description 303 F715 Multi purpose Trolley x2 303 F715 06 Trolley Link Bars 303 F715 04 Rear Subframe Trolley Adaptors 303 F715 05 Engine Subframe Trolley Adaptors 205 521 Rear Subframe Bush Removal 205 791 Rear Subframe Bush Removal use with 205 521 205 792 Rear Subframe Receiver Cup Part No Description 36 10 013 ...

Page 401: ...ar Subframe Bush Installer 310 040 Fuel Pipe Disconnect Tool 310 134 Filler Neck Disconnect Tool 310 140A Fuel Pump Install Remove Part No Description 303 667 Clutch Alignment 501 108 IP Alignment Pins 501 073A Airbag Simulators 501 103 Side Airbag and Pretensioner simulators Part No Description ...

Page 402: ...ck Disconnect Tool 412 132 Quick Disconnect Tool 412 038 Quick Disconnect Tool 412 040 Quick Disconnect Tool Part No Description 43 27750 MOST Tester 43 10047 Wiring Harness Repair Kit Break out Box to be used in conjunction with PCM II Test Lead 43 10048 43 10048 PCM II Test Lead Part No Description Image to follow ...

Page 403: ... Joint Splitter 418 583 Oxygen Sensor Diagnostic Lead 204 524 Front Suspension Support 501 F111 Door Service Trolley Part No Description 501 115 Front Veneer Removal 206 100 Brake Hose Install 501 112 Wiper Linkage to Wiper Motor 206 103 Handbrake Cable Removal Part No Description Image to follow ...

Page 404: ...op Manual October 2005 501 F116 IP Removal 204 321 01 Spring Compressor Adaptor Plate 303 021 02 Engine Support Brackets Part No Description 303 1185 Flywheel Locking Tool 303 1186 Crankshaft Vibration Damper Remover 303 1187 Oil filter Wrench Part No Description ...

Page 405: ...ft Rear Oil Seal Installer Remover 303 1190 Crankshaft Front Oil Seal Remover 303 536 Engine Lifting Brackets Part No Description Image to follow 303 749 Engine Lifting Brackets 303 750 Crankshaft Front Oil Seal Installer 303 F715 07 Trolley Adaptor 308 641 Gear Shift Locking Tool Part No Description Image to follow Image to follow ...

Page 406: ...Special Tools Pictorial Index Appendix Glossary 20 1 10 Workshop Manual October 2005 308 642 Gear Shift Cable Release Tool 310 155 Fuel Tank Drain Adaptor Part No Description ...

Page 407: ...nts extreme environments x x Check transaxle for leaks Every 32 000km 20 000 miles 3 Years Every 96 000km 60 000 miles 6 Years Every 160 000km 100 000 miles 10 years Check top up transaxle oil levels Every 64 000km 40 000 miles 4 Years Renew transaxle oil and clean filter Every 160 000km 100 000 miles 4 Years Renew engine coolant check specific gravity x x x Check top up engine coolant x x x Check...

Page 408: ...eck 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 suspension ball joints gaiters and bushings x Check tightness of driveshaft bolts x Check condition of underbody protection wheel arch liners Electrical Function Checks Every 112 000km 70...

Page 409: ...alve collars for correct location tyre pressure monitoring not Japanese market x x x Check Use by date of tyre repair kit and replace if expired or expiry date is within 12 months Anti Corrosion Check x x Check body panels and underbody for corrosion starting from the inside out excluding stone chips Final Checks x x x Degrease windscreen x x x Check clutch functionality x x x Check operation cond...

Page 410: ...2 2 7 17 5 3 3 M8 9 9 2 25 5 28 5 5 36 7 42 8 M10 19 5 3 9 50 5 9 5 56 10 72 13 84 16 M12 34 2 6 8 88 17 99 19 126 24 147 28 M14 54 4 10 9 140 28 157 30 200 40 235 5 46 5 M16 85 17 2 217 5 42 5 245 47 310 61 363 5 70 5 M18 116 7 23 4 313 5 58 5 433 80 509 94 M20 165 33 437 5 82 5 605 114 707 133 M22 225 45 602 5 102 5 832 157 974 187 M24 286 57 774 154 1070 213 1244 247 M27 417 83 1115 215 1547 29...

Page 411: ...87 135 71 136 45 137 19 137 92 138 68 139 40 190 140 14 140 87 141 61 142 35 143 09 143 83 144 56 145 30 146 04 140 78 200 147 51 148 25 148 99 149 73 150 46 151 20 151 94 152 68 153 41 154 15 210 154 89 155 63 156 36 157 10 157 83 158 58 159 31 160 05 160 79 161 53 220 162 26 163 00 163 74 164 48 165 21 165 95 166 69 167 43 168 16 168 90 230 169 64 170 38 171 11 171 85 172 59 173 33 174 07 174 80...

Page 412: ... 74 431 47 432 21 432 95 433 68 434 42 590 435 16 435 90 436 64 437 37 438 11 438 85 439 59 440 33 441 06 441 80 600 442 54 443 28 444 01 444 75 445 49 448 23 446 96 447 70 448 44 449 18 610 449 91 456 65 451 39 452 13 452 86 453 60 454 34 455 08 455 81 456 55 620 457 29 456 03 458 76 459 50 460 24 460 98 401 71 462 45 463 19 463 93 630 464 66 465 40 468 14 466 88 467 61 468 35 469 09 468 83 470 5...

Page 413: ... 725 02 725 76 726 50 727 24 727 97 728 71 729 45 990 730 19 730 92 731 66 732 40 733 14 733 87 734 61 735 35 736 09 736 83 Newton Metres to Pounds Feet Continued Pounds Feet 0 1 2 3 4 5 6 7 8 9 Pounds Feet to Newton Metres Newton Metres 0 1 2 3 4 5 6 7 8 9 Pounds Feet 0 1 36 2 71 4 07 5 42 6 78 8 13 9 49 10 85 12 20 10 13 56 14 91 16 27 17 63 18 98 20 34 21 69 23 05 24 40 25 76 20 27 12 28 47 29 ...

Page 414: ...3 521 98 523 34 524 70 526 06 527 41 390 528 77 530 13 531 48 532 84 534 19 535 55 536 90 538 26 539 62 540 97 400 542 33 543 68 545 04 546 40 547 75 549 11 550 46 551 82 553 17 554 53 410 555 89 557 24 558 60 559 95 561 31 562 66 564 02 565 38 566 73 568 09 420 569 45 570 80 572 16 573 51 574 87 576 22 577 59 578 93 580 29 581 65 430 583 00 584 38 585 71 587 07 598 41 589 78 591 14 592 49 593 85 ...

Page 415: ...0 1064 3 1065 7 1067 0 1068 4 1069 7 790 1071 1 1072 5 1073 8 1075 2 1076 5 1077 9 1079 2 1080 6 1081 9 1083 3 800 1084 7 1086 0 1087 4 1088 7 1090 1 1091 4 1092 8 1094 2 1095 5 1096 9 810 1098 2 1099 6 1100 9 1102 3 1103 6 1105 0 1106 4 1107 8 1109 1 1110 4 820 1111 8 1113 1 1114 5 1115 8 1117 2 1118 6 1119 9 1121 3 1122 6 1124 0 830 1125 3 1126 7 1128 0 1129 4 1130 8 1132 1 1133 5 1134 8 1136 2 ...

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